smart industry solutions in catalonia and slovakia

This project has received funding from the European Union’s Horizon 2020

research and innovation programme under grant agreement No 886905.

Smart Industry Solutions in Catalonia and Slovakia

Industry 4.0 SOLUTIONS FOR MODERN FACTORIES

Webinar, 16 June 2021

Electrical Experts for Machines & Installations Maintenance



INDEX

1. Current Situation

2. Problem to be solved

3. Solution: Electrical & Sustainable Maintenance Platform

4. Application exemples

5. Services

6. Sensors

7. IoT devices

8. Success Stories

9. Clients

10.Our Team



SLOVAKIAIs one of the European leaders in automatization and factories digitalization.

&

SIGMAIs one of the leading companies in the world, supporting the digital

transformation into the Industry 4.0 ecosystem, within the development, research and analysis of electrical data for

the MAINTENANCE of machines and installations.

CURRENT SITUATION



Let’s see how SIGMA can be useful for your company, to obtain an efficient, sustainable and reliable maintenance.

In order to:

➢ Avoid major failures.

➢ Increase the safety of your facilities.

➢ Maintain better machines for longer.

➢ Anticipate incidents and unplanned downtimes.

CURRENT SITUATION



18% of assets have an age-related failure pattern3

82% of asset failures appear random3

40% of preventive maintenance costs are spent

on assets with negligible affect on uptime failure1

30% of preventive maintenance activities are

carried out too frequently1

45% of all maintenance efforts are ineffective2

1 Source: Oniqua Enterprise Analytics, Reducing the Cost

of Preventive Maintenance,

2 Source: T. A. Cook, Maintenance Efficiency Report

3 Source: ARC view. Optimize Asset Performance with

industrial IoT Analytics

4. Source https://easa.com/resources/failures-in-three-

phase-stator-windings

Damage caused by bad electric contact in one phase Source4 :

PROBLEM TO BE SOLVED

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IF WE KNOW HOW ELECTRICITY BEHAVES,

WE CAN SOLVE THE PROBLEM FOREVER,

BECAUSE IT WORKS ON A CLOSED CIRCUIT

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SOLUTION: Electrical & Sustainable Maintenance Platform

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research and innovation programme under grant agreement No 886905. random

SOLUTION: Electrical & Sustainable Maintenance Platform

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Technology Assets covered Failure detection How is done

MCSA, motor current signature

analysis

Leakage current analysis

Voltage analysis

Power analysis

Smart electric protection

Electric efficiency

Transformer Wiring MotorPump

VFD FanGenerator

Vibration analysis

Thermal analysis

Wiring

Mechanical

• Unbalance

• Misalignment

• Bearing damage

Mechanical & electric

• Cold points

• Hot points

• Electric arch

• Fluid leaks

Mechanical & electric

• Electric arch

• Energy quality

• Mechanical in motors,

pumps, etc.

• Vibration sensors

installed over motors.

• Online or data logging

• Thermal cameras.

• Online or data logging

Electrical analysisfor Machines &

Installations Compressor

Motor Pump

Fan Generator

Compressor

GeneratorTransformer



APPLICATION EXEMPLES

USING

SIGMA’S SERVICES



APLICATION EXEMPLE: Generators and Electrical Transformers

POWER QUALITY ASSURANCE

Electric quality generation evaluation to ensure powered

assets performance

OVERLOAD & UNBALANCE

Ensure long availability for your key assets being

aware of their performance and power demand

POOR CONDITION CONECTIONS

Avoid erratic behavior and hot connections that can start

a fire

“Expand the life of your key assets by a permanent electric analysis”



APLICATION EXEMPLE: Electrical Motors

“Know in advance a potential fault in a motor, pump or compressor. Prevent

your process from stopping”

MOTOR OVERHEATING

Identify electric unbalance, overload or low voltage that

can produce motor overheat

SHORTCIRCUITS

Control isolation levels continuously to avoid

CURRENT LEAKAGE

Identify dangerous assets and avoid electro-erosion



APLICATION EXEMPLE: Frequency Drivers

“Notice if the drive is negatively influencing your engine, or if it is the

best option”

ELECTRICAL QUALITY POWER

Avoid driver deterioration identifying power quality

issues

WRONG SETTING

Avoid current reflux and high current peaks

HARMONIC GENERATION

Identify harmonic generation to improve quality

power in your plant



SIGMA’S SERVICES



SERVICES:

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DESCRIPTION

1. Web browser access to Sigma platform.

ELECTRICAL MONITORING 2. Continuous & automated electric data registration, up to 3 months

3. Power, consumption and electric event registration, up to 3 months


SURVEILLANCE & SUSTAINIBILITY 2. Continuous & automated electric data registration.

3. Power, consumption and electric event registration.

4. Electric alarm configuration.

5. Monthly status report by e-mail and exportation capabilities.


2. Continuous & automated electric data registration.

ELECTRICAL-BASED MAINTENANCE 3. Power, consumption and electric event registration.

4. Electric alarm configuration.

5. Monthly status report by e-mail and exportation capabilities.

6. Report electrical and mechanical problems of machines or installations.

ELECTRICAL-BASED PREDICTIVE MAINTENANCE

DIAGNOSIS OF ELECTRICAL FAULTS

SERVICES

B

Y

Y

O

U

R

S

E

L

F

B

Y

S

I

G

M

A

We provide you with a suitcase with all the necessary material to obtain

the electrical information and Sigma carries out the diagnosis to know the

current.

We offer the Electrical-based Maintenance service managed by us,

anticipating the problems that may occur now or in the next moths with

the aim of avoiding major accidents or failures that would cause large

costs to the company.



SENSORS:

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SENSORS PROTECTION REGISTER

ISM4M1

2 poles, from 5 to 280 A, 50 Hz

ISM4T1


ISM4R1


ISM4 Suitcase3 poles, 250 A, 50Hz

16


- 22 different electric

configurable protections

ISM2TFrom 63 to 125 A, 50Hz

ISM1MFrom 6 to 63 A, 50Hz

ISM1TFrom 6 to 63 A, 50Hz

MEASURE & PROTECT & REACTIVATE SENSORS:

MEASURING & PROTECTORS SENSORS:

MEASURING SENSORS:

- True RMS

- 0.1/0.2/0.4/0.5/1 % accuracy

depending on sensor model

- Electric real time data.

- Electric quality alarms.

- Power alarms.

- Electric status logs (ON/OFF, etc.)

- Electric quality problems register

(wave event)

- More than 100 electric parameter (V,

I, etc.)

- Active and Reactive power register.

- 64 Harmonics real-time analysis in

voltage and current.

Not Available

- 22 different electric

configurable protections

- Autonomous reclose system

- Remote operation available



32IOT DEVICES

IoT Communication:

Allows you to work up to with 10 machines/equipments connected at the same time.

You can choose with the following options:

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Reference Description

M2MIOT SERVER01- IoT Server to collect until 10 sensor data by Ethernet connection

(Ethernet hubs and/or switches not included)

- For Ethernet or WIFI integration

M2MIOT SERVER02 - As M2MIOTSERVER01 but including GSM capabilities for

integration through 3G

M2MIOT SERVER03- As M2MIOTSERVER01

- UPS capabilities for data registration under energy power fault

M2MIOT SERVER04- As M2MIOTSERVER02

- UPS capabilities for data registration under energy power fault



SUCCESS STORIES

USING

SIGMA’S PLATFORM



SUCCESS STORIES: Process Machine 1

PROBLEM:

Water pumping station

Several electric problems in the electric installation.

Occasionally the electric protections were damaged

and there was no acknowledgement about pumps status.



SUCCESS STORIES: Process Machine Outcome

OUTCOME:

Thanks to automated and continuous electric analysis the customer has real time visibility about the pumps

and can identify machinery and installation problems. As an example it has been identified high intensity

current peaks in breaking operation controlled by a soft starter. These peaks were damaging the installation

an electric protections.



SUCCESS STORIES: Backup Generator

Application:

Once the analyzer is installed after the transfer switch, Predictive Sigma will help to:• Identify the active power source:

showing energy consumption and quality.

• Inform if energy disruptions are happening and can damage the installation.

• Evaluate generator’s performance and inform about overload and generator’s health.

• Estimate diesel or gas consumption by usage, learning about real consumption during use.

• Inform about necessary maintenance calculated from real use.

• Predict possible generator failure by analyzing use and behavior.

Backup generator

Transfer switch

Bac

kup

Gen

era

tor

3G or WIFIconnection

L1 mainsL2 mains

L3 mains

N mains

N generator

L3 generator

L2 generatorL1 generator

NL3L2L1

To building

Current sensors

Analyzer

Power supply



SUCCESS STORIES: Backup Generator Problem

Backup generator in use

When the generator is giving power to the installation can suffer important impacts from the load.

On this example, we show how the connection of an important load generates a voltage disruption

and reduces voltage range from his connection.

This is an usual behavior but if it repeats frequently or is combined with generator overload can

damage the generator.

Backup generator disconnection

During generator’s or mains disconnection and depending on load, the energy can have important

inertia and remain in line during considerable time. This makes the line dangerous for human

interaction and it’s necessary to ensure the complete energy download before acting. This

disconnection can also generate overvoltage in the line. This overvoltage can damage the load

devices connected to the installation and is important to check continuously to avoid breakdown.

Mains power reconnection

If we add to the previous case the mains reconnection not giving enough time for energy discharge,

the problem multiplies his effect. On this example the remaining energy crashes with the mains

energy generating very important overvoltage that can burn devices and stop the process or

installation operation for a long time.



SUCCESS STORIES: Backup Generator Outcome

OUTCOME

Our customer modified the transfer switch

configuration giving additional few seconds before

reconnecting to the mains. With a simple modification

the problem was solved finishing with the breakdown

problems and asset damage in the factory.

The system continues under predictive-sigma

surveillance to confirm his correct behavior.




PROBLEM

Packaging machine for cosmetics with unexpected stops.

Long period required to resume process, also the need

to reprocess or dispose the production material that was

in the machine during the unexpected stop.




OUTCOME

Thanks to automated and continuous electric analysis it was identified a leakage

current problem.

Using the information the customer fix the root cause removing the unexpected stops.

In red

leakeage current



SUCCESS STORIES: Electrical Installation

PROBLEM

SME Company with continuous failure in

electronic control equipment, specially in

his main printing machine.

Losses for more than 200K € in two

years.



SUCCESS STORIES: Electrical Installation Outcome

OUTCOME

Thanks to automated and continuous electric analysis it is identified a high energy overvoltage in

the mains. Peaks shorter tan 2ms but repeated 2-3 times per minute. The customer finds an

alternative power source and request compensation to the electric distribution company.

High energy short

time overvoltage




Formwork panel cleaning machine in Düsseldorf (Germany)

PROBLEM

German company with automated

cleaning process for formwork

panels.

No visibility on the operation and

performance of their machines.

Commonly damaged brushes motors

not knowing the reason.

Stopped process and performance

reduction




OUTCOME

With the integration of sensors in different machine areas our customer won operation visibility in a

simple and low-cost way.

predictive-sigma identified recurrent power peaks overpassing heavily the nominal motor power due

to machine bad configuration. That was causing motor burning and process stops.

With the new information the operators have been trained and the process has improved drastically.

Overload peaks

for brushes motors




Pellet machine in Queretaro (Mexico)

PROBLEM

A new brand pellet machine installed

in Queretaro was integrated to the

platform to identify its behavior and

performance.

The pilot was focused to identify

potential problems and bad

performance with a low cost and plug

and play solution rather to install

vibration and temperature sensor on

top of the main machine motor.




Behavior indicating wrong electric connection Behavior indicating insufficient reactive consumption compensation

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OUTCOME

After machine integration predictive-sigma identified immediately a bad electrical connection that was making the

motor to rotate in the bad direction. This identification allowed the customer to correct the electrical installation and

avoid machine breakdown.

After a week of electrical analysis predictive-sigma identified that the machine was generating huge amounts of

Reactive current that was not compensated with the existing installation. This was causing important extra cost

regarding electrical payments.

Nowadays the machine is under surveillance to identify its normal behavior and help the customer to improve

efficiency.




Pellet machine in Queretaro (Mexico)

PROBLEM II

There was identified a high current

machine disconnection that stopped the

operation for minutes, a non expected

behavior. The current peak was so huge

that stopped the operation in the machine

and the complete process line for minutes.

The machine was reconnected without any

observation or information to the Process

Manager, he was not aware about the

incident.


research and innovation programme under grant agreement No 886905. random random


OUTCOME

Seeing the event, the customer was asked. After some investigation it was discovered that operators performing cleaning

on the machine left felt in a metallic plate that was blocking the motor. That produced a collapse in the machine that

triggered currents far away the machines operations level tripping the main electric protections for the complete lines.

predictive-sigma real time registration and analysis capabilities allowed the customer to be aware of the event and

perform corrective action to avoid the mistake in the future. After the incident, the machine is under continuous electric

surveillance to identify if the incident damaged the machine and its performance.



CLIENTS AND TEAM



CLIENTS

Manufacturing Utilities Infrastructures


research and innovation programme under grant agreement No 886905. random

TEAM

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Carles PaulScientific Director

Physicist and PhD candidate in Electromagnetism Experience Mathematical specialist,

R+D leader and link with the university

Patricio SáezCEO

Industrial engineer and Executive MBAExperience in developing industrial business

internationally

15years

Ramón SerraCTO

Industrial engineer and master in AI, robotics and automation. Experience in

industrial applications and product development

RodolfoElectrical expert

AdrianoBusiness advisor

JoseIoT expert

ClaudioBusiness dev.

JosepAnalyst

CarlaMarketing

BegoñaMarketing Mngr.

A balanced mix with more than 50 year of combined experience:

20years

30years



Thank you so much

for your attention!

Patricio SaezCEO

[email protected]

www.predictive-sigma.com

Electrical Experts, for Machines & Installations Maintenance

mailto:[email protected]

http://www.predictive-sigma.com/

smart industry solutions in catalonia and slovakia

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