FEBRUARY 2018 – INDUSTRY 4.0 – DIGITAL SOLUTIONS IN AGGREGATES

Nick Roseto – ABB Motors and MechanicalKey Account Manager – Mining, Aggregate and Cement Industries

Key Stats• Reside Chicago, IL

• 25 year industry experience

• Sales & Engineering background

• Univ. of Illinois – Bachelor of Engineering

• Purdue University – Master of Engineering

• Slogan – “I am here to help.”

The digital revolution – coming now to industrial markets

The digital platform – Industry 4.0

The digital powertrain

Applications in aggregates

Changing the paradigm

Types of digital solutions available

Digital solutions in action

Considering the bottom line

Summary

Agenda

—

The digital revolutionThe operation of business has changed and will certainly continue

Media is focused on B2C but the “killer app” is in B2B

Digital technologies are driving new innovation in industrial markets

Virtual/augmented

reality

Software-defined

machines Machine learning

Time-sensitive

networking Big data

Inexpensive computing Cloud computing Cybersecurity Connectivity Blockchain

Global trend – Fourth Industrial Revolution

The Internet of Things (IoT)

Industry 1.0 – 1712

First practical steam engine

Industry 2.0 – 1870

First elevated conveyor belts

Industry 3.0 – 1969

Electronics / software based control

Connect your assets to digitally perform and extend service life

Services

ThingsPeople

Industry 4.0 – today and tomorrow

Internet of …

A $4 – 11 trillion digital opportunity by 2025 (productivity or cost reductions)

Economic value migration opportunity

Range of sized potential

economic impact Low

High

Disruptive technologies will have substantial impact by 2025 (economic impact of 12 most significant technologies, $ trillions, annual)

3.9 – 11.1

3.7 – 10.8

5.2 – 6.7

1.7 – 6.2

1.7 – 4.5

0.2 – 1.9

0.7 – 1.6

0.1 – 0.6

0.2 – 0.6

0.2 – 0.5

0.1 – 05.

0.2 – 0.3

Internet of Things

Mobile internet

Automation of knowledge work

Cloud technology

Advanced robotics

Autonomous and near-autonomous vehicles

Next-generations genomics

Energy storage

3D printing

Advanced materials

Advanced Oil & Gas exploration and recovery

Renewable energy

1

2

3

4

5

6

7

8

9

1

01

11

2

Computing + connectivity + cloud + analytics set to unlock value

Industrial markets primed to adopt digital technologies

Time

Digital S-Curve

Level of

digitalization

ABB end-market

Other industries

Not “business as usual”

Accelerating rate of change: new entrants

42

22

0

10

20

30

40

50

2009 2015

Median Age of new entrants to the S&P 500

Closing the loop – producing, analyzing and acting on data

What does it take to win in digital?

From physical to digital differentiation

Maintenance

Operation

Control

Service action

Set points

Control signals

Plant / equip. health

Operational data

Measurements

—

The digital platformConnecting users to their machine

The digital platform

CustomersDigital Ability:Digitally connected products & services

Uptime

Speed

Yield

Safety

Security

Expertise

Information

Technology

Know-how

Digital solutions built on a common set of standard technologies

Unlocking the potential in digital

Open access, intelligent cloud

Closing the loop with connected devices

New end-to-end digital solutions

Systems to master process control

Digital solutions & platform

Digital

Ability

Provides efficiency and

scale

Delivers customer benefit

(uptime, speed, yield…)What

HowPlatform

(common technologies for device, edge, and cloud)

Utilities

solutions

Industry

solutions

Transport &

Infrastructure

solutions

Suppliers x system integrators x developers x 3rd party apps = user leverage

Benefits of an industry-standard platform

IT innovations + OT expertise

Developers

System integrators

Core platform

Thousands of application needs available

Innovation takes ability

Utilities Industry Transportation &

Infrastructure

180+ digital solutions

Improved productivity (>200%), reduced energy (<30%), & longer product life (<30%)

Industry SELECTION

Connected robots

Manufacturing execution

systems Energy assessment Cybersecurity assessment

Digital simulation for robot

deployment

Power quality monitoring &

demand-response Distributed control systems

Remote monitoring &

optimization

Proactive detection of faults (<90%), reduced maintenance costs (<20%) and energy costs (<5%)

Transport & Infrastructure

EV charging with cloud management Flash-charging electric buses Energy management for mega-datacenters

Remote monitoring for ship

electrical systems Building automation

Vehicle-to-grid demand/supply

coordination

Navigation optimization

for fleets

Digitally connected products and services providing expertise

Digital solutions deliver value

Do more AutomateAct

Do better Optimize

AssessKnow more

Analyze

Sense

Digitally connected products and services providing expertise

Digital solutions deliver value

Know more

Do more

Do better

Together

Assess

Automate

Optimize

CollaborateAnalyze

ActSense

Analyze

ActSense

Analyze

ActSense

Analyze

ActSense

On-premise, in the cloud, and in an ecosystem

Leveraging the digital platform

Fog Cloud Intercloud

Edge

Device

Cloud

Edge

Device

Lumada

Predix Mindsphere

Ecostruxure

Digital Ability

Making solutions and data safe for mission-critical applications

Digital ability: security, data, and IP

What is your IoT data manifesto?

What is your intellectual

property position?

What are your cybersecurity

standards?

Secure your systems:

Secure operations

Threat detection

Secure communications

Secure updates

Secure boot

You own your data:

Identity

Measurement data

You know what we do with your data

We only share data with your consent

You own your IP:

No loss of intellectual property

when using Digital Ability solutions

𝑓(x)=$

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The digital powertrainConnecting users to their machine

What is the Digital Powertrain?

An intelligent powertrain, equipped with sensors and cloud connectivity, comprises motors, drives, mechanical components including bearings,

couplings and gearboxes, and applications like pumps, fans and compressors.

• For a client it is not important if a motor or a drive has a problem; it is about the availability of the application

• Combining information from different components allows for better predictions on the connected behavior

• Partnering with pump, compressor and fan manufacturers allows for increased value to the end-client

• Today, more than 80% of powertrains are not monitored. Therefore providing a simple, cost-efficient solution will

be a game-changer

• Providing advanced services at the click of a button enhances the experience and efficiency

It’s not about fancy graphs

Digital Powertrain: The client’s perspective

It’s about saving money

Digital Powertrain: The client’s perspective

Types of digital powertrain connectivity

Low End connector solutions High End connector solutions

• Remote Condition Monitoring and Assistance

• Predictive maintenance

• On site condition Monitoring

• High data traffic for Analytics

• Multi device, to cloud Communication

• OEMs Cloud Data Sharing

• 1 internet access per site

• Possible use customer network

• Remote Condition Monitoring and Assistance

• Installation cost optimized

• 1 internet access per device

• Or Bluetooth gateway

Scalable solution on site, and 1 unique portal, end customers and OEMs

An expert or the end customer log in RCM portal, check KPIs calculated with data coming from:

Low and high end connected solutions

Digital powertrain process flow chart for end users

Digital advantage delivered through the digital powertrain

MOUNTED

BEARINGS

MOTOR OR

GENERATOR

DRIVE OR

CONVERTER

TRANSFORMER CUSTOMER

APPLICATION / PUMP

A digital advantage that accelerates efficiency, predictability and safety

Cloud

Digital Powertrain

—

Applications in aggregatesPrimary focus integral to all quarries, sand and asphalt production

Process map – conveying, crushing, screening, and pumping

Aggregates in action

Conveying

Aggregate application

Conveyor applications: moving rocks between processes

Application requirements

Severe duty

High efficiency

Normal and high torque designs

Torque multiplication

Mounted bearings

Pulleys and shafting

Motors, gear reducers, pulleys, bearings

Overland Stackers

Blending

Load out

(Barge/ Rail/ Truck)

Aggregate applicationCrushing

Crusher applications: making little rocks out of big rocks

Application requirements

High torque design

Belt driven

Roller bearings/ belted duty

Severe duty and vibration

Variable speed operation

Motors, variable frequency drives, belt drives

Jaw Crushers Cone Crushers

Horizontal or

Vertical Shaft Impactors Hammer Mill

Aggregate applicationScreening & Classifying

Screening applications: separating size ranges

Application requirements Typical inclined screen

Severe duty and vibration

High efficiency

Variable speed operation

High torque design

Above normal service factor

Roller bearings / belted duty

Motors, belt drives

Wire screen

cloth

Pumping

Aggregate market

Pumping applications: processing and circulating water

Application requirements

Severe duty

Premium efficiency

VFD operation

Normal torque designs

Normal service factor

Coupled duty or belted duty

Motors, variable frequency drives

Dewatering Storm water control

Washing Sediment removal

—

Changing the paradigmMaintenance versus service life of product

Equipment failuresElectric motors

51%

16%

16%

5%

2%

10% Bearings

Windings

External Factors

Rotor Bar

Shaft/Coupling

Unknown

51%– Bearing failures cause 51% of motor failures

– Preventative mechanical maintenance

• Greasing bearings

• Cleaning surfaces

• Verify load connection (couplings/belts)

Equipment duty classificationElectric service condition = severe

Service

ConditionAmbient Temp Bearing Load Atmosphere

Operating HRS.

per Day

Standard -18C to 40C Steady Clean 8

Severe-30C to 50C

(1)

Medium Shock

Vibration (<0.2

in/sec)

Medium Dirt

Abrasives

Corrosion

8 to 24

Extreme-54C to 65C

(1)

Heavy

Shock Vibration

(<.44 in/sec)

Heavy Dirt

Abrasive

Corrosion

8 to 24

Lubrication frequencyElectric motors

Speed Frame Standard Severe Extreme

=<1800 182-215 3 years 1 year 6 months

=<1800 254-365 2 years 9 months 3 months

=<1800 404-449 1 year 6 months 3 months

=>3600 All 6 months 3 months 1 month

Equipment failuresMounted Bearings

– 80% of premature bearing failures are due to lubrication

– Preventative mechanical maintenance

• Follow manufacturers guidelines

• NLGI #2 lithium base grease

80%

10%

9%

1%

Lubrication Installation

Wrong bearing Mfg defects

5%

15%

20%

20%

20%

Liquid contamination Insufficient lubricant Solid contamination

Aged lubricant Wrong lubricant

Modes of failureMounted Bearings

Lubrication frequencyMounted bearings

Lubrication Guide – suggested lubrication period in weeks

Hours Run

Per Day

1 to 250

RPM

251 to 500

RPM

501 to 750

RPM

751 to

1000 RPM

1001 to

1500 RPM

1501 to

2000 RPM

2001 to

2500 RPM

2501 to

3000 RPM

8 12 12 10 7 5 4 3 2

16 12 7 5 4 2 2 2 1

24 10 5 3 2 1 1 1 1

Typical of aggregate industry applications

—

Types of digital solutions availableHow do these devices work?

System layout

Digital Smart Sensor

Cloud Services

Customer Site

Cloud-based platform and User portal

Customer portalCustomer

or engineer

Sensors

on motors

Gateway

– Cloud-based data trend storage and backup

– Increased sensor battery life time

– Perfect solution for location where H&S rules do not

allow using hand held devices

– On-line monitoring several sensors in gateway range

– Continuous monitoring of critical applications

– Remotely adjust alarms based on data trends

– Quick overview of the site assets health status

– Easy assets performance comparison

Digital Smart SensorConnecting multiple devices - Gateway

Cloud

Gateway

– Significant installed base

– Bearing is a critical component of the overall system, industrial

fan, conveyors, processing equipment, etc.

– Monitoring of the bearing is a standard maintenance practice

– Bearing is the first indicator of potential system problems

Smart sensor for mounted bearingsMounted bearings have a finite life

– Wireless communication – Bluetooth

– Measures vibration and temperature

– Advanced algorithms for bearing diagnostics

– On board storage: 30 days data storage

– Connection to common platform

– Software: Android & iOS

Smart sensor for mounted bearingsSensor particulars

– Visual diagnostic of asset without physically looking at it

– Warnings on decreasing assets health status

– Ability to properly analyze why a bearing failed

– Continuously collect reliable data to central storage

– Ability to reduce downtime

– Ability to reduce unplanned, unscheduled maintenance

– Easy installation

– Small investment to prolong application availability

Smart sensor for mounted bearingsCustomer benefits

Digital portal – mounted bearingsCentral storage of information

Smart sensor for electric motorsSmart sensor

• Safety - Improve safety at work with maintenance inspections from a distance

• Reliability – Reduce downtime with a transition from reactive to proactive maintenance

• Energy Savings - Save energy with proper sizing of motors

• Maintenance Savings - Save time and effort of maintenance engineers with early warning systems

• Net Working Capital – Equipment can live longer with less redundant plant and inventory

• Risk Mitigation – Minimise your liabilities, such as warranty, uptime guarantee, transportation, etc.

A sensor is like a fitness wristband for electric motors.

Fit it easily to the surface of a motor, without wiring or

machining, and collect operational data and health info

of the motor.

Maintenance and operation can be optimised in a way

that was not possible before.

The benefits can be huge, payback time expected to be

less than one year in most cases.

With IoT-technology the sensor does things at a low cost

that was unthinkable a few years ago.

Basis of installation

Smart sensor for electric motors

UNF 1/4"- 28 as mechanical interface.

“Future proof" for possible upcoming Smart Sensor of different design.

The sensor mount is permanently installed on the

motor using adhesive putty (Henkel Loctite 3463).

6 sizes of sensor mount are available initially.

Low Energy

Built-in batteries (Not user exchangeable.)

Firmware with FOTA (Firmware Over-The-Air, i.e. updates via smartphone)

Initial certification logos:

CE, Bluetooth, UL, FCC, WEEE

"Wheelie"

Range:

- theoretical max: > 100 m

- realistic: ~ 50 m

- industrial environment: < 25 m

MEMS Multi-Sensor System inside

No electrical wiring required / possible.

What does it monitor?

Smart sensor for electric motors

Parameters supported Problem or operating characteristic Release

Overall Vibration

Unbalance, loose mass, coupling management,

load effects, soft foot, etc.

Axial Vibration

Radial Vibration

Tangential Vibration

Bearing Condition Bearing damage

Cooling Condition Overheating due to blocking of air flow

Airgap Eccentricity Soft foot/bent shaft/thermal bow

Rotor Winding Health Cracked rotor bar/ring detection

Skin Temperature/ °C or °F Operating information

Energy Consumption/kWh Process change, replacement decision

Operating Hours/h Operating information

Operating Power/HP Process change, reliability (overloading)

Number of Starts Operating information

Speed/rpm Operating information

Motor Supply Frequency/Hz Operating information

Notifications

Re-greasing Advice

Battery indicator

First release -

Future release - □

Covered motor types (First release):

– Standard 3-phase LV induction motors

– Rib-cooled frame, TEFC

– 140-440 NEMA, 160-450 IEC frames

– Safe area

– S1 duty

– Fixed Frequency, Low Dynamic VFD

Many other types and duties will become

available during 2018.

Health Parameters are provided

with latest reading and color

coded indication

• Red- Critical

• Yellow- Alert

• Green- Healthy

Latest operating parameters

are provided

Operational and Health ParametersFeatures of the APP

App provides notifications

about certain parameters

Select “Take action” and log

what maintenance action

was performed to address

the issue

Then a history is kept of all

maintenance actions taken

on that motor

Built in Maintenance log

Features of the APP

Motor nameplate data is

readily available and easy to

read

Sensor information is

available to ensues the most

up to date version is being

used.

Nameplate and Sensor Data

Features of the APP

Organization Overview

Web portal dashboard – electric motors

Bearing Condition

Web portal – case study on electric motors

Vibration Case Study

Web portal – case study on electric motors

Using similar sensors for multiple components

Smart sensor for pump applications

Pump Parameters

• Vibration

• Temperature

• Number of

Starts

• Operating Hours

• Bearing

Condition

• Blade Imbalance

• Cavitation

• Unbalance

• Flow Turbulence

Common failure modes of idler rollers

Digital solutions for conveyors

Failure Modes

• Damaged bearings

• Worn shells

• Tracking problems

• Operating Hours

• Blown ends

• Temperature issues

Monitoring the idlers

Digital solutions for conveyors

A crawling robot for larger motors with air gap over 10 mm

Digital solutions for large motors for air gap eccentricity

Know the health of your critical assets

Digital solutions for transformers

Organization

Organizational ManagementControl who can see what assets for added security and efficient maintenance.

Asset Group 1

Asset Group 2

Asset Groups

User Group

User Group 1

User Group 3

User Group 2

Organization ABC

—

Digital solutions in actionPictures of digital solutions in action

Customer test sites

Application – centrifugal fan Bearings – P4B-IP-307R, RE Continuous data through gateway

Fan OEM

Customer test sites

Application – Primary Crusher Tail pulley – P4B526-TAF-407R, RE Data pull via Mobile Phone

Quarry

Customer test sitesQuarry

Customer test sites

Application – washing, sorting Bearings – P4B-DI-407R, RE Data pull via Mobile Phone

Quarry

Customer test sites

Application – Plenum fan Bearings – P2B-IP-111LE, P2B-DL-111 Continuous data pull via gateway

Fan OEM

Customer test site

Application – Troughing Mixer Application Trunnion Wheel Data pull via mobile phone

Mixer, Dryer

Customer test sitesThings to think about at your location

Important considerations

‒ Availability of cell service

‒ Bluetooth range can exceed 60 feet without obstacles

‒ Know your company’s IT policies

‒ Who will have access to the sensor data and portal

‒ Will you allow your supplier to have access to your sensor data?

‒ Consider use of a gateway for continuous data monitoring

‒ Consider applications that are choke points, or primary

‒ Monitoring a system and not just a bearing

—

Considering the bottom lineWhat is your downtime worth?

– Revenue (sales)

– Cost of goods sold

– Gross profit

– Operating costs (overhead)

– Net profit before tax

– Tax

– Net income (profit)

ProfitabilityDigital technology improving the bottom line

$140,000,000

($ 91,000,000)

$ 49,000,000

($ 38,000,000)

$ 11,000,000

($ 4,000,000)

$ 7,000,000

The digital revolution and platform

The digital powertrain

Applications in aggregate

Changing the maintenance paradigm

Types of digital solutions available

Considering the bottom line

Summary

Using connected digital solutions to deliver expertise for customer value

Future blueprint for digital solutions

Integrated

Connected

Supported

Data-driven

Physical + Digital

Flexible

Secured & Trusted

Expertise