How can complex forming processes be monitored continuously and at high resolution?

Effective monitoring requires the continuous and time-synchronous acquisition of all relevant process signals across multiple process stages. With ibaPDA, data from control systems and fieldbus networks can be centrally acquired, while ibaPADU enables the direct integration of additional sensors. This creates full data transparency along the entire value chain. The high temporal resolution also allows for detailed analysis of dynamic process conditions.

How can sporadic faults in thermal and mechanical processes be reliably analyzed?

Sporadic faults require a combination of continuous data acquisition and context-based evaluation. By using ibaCapture, video data can be recorded in time synchronization with process signals and correlated accordingly. This enables the identification of influences that are not directly measurable, such as material behavior or mechanical effects. As a result, root cause analysis becomes significantly more precise and reproducible.

What approaches enable a sustainable reduction of unplanned downtime?

Comprehensive recording of all process data combined with long-term storage provides the foundation for identifying recurring fault patterns. With ibaAnalyzer, data stored in ibaHD-Server can be evaluated both interactively and automatically to detect anomalies and patterns. Based on these insights, targeted measures for fault prevention and process stabilization can be implemented, leading to a significant increase in plant availability.

How can data-driven preventive maintenance be implemented in production?

Continuous analysis of process deviations enables the early detection of indicators for wear or malfunction. ibaAnalyzer allows historical data to be evaluated in order to derive condition-based maintenance strategies. In combination with real-time visualization via ibaQPanel, critical conditions can be identified quickly. This reduces unplanned interventions and optimizes maintenance cycles.

How can scalable long-term analysis of production data be achieved?

Scalable long-term analysis requires continuous data storage without relevant time limitations. With ibaPDA, large volumes of data can be efficiently acquired and archived in ibaHD-Server, while ibaAnalyzer enables evaluation over extended time periods. This makes it possible to identify trends, gradual process changes, and optimization potential. The combination of data depth and analytical capability supports sustainable process optimization.

Hirschvogel Group Increases Productivity With the iba System

Detect Causes of Faults Faster and Reduce Unplanned Downtime

The Hirschvogel Group, one of the largest, globally operating automotive suppliers in the field of massive forming of steel and aluminum, decided to install the iba system in several forging plants.

About the Project Business Benefits The Technology Used Functions More Success Stories

A forging plant operates in different process sections: After the raw parts have been fed in and heated, the actual forming takes place in a press. Subsequently, the workpieces are transported further for controlled cooling. A large number of measurement values and signals are available during the entire production process. Powerful analysis of the acquired measurement data can reveal numerous opportunities for process and machine optimization.

In order to exploit this potential, the Hirschvogel Group, one of the largest, globally operating automotive suppliers in the field of massive forming of steel and aluminum, decided to install the iba system in several forging plants. With the help of the iba solution, the company was able to gain valuable insights, identify many sources of error and eliminate them permanently. According to Hirschvogel, the productivity of the plants was measurably and significantly increased.

Reduction of unplanned production downtime

and increase of machine availability

Improvement in product quality

and productivity

Preventive maintenance measures

based on detected deviations

Permanent recording

of all relevant measurement data

The Technology

With ibaPDA, the acquisition of measurement data is powerful, flexible and continuous.

Thanks to the comprehensive connectivity of the iba system, not only data from the control systems are recorded, but also sensors (e.g. pressure or displacement signals) can be directly connected to the ibaPDA via ibaPADU. Thus, complex installations and configurations of mobile systems are not necessary.

In addition, ibaCapture records video information synchronously to the other measurement data and stores it continuously. Both measurement and video data are available to the plant operator online and historically in the ibaQPanel-based visualization. Furthermore, maintenance staff and technologists use the powerful analysis tool ibaAnalyzer to analyze the historical measurement and video data both interactively and automatically.

Due to the consistent and continuous data acquisition, errors can be analyzed in detail already after their first occurrence and measures for error elimination can be defined. Since the recording duration of the data is only limited by the granted storage space, Hirschvogel uses the iba system not only for current malfunction and weak point analysis, but also for long-term analysis.

Large press at Hirschvogel production site

Example

Detecting faults with video and signal recording

Problem

The steel blanks sporadically stick together at the outlet of the heating system. Each time, the machine operator has to interrupt production and eliminate the problem manually.

Solution

Using time-synchronized recording of video and process data, the induction heating process was analyzed in depth. This allowed the specific triggers of the problem to be identified: By making a mechanical change and optimizing the outlet, it was possible to avoid stitching and the subsequent sticking of the blanks. This source of error and the resulting machine downtimes could thus be permanently eliminated.

Not only the frequency of unplanned plant shutdowns, but also the fast and correct analysis of the causes could be significantly improved with the iba system.

Stephan Burkart
Maintenance Machinery Electrical System, Hirschvogel Umformtechnik GmbH

Schematics of the iba system at Hirschvogel production site

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Used Functions

The following functions of the iba system are used in this success story.

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Frequently Asked Questions (FAQ)

How can complex forming processes be monitored continuously and at high resolution?: Effective monitoring requires the continuous and time-synchronous acquisition of all relevant process signals across multiple process stages. With ibaPDA, data from control systems and fieldbus networks can be centrally acquired, while ibaPADU enables the direct integration of additional sensors. This creates full data transparency along the entire value chain. The high temporal resolution also allows for detailed analysis of dynamic process conditions.
How can sporadic faults in thermal and mechanical processes be reliably analyzed?: Sporadic faults require a combination of continuous data acquisition and context-based evaluation. By using ibaCapture, video data can be recorded in time synchronization with process signals and correlated accordingly. This enables the identification of influences that are not directly measurable, such as material behavior or mechanical effects. As a result, root cause analysis becomes significantly more precise and reproducible.
What approaches enable a sustainable reduction of unplanned downtime?: Comprehensive recording of all process data combined with long-term storage provides the foundation for identifying recurring fault patterns. With ibaAnalyzer, data stored in ibaHD-Server can be evaluated both interactively and automatically to detect anomalies and patterns. Based on these insights, targeted measures for fault prevention and process stabilization can be implemented, leading to a significant increase in plant availability.
How can data-driven preventive maintenance be implemented in production?: Continuous analysis of process deviations enables the early detection of indicators for wear or malfunction. ibaAnalyzer allows historical data to be evaluated in order to derive condition-based maintenance strategies. In combination with real-time visualization via ibaQPanel, critical conditions can be identified quickly. This reduces unplanned interventions and optimizes maintenance cycles.
How can scalable long-term analysis of production data be achieved?: Scalable long-term analysis requires continuous data storage without relevant time limitations. With ibaPDA, large volumes of data can be efficiently acquired and archived in ibaHD-Server, while ibaAnalyzer enables evaluation over extended time periods. This makes it possible to identify trends, gradual process changes, and optimization potential. The combination of data depth and analytical capability supports sustainable process optimization.