Interested in maximizing productivity? Look no further than predictive maintenance. Predictive maintenance applies failure prediction techniques to detect equipment issues that could cause unscheduled downtime. By identifying problems early, organizations can strategically plan maintenance and increase uptime. The result is higher throughput, improved quality, and reduced cost of ownership. This is not a description of some future technology predictive maintenance can be enabled within drives, sensors, and encoders today. In fact, it may be embedded in components you already own or use. All you have to do is take advantage of it.
Manufacturing is challenging
尽管经济蓬勃发展，但对于为其服务的生产商和OEM而言，制造业仍然具有挑战性。消费者要求以岩石价格的价格进行高性能和定制。作为回应，制造商试图最大程度地提高其设备的吞吐量和可用性，以及其生产优质产品的能力。可以使用称为操作设备有效性（OEE）的度量来监视这些因素。最大程度地减少停机时间是OEE的核心原则，也是产生总体运营成本的总体动力的一部分。制造商寻求OEM和机器建造者进行交付。
OEM的作用一直是构建执行功能并解决客户痛点的设备。为了改善OEE，机器制造商需要找到一种增加正常运行时间的方法，而不会增加设备和支持的成本。后者是一个重要的问题。经济低迷之后，制造商剥夺了工程部门。他们没有维护大型维护人员，而是与小型团队合作，并依靠其机器建造者和集成商来填补空白。尽管OEM会很乐意承担维护和支持职责，但负责在远距离部署的大量机器负责可能是具有挑战性的。预测维护为最终用户和机器构建器提供了一个很好的解决方案。
Inside predictive maintenance
预防性维护一直是寻求维持正常运行时间的组织的首选方法。问题在于它基于可能不一定反映实际操作的用法模型。它还假设正确执行维护任务，这绝不是给定的。预防性维护是基于应该发生的事情。预测维护是基于实际发生的事情。
Preventative maintenance involves predicting failure by analyzing changes in key metrics like friction, vibration, and positioning error. Sudden changes in any of these characteristics can provide advance warning of issues such as bearing defects, lubrication breakdown, guide wear, etc.
这是特别重要的应用预测模型aintenance to critical assets that are the chokepoints of an entire process. If the motor on a depalletizing conveyor fails, for example, it may shut down the entire operation. A cloud-based predictive maintenance solution can send alerts to the on-site maintenance department and the OEM, enabling them to immediately assess the data and determine an appropriate response. In some cases, the issue can be solved by downloading a software patch or updating firmware. In other cases, the OEM support member may still need to travel to the customer, but this time they have all the relevant data at their fingertips and can rule out common issues even before leaving the office.
预测维护有可能从根本上改变OEM业务模型。支持服务级协议变得更加容易。他们可以使用数据来潜在地跟踪设备是否适当操作，或者用户是否违反了规格或保修条件。在部署机器上捕获的数据可以为未来平台的设计提供见解。
关于预测性维护的真相
Given the benefits for both end-user and OEM, predictive maintenance should be commonly deployed. Certain forward-looking sectors like semiconductor fabrication and automotive have been implementing predictive maintenance for years. For the most part, however, adoption has been slow, based in large part on misconceptions:
一个误解是预测性维护很复杂。在当前的市场中，许多机器制造商正在奔跑。他们可能有很多订单，以至于他们觉得他们没有时间构建更多版本的当前平台，更不用说修改它们以包括新技术了。事实是他们不必这样做。有了当今的智能组件，他们可能能够使用已经使用的设备实施预测性维护。例如，在某些三菱MR-J4驱动器中，内置了预测维护功能（请参见侧栏）。驱动器仅需要简单的配置才能正确激活和部署。可以通过用户界面或HMI更改应用程序参数，以启用此有用的功能。无需其他传感器，软件或分析。
图1：Another misconception is that the technology is expensive. Budget is always a concern in the industrial environment. Machine builders don’t want to increase cost or pricing. Built-in functionality means that the technology is available without any additional investment. This is an important attribute. It enables OEMs to:
• add value to their machines without increasing cost or price
•增加了这些客户已经拥有的机器上客户的功能
•通过降低新机器的支持成本和现场的支持成本来节省资金
最终用户和OEM预测维护的好处是不可否认的。具有内置预测维护功能的智能驱动器可为这些收益提供，而不会增加成本或复杂性。这些驱动器为OEM配备了OEM，从而在不改变其BOM的情况下为新机器增加了预测性维护。他们可以为客户提供预测性维护功能，而无需额外的费用。鉴于这一点，我们预测广泛的部署就可以实现了。
Product Spotlight: MELSERVO-J4 features built-in failure prediction
对于希望尝试预测性维护的公司，Melservo MR-J4-GF（-RJ）伺服驱动器提供了理想的切入点。Melservo MR-J4-GF（-RJ）提供完整的AC伺服驱动功能，具有重要的附加功能：全面的内置故障预测功能。这个24/7监视功能使资产所有者和最终用户能够在足够进展之前先检测到设备问题，从而导致未定的停机时间。维护团队可以尽早诊断问题，并在影响最小的吞吐量时安排维修。故障预测功能可在易于实施的解决方案中提供可靠的保护，该解决方案不需要OEM或所有者的额外投资。
The MELSERVO MR-J4-GF(-RJ) provides information on machine condition without any need for additional sensors. It applies sophisticated algorithms to standard drive data such as positioning error and torque increase. Capabilities include:
•摩擦故障预测函数：驱动器预测导致指南和击球板的变化引起的故障
•振动故障预测函数:开车models changes to magnitude and frequency of the vibration spectrum, using it to predict failure based on aging in guides, ballscrews, and belts.
• Total distance failure prediction: In the drive applies data on lifetime travel distance of the servo motor to identify when ball screws and bearings are approaching end of product life.
图2：MELSERVO MR-J4-GF(-RJ) drives analyze standard torque and feedback data to diagnose issues that could lead to premature failure and unscheduled downtime.
驱动器可以将警报发送到图形操作员终端（GOT）或HMI。根据实现的不同，它可以用作启用云的预测维护系统的一部分，该系统允许OEM监视警报并访问当前和历史机器性能数据以确定根本原因。
The MELSERVO MR-J4-GF(-RJ) also incorporates auto tuning capabilities. These functions allow the drive to automatically compensate for the detected errors to maintain optimal performance until such a time as maintenance addresses the true issue.
The failure prediction function is available on MELSERVO MR-J4-GF(-RJ) servo amplifiers with software version A3 or later.
