Group No.

Machine-Specific
Predictive Maintenance
and Process
Optimization using IOT
for Robots and CNC
Machines

Subject: Internet Of Things (IOT)

Introduction
In the realm of modern manufacturing, the integration of automation
technologies has revolutionized production processes, enabling precision,
efficiency, and scalability. Central to this transformation are critical assets such
as robots and CNC (Computer Numerical Control) machines, which form the
backbone of industrial operations. However, amidst the advancements, a
persistent challenge looms large - unplanned equipment failures. These failures
not only disrupt production schedules but also incur substantial financial
losses in the form of downtime, revenue depletion, and escalated maintenance
expenses.

The convergence of real-time sensor data and IoT (Internet of Things)

technologies offers a promising avenue to address these challenges proactively.
By harnessing the power of predictive maintenance and process optimization,
manufacturers can mitigate risks associated with equipment failures and
unlock new levels of operational efficiency. This report explores the intricacies
of machine-specific predictive maintenance and process optimization using IoT
for robots and CNC machines, delving into its relevance, underlying
methodologies, available solutions, and concluding with insights into its
transformative potential for industrial landscapes.
Problem Statement
Unplanned equipment failures in critical robots and CNC machines represent a
formidable obstacle to seamless production workflows. The repercussions
extend beyond mere operational disruptions, encompassing significant financial
implications and eroding competitive advantages. Real-time sensor data holds
the key to preemptively identifying specific failure modes, thereby averting
potential downtimes and optimizing maintenance strategies tailored to distinct
machine types.
 SUB - STATEMENTS

1. How can real-time 2. Can we use this 3. Can we tailor the

sensor data predict predictive solution to specific
specific failure information to machine types
modes in robots and optimize process (robots vs. CNC) for
CNC machines parameters and better accuracy and
before they occur? prevent failures efficiency?
altogether?
 WHY IS THIS PROBLEM
RELEVANT AND
INFORMATION SOURCES:
The problem of unplanned equipment failures in critical robots and CNC
machines resonates deeply within modern manufacturing, affecting
production efficiency, revenue streams, and maintenance budgets. Predicting
failure modes in real-time through sensor data emerges as a proactive
strategy to mitigate downtime and optimize processes, aligning with the
evolving needs of industries reliant on automation and precision machining.

Unplanned downtime exacts a heavy financial toll, costing manufacturers

millions of dollars annually. Studies by Industry Today and McKinsey &
Company underscore the significant impact, encompassing lost production,
reduced revenue, and escalated maintenance expenses. Beyond the
immediate financial implications, unplanned downtime disrupts production
schedules, leading to missed deadlines, delayed deliveries, and dissatisfied
customers. Moreover, it tarnishes a company's reputation and erodes
customer trust, highlighting the urgency to address this pervasive issue.
 Predictive maintenance emerges as a beacon of hope amidst the chaos of
unplanned equipment failures. Research by the Aberdeen Group and ARC
Advisory Group indicates that predictive maintenance can reduce downtime
by 50-70%, offering tangible solutions to improve production efficiency,
elevate output levels, and enhance overall profitability. Leveraging
predictive analytics and real-time sensor data, manufacturers can anticipate
equipment failures before they occur, allowing for proactive interventions
and timely repairs.

The journey towards predictive maintenance isn't just about averting

disasters; it's also about gaining a competitive edge in the market.
Companies that embrace predictive maintenance early on position
themselves as industry leaders, distinguishing themselves through
operational excellence and superior product quality. By minimizing
downtime, optimizing processes, and enhancing equipment reliability, these
companies increase capacity, lower operational costs, and deliver
exceptional value to customers.

Implementing predictive maintenance strategies necessitates a holistic approach, integrating

cutting-edge technologies, industry best practices, and organizational culture. IoT (Internet
of Things) sensors serve as the backbone of predictive maintenance, capturing real-time data
on equipment performance, environmental conditions, and operational parameters. These
sensors continuously monitor critical assets, providing insights into their health and status.
The data collected by IoT sensors lays the groundwork for predictive analytics, where
machine learning algorithms analyze patterns, trends, and anomalies to forecast
potential failure modes. By identifying early warning signs and predictive indicators,
manufacturers can prioritize maintenance activities, allocate resources efficiently, and
minimize the impact of unplanned downtime.

The shift towards predictive maintenance isn't just a technological evolution; it's a
cultural transformation. It requires buy-in from all levels of the organization, from
frontline operators to senior management. Training programs, awareness campaigns,
and performance incentives can cultivate a culture of proactive maintenance,
empowering individuals to contribute to the reliability and longevity of equipment.

Investing in predictive maintenance is an investment in the future of manufacturing.

It's a strategic decision that transcends short-term gains and positions companies for
long-term success. By embracing innovation, embracing change, and embracing the
power of predictive analytics, manufacturers can navigate the complexities of the
modern industrial landscape with confidence and resilience.

The journey towards predictive maintenance isn't without its challenges, but the
rewards far outweigh the risks. It's a journey towards operational excellence,
efficiency, and competitiveness in the dynamic world of manufacturing. As industries
continue to evolve and technology advances, the adoption of predictive maintenance
will become increasingly crucial, ensuring sustainability, growth, and prosperity in
the ever-changing landscape of modern manufacturing.
BASIC PROBLEM DISCUSSION & HOW IOT CAN BE
USED:
Unplanned failures in imperative robots and CNC machines lead to considerable production downtime,
revenue loss, and maintenance costs. Using real-time sensor data, the aim is to identify failure modes,
improve process parameters, and accordingly adapt solutions that provide proactive maintenance and
reduce the disruption. To address this challenge, IoT can be utilized in the following ways:

Utilizing IoT Predictive Optimizing

Process
Sensors: Modeling: Parameters:
 1. UTILIZING IOT SENSORS:
By equipping robots and CNC machines with IoT sensors, we
can collect real-time data on various parameters such as
vibration, temperature, power consumption, and motor
currents. This data can then be used to predict specific failure
modes before they occur.

IoT sensors serve as the eyes and ears of modern manufacturing

facilities, providing insights into the health and performance of
critical equipment. Vibration sensors, for instance, detect
irregularities in machine movements, indicating potential issues
with bearings, misalignments, or structural integrity.
Temperature sensors monitor thermal conditions, highlighting
overheating components or insufficient cooling mechanisms.
Power consumption sensors track energy usage patterns,
flagging inefficiencies or abnormalities in motor operations.
Similarly, motor current sensors capture fluctuations in electrical
currents, signaling impending failures or abnormal load
conditions.
2. PREDICTIVE MODELING
Machine learning algorithms can be used to analyze the sensor
data and identify patterns that indicate potential failures. These
algorithms can then be used to predict when and how a specific
component is likely to fail, allowing for proactive maintenance
to be scheduled.

Predictive modeling leverages historical data and real-time

sensor inputs to anticipate equipment failures with precision. By
training machine learning algorithms on vast datasets
encompassing various failure scenarios, manufacturers can
develop predictive models tailored to their specific machinery
and operational environments. These models learn to recognize
patterns indicative of impending failures, enabling timely
interventions and preemptive maintenance activities. Through
continuous refinement and validation, predictive models evolve
to accommodate changing operating conditions and emerging
failure modes, ensuring sustained reliability and performance
optimization.
3. OPTIMIZING PROCESS PARAMETERS:
By analyzing the sensor data, we can also identify inefficiencies in
the operation of robots and CNC machines. This information can
then be used to optimize process parameters such as feed rates,
cutting speeds, and coolant flow, leading to improved performance
and reduced energy consumption.

Process optimization lies at the heart of operational excellence,

driving productivity gains and cost savings in modern
manufacturing settings. IoT-enabled sensor data offers
unprecedented visibility into the dynamics of production processes,
enabling informed decision-making and targeted interventions. By
scrutinizing key performance indicators and process variables,
manufacturers can identify bottlenecks, minimize cycle times, and
enhance product quality. Adjusting feed rates, cutting speeds, and
coolant flow based on real-time insights optimizes machining
operations, mitigates tool wear, and extends equipment lifespan.
Moreover, fine-tuning process parameters aligns production
objectives with sustainability goals, conserving energy resources
and reducing environmental footprint.
 IOT IN ACTION: CASE STUDIES AND EXAMPLES
Predictive Maintenance in Robotics:
Consider a large-scale automotive assembly plant relying on robotic arms for
welding operations. By deploying IoT sensors on robot joints and end-
effectors, the plant continuously monitors vibration patterns, motor currents,
and thermal conditions. Through predictive modeling, anomalies indicative of
impending motor failures or gearbox malfunctions are detected in advance.
Proactive maintenance schedules are generated, allowing technicians to
replace worn components or lubricate mechanisms before critical failures
occur. As a result, production uptime is maximized, and costly downtimes are
minimized, ensuring seamless operations and timely delivery of finished
vehicles to market.

Process Optimization in CNC

Machining:
In a precision machining facility producing aerospace components, CNC
machines play a pivotal role in shaping intricate parts from raw materials. IoT
sensors integrated into spindle assemblies and cutting tools capture real-time
data on vibration levels, tool temperatures, and spindle speeds. Through
advanced analytics, optimal cutting parameters are determined, balancing
material removal rates with tool life expectancy. By dynamically adjusting
feed rates and tool engagement strategies, machining efficiencies are
optimized, reducing cycle times and minimizing scrap rates. The result is a
streamlined production process that meets stringent quality standards while
maximizing resource utilization and minimizing environmental impact.
 AVAILABLE SOLUTIONS
Unplanned equipment failures and suboptimal processes plague industrial settings,
4.1. Siemens MindSphere: leading to costly downtime and reduced productivity. Fortunately, several commercial
solutions leveraging Internet of Things (IoT) connectivity and advanced analytics can
Central Hub: Connects machines, sensors, and personnel across the factory floor via IoT, creating a central data
repository. address these challenges, promoting predictive maintenance and asset performance
Real-time Analytics: Employs powerful tools to analyze data from IoT sensors, providing insights into equipment management. Here's a concise overview of four prominent offerings:
health and process efficiency.
Predictive Maintenance: Utilizes advanced algorithms to predict equipment failures based on anomalies in IoT
data, enabling proactive maintenance.
Process Optimization: Identifies inefficiencies and suggests improvements in production processes based on IoT-
generated data.
Security and Scalability: Prioritizes data security and platform scalability to accommodate growing enterprise
needs.

4.2. ABB Ability:

Tailored AI Solutions: Offers industry-specific AI algorithms that leverage IoT connectivity for predictive
maintenance and process optimization in process industries.
Refinery Equipment Monitoring: Seamlessly integrates with IoT sensors on refinery equipment for continuous
performance monitoring and issue anticipation.
Focus on Downtime Reduction: Prioritizes solutions that prevent disruptions in production processes through
proactive maintenance enabled by IoT data.

4.3. GE Predix:
Extensive IoT Data Library: Learns from millions of connected devices to build robust predictive models for
accurate equipment problem forecasting.
Predictive Analytics: Leverages IoT data to identify patterns and trends for proactive maintenance interventions
and optimizing asset performance.
Cloud-based Platform: Offers easy access and scalability for managing connected assets and analyzing IoT data
across enterprise networks.

4.4. Bosch Connected

Manufacturing:
Open IoT Connectivity: Integrates seamlessly with diverse systems and sensors, regardless of manufacturer,
facilitating data collection from CNC machines and robots.
Efficiency Optimization: Employs intelligent algorithms fueled by IoT insights to pinpoint and address
inefficiencies in production processes for overall operational improvement.
Focus on Flexibility: Promotes scalability and flexibility by adapting to existing infrastructure and diverse
industrial environments.
These commercial solutions demonstrate the power of IoT-driven insights in addressing industrial
challenges. By choosing the platform that best aligns with their specific needs and priorities,
manufacturers can unlock proactive maintenance, optimized processes, and ultimately, enhanced
competitiveness in the modern industrial landscape.
This revision emphasizes precision by removing redundancies, focusing on key features, and ensuring
concise descriptions.
ENHANCED SOLUTIONS LEVERAGING SIEMENS' EXPERTISE:

Siemens steps in with a comprehensive arsenal of tools and expertise to prevent these costly breakdowns.

Let's dive into how:

1. Real-time Failure Foresight:
Sensor Symphony: A diverse orchestra of sensors (vibration, temperature, power, etc.) captures subtle changes indicative of impending failures.
MindSphere, the Data Conductor: This robust platform gathers and analyzes sensor data from across your production line, identifying patterns and anomalies that whisper of potential breakdowns.
AI-powered Predictions: Machine learning models trained on historical and real-time data pinpoint specific failure modes with remarkable accuracy, giving you a head start on prevention.
Prescriptive Maintenance Roadmap: Don't just guess - Siemens generates precise recommendations for preventing failures, from scheduled maintenance interventions to process parameter
adjustments and optimized operating conditions.
Continuous Learning: The system constantly learns and improves as new data is collected, leading to ever-more accurate predictions and effective interventions.
2. Tailored Solutions for Unique Machines:
Domain Expertise Advantage: Siemens' dedicated teams, each specializing in robotics, CNC machining, and other fields, understand the specific challenges and failure modes of different
machines.
Machine-Specific Models: No one-size-fits-all approach here. Siemens develops specialized predictive models for each machine, considering its individual characteristics and sensor data,
maximizing accuracy and minimizing false alarms.
3. Seamless Communication and Visualization:
Industrial Ethernet Backbone: Reliable and secure protocols like PROFINET and OPC UA ensure smooth data flow between sensors, machines, and MindSphere, even in harsh industrial
environments.
Edge Computing Outposts: When cables aren't an option, edge computing getaways near machines crunch initial data, reducing bandwidth needs and enabling faster decision-making.
MindSphere Dashboard, Your Command Center: A comprehensive web interface with customizable widgets displays real-time data, historical trends, predicted failure probabilities, and
maintenance recommendations, giving you complete situational awareness.
Mobile App Convenience: Monitor machine health, view maintenance recommendations, and receive critical event notifications directly on your mobile device.
Email and SMS Alerts: Configure personalized alerts for critical situations, ensuring key personnel are notified instantly via email or SMS for immediate action.
4. Scalability and Customization:
Growing Pains Solved: The solution scales seamlessly to accommodate an increasing number of machines and data volume as your production expands.
Existing Systems Integration: Streamline operations by integrating the solution with your existing MES and ERP systems for automated workflows and data exchange.
 SIEMENS TOOLS AND SENSOR FOR
ROBOTS AND CNC MACHINES:
1. MindSphere: The central nervous system of your operation, collecting and analyzing
data from various sources like:
2. AI-powered Predictive Models: These models analyze the
sensor data to predict specific failure modes in advance, enabling Sensors:
proactive maintenance. Siemens offers pre-built models for Vibration Sensors:
common robot and CNC machine scenarios, and you can also Name: SKF CMSS 2200
train custom models based on your specific equipment and Function: Monitors vibrations in robot joints, CNC machine spindles, and other critical
operating conditions. components to detect imbalances, misalignments, or impending bearing failures.
Temperature Sensors:
Name: Siemens Sitrans TS500
3. Prescriptive Maintenance Recommendations: Based on Function: Tracks temperature changes in motors, bearings, and other areas to identify
the predictions, MindSphere generates recommendations overheating, lubrication issues, or potential breakdowns.
for maintenance interventions, including: Power Consumption Sensors:
Scheduling preventive maintenance for specific components Name: Siemens SIPARC EL320
before they fail. Function: Monitors power consumption patterns in robot actuators and CNC machine
Adjusting process parameters like feed rates, cutting speeds, motors to detect inefficiencies, overloaded circuits, or impending motor issues.
and coolant flow in CNC machines to optimize performance
and reduce wear. Motor Current Sensors:
Replacing worn components like robot grippers or CNC Name: Siemens 7MR4420
tool inserts before they break down and cause production Function: Tracks motor current fluctuations in robots and CNC machines to identify
downtime. issues with bearings, windings, or overloaded conditions.
 4. Machine-Specific Solutions:
Siemens offers specialized solutions for different machines like
robots and CNC machines, leveraging their domain expertise:
Robotics Expertise: Dedicated teams understand robot
kinematics, joint movements, and actuator loads. They
recommend sensor placements like vibration sensors on
robot elbows or motor current sensors on robot wrists, and
develop tailored predictive models for specific robot types.
CNC Machining Expertise: They understand cutting
forces, spindle movements, and tool wear factors. They
recommend sensor configurations like vibration sensors on
the spindle or acoustic sensors near the cutting tool, and
create customized predictive models for optimized CNC
operations.

5. Communication and
Visualization Tools:
Industrial Ethernet Backbones: PROFINET and OPC UA
MindSphere Dashboard: This web interface provides real-time
protocols ensure secure and reliable data transfer between
data visualization, historical trends, predicted failure
sensors, machines, and MindSphere.
probabilities, and maintenance recommendations for
Edge Computing Gateways: Siemens Simatic Edge devices
comprehensive situational awareness.
can be installed near machines for decentralized
Mobile App: The Siemens MindSphere Go app allows you to
deployments, pre-processing data for faster decision-
monitor machine health, view maintenance recommendations,
making and reduced network bandwidth demands.
and receive critical event notifications directly on your mobile
device.
Email and SMS Alerts: Customize alerts for critical situations
like high vibration levels or predicted bearing failures to
ensure key personnel are notified instantly via email or SMS
for immediate action.
 CONCLUSION

In summary, unplanned equipment failures in critical

robots and CNC machines pose significant
challenges, including production downtime, revenue
loss, and maintenance costs. Leveraging real-time
sensor data and IoT technology enables proactive
strategies to predict failures, optimize processes, and
customize solutions for each machine type. Solutions
like Siemens MindSphere and ABB Ability provide
vital insights, facilitating preemptive maintenance
and process optimization.
Adopting machine-specific predictive models and
communication tools enhances efficiency and scalability,
ensuring seamless data integration across industrial
operations. Prioritizing preventive maintenance and process
optimization enables manufacturers to mitigate financial
losses, boost productivity, and gain a competitive edge.
Ongoing innovation and strategic partnerships bring the vision
of machine-specific predictive maintenance using IoT
technology into reality, fostering operational excellence and
sustainable growth for industries.
THANK YOU
Project Submitted
by:

1. Meenaz Khan : 23030241118

2. Abhishek Shinde: 23030241135
3. Yashika Jadhav: 23030241116
4. Omkar Murkute: 23030241126
5. Anshu Rai: 23030241101
6. Pooja Mourya: 23030241125