Hannover Fair covers power transmission and control | Automation.com

Hannover Fair covers power transmission and control

January 29, 2009 - Manufacturers of power transmission technology are known for their technical inventiveness and their attention to detail. The trade fair Motion, Drive & Automation (MDA), part of the line-up at this year's HANNOVER MESSE (20 - 24 April 2009), will show how important the issue of efficiency has become for manufacturers and users of power transmission systems. One aspect of this is the rise of so-called condition monitoring systems, which form the subject of the special CMS display in Hall 24. This event shows how a little bit of innovation can deliver significant economic benefits.

"Trends are a window with a view to the future," observes Manfred Kutzinski, Project Manager at Deutsche Messe. The leading trade fair Motion, Drive & Automation (MDA) with over 1,000 exhibitors is one of the jewels in the crown of HANNOVER MESSE (20 - 24 April 2009). Every two years this gathering of all the big names in power transmission technology from all over the world attracts more than a hundred thousand visitors to Hannover. The reason: this is where emerging trends can be spotted in the shape of products and solutions that are available now.

What started out as a customized solution for users or equipment suppliers with a particular eye for detail is increasingly viewed by plant operators as an effective means of increasing their competitive lead in the marketplace. "Manufacturers of machinery and plant are well advised to take full advantage of the potential that today's condition monitoring systems offer", says Peter-Michael Synek, Project Manager at the VDMA (German Engineering Federation) and co-organizer of the special display of CMS in Hall 24 at HANNOVER MESSE.

CMS special display is an opportunity for buyers and suppliers
Being there is everything - and that applies both to the suppliers of such systems, who can book space on this dedicated presentation area for a flat fee, and to the potential users of this sophisticated machine monitoring technology. Both groups can gain a great deal from Condition Monitoring - the event and the concept.

Just one example from the metalworking industry: A French manufacturer of engine parts had problems with some of his 110 machine tools. In order to localize the defective machine component as quickly as possible, the plant owner commissioned FAG Industrial Services (F'IS). This enterprise is responsible for the worldwide servicing business of the Schaeffler Industry Group, and specializes in condition monitoring. Via offline measurement of the machine tool parameters, which only cost the company 1,700 euros, including the project work, the cause of the problem was quickly identified: a defective machine component close to the X axis.

Knowledge is the key to cost savings
Instead of having to cope with an unscheduled stoppage, the plant operator was able to replace the defective component during a scheduled period of shutdown. Had it been necessary instead to repair the entire linear axis of the machine following a complete component failure, this would have taken four days - as past experience shows. And this one incident would have cost around 80,000 euros in lost production.

"A case like that, which occurs countless times every day in manufacturing industry, demonstrates the value of condition monitoring systems", emphasizes Peter-Michael Synek. At the CMS special display in Hall 24 F'IS will be showing visitors product and service solutions that look at the whole life-cycle of machinery and plant, with a view to minimizing the so-called "total cost of ownership" (TCO) - thereby helping to make the business more competitive.

As well as the opportunity to see all the CMS exhibitors conveniently brought together in one place, visitors will also find instructive examples of CMS in action at the MDA Forum. The 1,000 m² Forum forms part of the CMS special display and is run by industry experts. They will be giving a series of talks to visitors showing the many different options available to them for optimizing the performance of power transmission and control systems.

As Kutzinski points out: "Manufacturers of machinery and plant need to know what technology is available for improving efficiency, how it works and where they can buy it." This is why Deutsche Messe has chosen to place the special display CMS and the MDA Forum within the flagship trade fair MDA. It means that visitors don't have far to walk - and they can relate what they find directly to the exhibits of electrical, pneumatic, hydraulic and mechanical power transmission technology at the show.

CMS and E-Motive: major new trends in mechanical and plant engineering
The expert speakers at the MDA Forum will be telling their audiences about condition monitoring systems, energy efficiency in industrial processes and examples of current trends in E-Motive. The term "E-Motive" refers to alternative electrical drive systems of the kind already to be found in the automotive industry. In the light of the current intense debate about energy-saving power transmission solutions, this trend towards electrically based systems is rapidly gaining in importance. "We want to make people aware of this development at an early stage and create a platform for innovative work in the future", explains Kutzinski.

But to return to the subject of CMS: Different types of systems are now available for the monitoring and diagnosis of machinery and plant. As well as the offline diagnosis described above, where sophisticated measuring technology is deployed to search for potential causes of damage, there are also online solutions on the market. These record and analyse machine performance data on a continuous basis, so that any incipient changes can be detected at an early stage.

The benefits or savings this can deliver have been calculated by F'IS, as can be clearly demonstrated by the example of a wind turbine. An online monitoring system detected the early signs of damage to a bearing. Instead of a complete gearbox exchange costing 210,000 euros, the turbine operator only had to replace the damaged bearing - at a cost of 4,700 euros. The same applies to the generator. Exchanging the whole unit during an unscheduled shutdown would have cost 140,000 euros, whereas a simple bearing replacement cost only 3,400 euros. Given that the cost of installing the entire condition monitoring system for the nine wind turbines in this particular energy park was 80,000 euros, this investment had already paid for itself after one year.

Troubleshooting electric motors enable manufacturers to improve their performance
"These and many other case histories demonstrate how CMS delivers competitive advantages and/or cost savings that should not be underestimated", says CMS expert Peter-Michael Synek. But it doesn't always have to be a high-end system with correspondingly high investment costs. Sometimes it just takes a small push in the right direction to keep machinery and plant running and avoid costly damage, or else just to fine-tune control or process engineering systems. Here too CMS specialist F'IS cites a specific case history:

Several large electric motors in a Venezuelan repair workshop had become unusually noisy, and the owners were poised to replace the bearings because they thought the motors were about to break down completely. This would have cost 3,000 euros. Experts from F'IS measured the vibrations on the motors, and determined that the bearings were in good order. They concluded that the excessive running noise was due to electrotechnical shortcomings. So the true source of the noise was identified at relatively little cost, and appropriate measures could then be taken to resolve the problem.

Prevention is cheaper than cure
All these examples of condition monitoring in action demonstrate clearly that prevention is cheaper than cure. Many industry professionals have understood this message, as attested by visitor numbers of around 20,000 for the last two CMS special displays in 2005 and 2007. What new types of condition monitoring systems are available, how much they cost, where they can be used and what benefits they offer - all this and more can be found out at the special display "Condition Monitoring Systems" at this year's HANNOVER MESSE in Hall 24.

CMS and E-Motive: a great line-up
Right next door to the special display "Condition Monitoring Systems" at Hannover Messe (20 - 24 April 2009) in Hall 21 is the group presentation "E-Motive." The eponymous initiative, founded by the VDMA and the Power Transmission Research Association (FVA), is concerned with electric drives for vehicles, and the presentation is aimed at manufacturers and developers of alternative electrical power transmission systems for cars and other vehicles.

The range of exhibits extends from hybrid drives and fuel cell-based solutions to power electronics and energy storage/buffer units for the automotive industry. All these themes will also be covered by expert speakers at the MDA Forum located within the special display CMS and next door to "E-Motive", where the present and future possibilities of electric drive systems will be discussed in detail.

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