New EcoScreen Maintenance Assistant

First digital maintenance assistant in use at automotive paint shops

Bietigheim-Bissingen, July 18, 2017 – Dürr’s digital maintenance assistant determines the maintenance status of a painting or sealing robot based on actual use. In this way, the newly developed software ensures higher plant availability and is a key component in the digital@Dürr concept for Industry 4.0 solutions. The intelligent system has recently been used for the first time in practice worldwide.

An illuminated green wrench on the screen shows: Everything is fine. If it is yellow, maintenance should be planned in the near future, and if it is red, maintenance work is required immediately. With the help of a traffic-light system, the new EcoScreen Maintenance Assistant shows the current maintenance needs and simultaneously indicates work that will shortly be pending. Using a control computer, the paint shop personnel can access the relevant painting station and display the status of the individual robots.

Standard practice up to now has been to document maintenance tasks in operating instructions and perform maintenance based on prescribed time intervals. Compared with this, the digital maintenance assistant offers many advantages. It provides the maintenance plans clearly arranged on a PC or on the EcoPad tablet, establishes a direct link to the technical operating instructions, updates the maintenance history online, and is oriented to the actual use of the individual plant components. “The actual condition of a painting booth is determined using everything from component operating times, counters, and test functions to intelligent wear models. This preventive maintenance planning is essential for further service measures, which in turn increase the plant uptime availability over the long term,” explains Dr. Hans Schumacher Board Spokesman of Dürr Systems AG.

The EcoScreen Maintenance Assistant determines the status of a robot using variables like the number of valve switching cycles or from the servo motor load profiles.

In the future, the system will independently analyze data and use intelligent model calculation to perform long-term observations and make comparisons across robots and stations. As a result, the EcoScreen Maintenance Assistant will transform the conventional monitoring of a plant purely on the basis of runtime into true condition monitoring and continuously optimize the maintenance intervals with its intelligent, networked technology.