Drive systems

360° monitoring of the drive train

The Drivetrain Analyzer Cloud App and plug-and-play connection module IOT let you connect, analyze and optimize your drivetrain: take a detailed look at the current health of your entire drivetrain to catch anomalies before they cause problems, or monitor your drivetrain's energy usage and costs and get recommendations for improvements.

Plug-and-play monitoring

Imagine setting up your entire monitoring system in no time at all... The plug-and-play Connection Module IOT can be mounted and up and running in minutes. Its numerous sensors measure raw data and automatically transfer it to the cloud – without the need for additional expertise or in-house software development.

Comprehensive measurement concepts to choose from

The IOT connection module provides data in various measurement formats that can be analyzed in the Drivetrain Analyzer Cloud. On the one hand, the sensor provides continuous data for trend analyses and long-term monitoring. It also provides a daily raw data fingerprint for FFT analysis as a source for spectrum-based condition monitoring. The quality of the built-in sensors and measurement intervals of up to one minute enable superior and in-depth data analysis for continuous motion applications. The module can be operated with an external 24 V power supply or with a battery, providing the highest degree of flexibility.

Monitor what you need to know

The Drivetrain Analyzer Cloud analysis application displays data from the various drivetrain components in a state-of-the-art user interface that can be customized to suit the user's needs. The app provides detailed analysis for common thresholds, operating point detection, operating point specific limits, anomaly detection, fingerprinting, health KPIs, and even energy optimization and an operating hour-based maintenance counter. Except for defining the fingerprint, none of these features requires any kind of manual input – the analysis is fully automated.

Mechanical analysis and anomaly detection

In addition to the continuous measurement of data, the sensor module captures a comprehensive raw data snapshot daily, which is used for in-depth analysis. Based on these raw data snapshots, as well as the application type and bearing specifications, FFT and a trained analysis model are applied to perform robust real-time mechanical analysis (bearing, unbalance, and misalignment). This enables early detection of potential mechanical failures and the generation of corresponding proactive notifications.

A model is trained based on the bearing signals, unbalance and misalignment for each of the most common operating points. A traffic light is generated based on historical machine data that takes into account overall vibration in accordance with ISO 10816.

The traffic light remains in the calibration state until the new model has been sufficiently trained. Once enough data has been collected and the model has been trained, the user is notified and continuous mechanical analysis begins.

Based on the trained model, the values of the received status signals are evaluated for each operating point. If the values indicate a low to medium probability of failure, indicating a minor bearing damage or an increase in unbalance/misalignment, the traffic light turns yellow.

If the probability of failure increases above a certain level over a period of time due to several factors, indicating a major bearing failure, or if critical unbalance/alignment values are exceeded, the traffic light turns red. The user also receives a notification. The user should then check the condition of the motor on site as soon as possible and replace the corresponding bearing before more damage occurs.

Operational transparency based on energy consumption and operating hours

In the “KPIs” view, the user can see all the important data for the selected system: The “Total Energy Statistics” area shows the engine's total CO₂ emissions, total energy consumption and total energy costs since commissioning. The values are initially calculated using the extended equivalent circuit diagram of the respective engine and parameters from the “World Energy Council”.

Drivetrain Analyzer Cloud analyzes the motor's operating energy consumption and compares the energy KPIs to an alternative higher-efficiency motor. This makes it easy for users to identify the savings potential in terms of CO₂ emissions and money based on the real load profiles of the application. The potential savings in terms of energy consumption, CO₂ emissions and energy price are given as annual averages. The alternative motor and savings are recalculated every week.

The ROI is calculated based on the customer price of the alternative motor and the annual energy cost savings. Optional “fleet statistics” display asset KPIs and energy consumption information at the fleet level to compare assets. In addition to energy statistics and optimization, operating hours are counted and can optionally be used for time-based maintenance intervals. This feature can be useful for implementing time-based, machine-specific maintenance intervals in addition to the condition-based approach for the engine itself.

Inverter data integration

Drivetrain Analyzer Cloud supports drives and provides a comprehensive set of monitoring, notification, and support resources in its user interface. The app provides access to and recording of drive signals such as current, power, CU temperature, DC bus voltage, output voltage, speed, speed setpoint, actual torque, alarm and fault number, and status word. You can customize the display of up to three key drive signals together (e.g. current, speed and power). Define alarm and fault levels and log messages in a dedicated logbook for historical analysis and troubleshooting purposes. You can receive timely notifications (including by email) when predefined levels are exceeded. You also get instant access to support links via Siemens Industry Online Support (SIOS) and “Spares On Web” by entering the MLFB and serial number.

General vibration monitoring

Besides low voltage motors, the Connection Module IOT can also be mounted on other components of the drive train. This enables vibration analysis of all moving parts in your drive train to provide you with additional insights. These include the following components: