The history of industrialisation extends over several centuries but the latest industrial revolution has led to rapid changes like nothing before. It raises many questions but also yields an enormous potential.

Added value to boost your success

Information collected directly within manufacturing processes is becoming a key strategic input to broader business success. Emerson brings direct added value to your IoT concept, with smart components that can be seamlessly integrated into a digital environment thanks to built-in intelligence and compliance with all relevant communication standards. Our solutions are aimed at the flexible use of the generated information. Local evaluation and storage of the components, in a local database, in a private public cloud – all options are covered. 

Smart Pneumatics Monitor (SPM) – our core product for digital process networks

Want to check the state of wear of actuators? Need information on energy efficiency of your pneumatic systems? Information collected directly within manufacturing processes is becoming a key strategic input to broader business success. The new AVENTICS™ Smart Pneumatics Monitor offers reliable and valuable answers to users. It sends pre-processed status messages to defined employees and parent IT systems without detouring to the machine controller. This information reduces the risk of machine downtime and significantly lowers operating costs.

How it works: data flows

The collection of operating states and their predictions as the basis for anticipatory maintenance and control concepts offer immediate benefits, specially for customers using IoT applications. Together with our AVENTICS™ AES fieldbus solution, the Smart Pneumatics Monitor (SPM) IoT Gateway analyses existing sensor signals and uses the result to generate reliable status information. For example, to check the wear of a shock absorber, the SPM breaks down the limit switch signals to evaluate the cushioning sequence. Algorithms written by Emerson based on the company’s application experience analyse this data internally and send the information either to defined persons or to the parent MES or ERP systems via the OPC UA interface.

Easy configuration and operation, major benefits

Using drag and drop, the components to be monitored are combined and linked in the SPM. Upon request, the module monitors the current energy consumption or the degree of wear. For example, users can take measures for optimisation at an early stage and thus meet the requirements of the EU Energy Efficiency Directive and minimise unplanned system downtime. 

The four below mentioned SPM applications are characteristic examples that illustrate the simple operation and the great flexibility of this innovative IoT gateway:

  • Maintenance monitor
  • Data management
  • Energy efficiency
  • Optimised consumption

 1. Maintenance Monitor – Determining Wear

The shock absorber in this configuration had been replaced in regular routine intervals determined on the basis of past experience with the individual application – purely as a precautionary measure and not based on actual facts. The SPM now uses the cylinder sensor data to analyse the timing characteristics of the cushioning. Because the cushioning time decreases over the service life of the shock absorber, it provides direct proof of its state of wear. Once a critical value has been reached, an error message can be output to exchange the shock absorber before it fails.

2. Data Management – Counting Switching Cycles

A valve’s state of wear is very difficult to determine from the outside but additional internal sensors would increase its size and add to costs. The SPM, on the other hand, can provide information on the expected service life of the valves – without incurring additional costs and effort. By measuring the exact switching cycles of the valve, it is possible to extrapolate the end of its typical service life. Preventive maintenance can then be carried out to prevent downtime in critical applications.

3. Energy Efficiency – Detecting Leakages

Energy efficiency is an important economic factor. The SPM gives a clear indication of where and how the compressed air consumption changes – and allows users to determine the location of possible leakages. Predictive diagnostics is one of the main arguments for efficient use of the SPM.

4. Optimised Consumption – Creating Optimal Compressed Air Balance

Whether during the initial configuration or to improve ongoing operation: an optimum compressed air level saves money and prevents wear of the components. An SPM analysis helps you to determine the optimal operating point for a perfect balance between the activities to be performed and the supplied energy.

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