In today’s dynamic market environment, with shifting workforce availability, production costs, and product lead times, there is a pressing need for increased productivity and intelligent machines. Despite the many articles written about the industrial internet of things (IIoT), machine asset managers and machine designers still struggle with how to practically implement and use the many types of data that IIoT can deliver.
A whitepaper “Why creating intelligent machines may not be as difficult as you think” by Erik L. Barnes considers this. It presents a practical blueprint for leveraging simple intelligence in electric motor control systems.
Electric motors are at the heart of industrial machines and processes, converting electrical power into rotational mechanical power. However, traditional motor control methods lack visibility into performance issues until an unplanned shutdown occurs. This paper discusses the application of intelligent motor starters in terms of how the data relates to motor/load performance. It also considers the methods to apply this data to practical applications, resulting in greater productivity and labour utilisation.
Intelligent Machines
It makes a compelling case that embedding basic intelligence into motor control systems can unlock significant benefits. For example, by minimising downtime, increasing output, enabling initiative-taking maintenance, improving energy efficiency, closing skills gaps, and enhancing safety. It outlines practical steps to devise intelligent motor controls by identifying key issues, measurement indicators, alarm triggers, and corresponding actions.
It can detect abnormal current levels that indicate issues like jams, debris, cavitation, or filter blockages and other issues. The smart motor controls can then raise appropriate alarms to alert operators or initiate automated corrective actions before disruptions occur. This indicative approach provides valuable insights without the complexity of cloud analysis or excessive motor data processing.
The whitepaper highlights TeSys Island by Schneider Electric as a pre-engineered, modular solution that embeds this simple intelligence. TeSys Island manages motors up to 40 kW, monitors energy usage and diagnostics, integrates seamlessly into automation systems, and promises faster design, installation, and commissioning through its innovative features
Overall, this compelling read demonstrates how straightforward intelligent motor control can be using the right solution approach. Engineers looking to elevate their machine capabilities and tackle common industrial challenges should strongly consider the strategies outlined in this practical blueprint.
By leveraging simple, embedded intelligence in motor controls, engineers can significantly enhance machine performance, reduce downtime, and improve energy efficiency. Moreover, it offers a clear pathway for implementing these advancements, making it a must-read for any engineer looking to stay ahead in the field of industrial automation.
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