Keeping the uptime, i.e. the operational capability and availability of mobile machinery, as high as possible is one of the most important requirements in the off-highway sector. This will also be a key topic at SYSTEMS & COMPONENTS, which takes place from 9 to 15 November at the same time as AGRITECHNICA. Condition monitoring, remote diagnostics and predictive maintenance are among the key topics at the exhibition centre. Solutions will be on show in Hanover that use intelligent sensors and data analyses to draw attention to malfunctions in good time - making it possible to plan maintenance measures and better utilise reserves of wear parts.

Off-highway machines are indispensable for heavy-duty tasks in the field or on construction sites. The extreme operating conditions require components that can withstand the highest loads. But sooner or later the point comes when wear occurs. The driver in the cab often notices the signs of wear too late. Any damage to the vehicles means expensive repairs and long downtimes, which is why the classic "run-to-failure" procedures of reactive maintenance reach their limits here. Prevention is therefore the motto at the exhibition centre in Hanover.

"Recognising faults and defects in advance and taking maintenance measures promptly - these are crucial factors for working efficiently, and not just for agricultural machinery manufacturers, contractors and farmers," says Petra Kaiser from the DLG (German Agricultural Society). Predictive maintenance, i.e. the combination of modern sensor technology and real-time data analysis, which uses algorithms to predict when damage will occur based on current and historical data, also helps to determine the perfect repair time on the construction site. "The companies exhibiting in Hanover are working flat out on solutions that are based on predictive maintenance strategies and localise mechanical, hydraulic, electrical and electronic faults before they become costly," says the SYSTEMS & COMPONENTS Brand Manager. The total cost of ownership (TCO) of the vehicle over its useful life is always kept in mind. In addition to the benefits for customers, the information obtained using monitoring and diagnostic apps also has great potential for engineering, sales and service. For example, the design of machines - long before they are built - can be optimised using real load spectra and usage data.

Machine information in real time

Digitalisation is an important driver in the development of predictive maintenance systems in the off-highway sector. It makes it possible to collect and analyse large amounts of information from various sources along the entire drivetrain. Smart sensor technologies expand the available database, while powerful telematics units with numerous interfaces ensure secure data transmission in demanding application scenarios. The exhibitors at SYSTEMS & COMPONENTS have taken on the challenges of agriculture, forestry, construction and mining and offer systems that promise maximum diagnostic reliability despite adverse conditions.

Condition monitoring focuses on vibration measurements, among other things. If they are carried out on the running machine, they are an effective method for detecting wear on drive shafts, roller bearings, gearboxes or motors in good time. The insight provided by the data extends deep into the system and component level of the vehicles. The sensors record the stresses and material fatigue directly at the relevant points. Whether torque measurement in shafts of main or auxiliary drive trains or tensile force detection in force measuring bolts - many of the wireless solutions that will be presented in Hanover are characterised by their user-friendly plug & play philosophy. With a combination of IIoT sensors, gateways and cloud services tailored to individual requirements, nothing stands in the way of subsequent integration into the system architecture of the machines.

Sensors for use in harsh environments

Smart, integrated and remote, the sensors are little helpers with a big impact. In addition to their basic function of recording a measured variable, they provide further information and recommendations for action - for example, as a variant with an additional black box function from which historical data can be retrieved if required. Or as a sensor that uses algorithms to provide initial recommendations for action to the driver in the cab. This means that the systems can also be used autonomously in environments without a data connection, for example in mines. They can be used to predict exactly when the next maintenance is due. This makes maintenance planning easier because it can be better synchronised with inspections.

The latest innovations include electronic sensors for construction machinery that provide real-time information on the wear condition of the crawler track without the need to measure the track link. They are used as standard on Cat dozers with an HD-XL undercarriage from the D5, D6 and D8 series as well as on Cat 953 and 963 track loaders. The sensor is installed securely in the track link so that it is not affected by impact loads. Both chain strands are equipped with such an intelligent chain link, so each machine has two sensors. At a wear reference value of 40 per cent, an initial inspection of the drive is recommended. If the wear value reaches 100 per cent, replacement is necessary. Over 2,000 Cat machines have been equipped with the technology to date. "Over 60 of them are currently in use across Germany," confirms Andreas Kurz, Senior Product Manager Undercarriages at Zeppelin Baumaschinen GmbH. One sensor has already been triggered, "which has prevented machine failure and repairs."