Avoid downtime, make plant condition transparent

The positioning systems from Lang GmbH & Co. KG are now equipped with a predictive maintenance function. Through continuous analysis of following error, the automation systems detect changes in the motion and system behavior of axes at an early stage. This enables condition-based maintenance planning, reducing unplanned production downtime and utilizing plant resources more efficiently. The function is integrated into the controllers of the LStep express, LStep PCI express, and LSMART express series and can be visualized directly in WIN-Commander.

The application helps users plan maintenance measures based on real-world operating data – instead of relying solely on fixed maintenance intervals or reacting only after a defect occurs. This significantly increases plant availability and process reliability.

"With the integration of following error analysis, we are expanding our controllers with a practical condition monitoring function," explains Ralf Rink, Head of Automation Systems Development at Lang. "Users gain additional transparency into the behavior of their axes and can perform maintenance measures in a targeted and predictable manner."

From Reactive Maintenance to Condition-Based Maintenance

Mechanical components such as motors, gearboxes, ball screws, and bearings are subject to wear due to their design. If a defect is only detected after it has occurred, this can lead to unplanned downtime and disruptions to upstream and downstream production processes.

Even maintenance at fixed intervals only partially reflects the actual condition of a system and can cause unnecessary interventions or production interruptions.

The new function of the Lang controllers therefore supports a predictive maintenance approach: Maintenance measures can be scheduled when operating data indicates changes in the system condition.

Following Error Analysis as an Indicator of Wear

The core of the solution is the continuous evaluation of the following error, i.e., the deviation between the target and actual position of an axis. Changes in this value can provide indications of mechanical changes or increasing loads in the drive system.

This requires encoder evaluation on the relevant axes. This can be performed on both the drive (motor) and output sides. The controller continuously acquires data. Trends or noticeable changes in the axis's movement behavior can be detected by the application.

Visualization and Analysis in WIN-Commander

The evaluation is performed directly at the controller level and displayed in WIN-Commander, the central operating and visualization software for the controllers. Users can graphically analyze position and motion data as well as the progression of relevant parameters.

An integrated oscilloscope function supports the detailed examination of motion profiles and system responses. The application can also be integrated into existing automation environments via the Lang API. This makes the solution suitable for both new systems and existing systems – provided the necessary encoders are available.

Greater Transparency for Stable Production Processes

Production environments with high demands on availability and process stability – such as in precision mechanics, toolmaking, or medical technology – particularly benefit from this new function. Maintenance measures can be planned more effectively, downtime reduced, and mechanical assemblies utilized more efficiently.

“With this development, we are giving our customers a tool that will allow them to better understand the condition of their systems and make more informed maintenance decisions,” said Ralf Rink.