Industry 4.0 refers to the comprehensive digitalization and networking of industrial production, which is intended to enable a self-organized factory and optimize the entire value chain. So much for the theory. In practice, implementation often fails due to a lack of communication and networking of components.

As part of our interview series "Three questions for...", we ask leading minds in drive technology about the potential of digitalization for drive technology and the challenges that drive technology still has to face.

Our questions were asked by:

Tim Foreman, European Manager R&D at Omron

Michael Burghardt, Head of Product Marketing for Danfoss Drives

Frank Maier, CTO at Lenze

Johannes Moosmann, Head of Industrial Drive Technology at ebm-papst

Peter Fenkl, Chairman of the Executive Board of Ziehl-Abegg SE

Jörg Niermann, Head of Marketing at the Nord Drivesystems Group

Omron: "Our artificial intelligence works on the edge"

Tim Foreman, European R&D Manager at Omron Europe.

© Omron

With currently 27 years of service at Omron, Tim Foreman has observed many stages of development in drive technology and has also been able to influence them with his responsibility for the development of new technologies.
Foreman is therefore the ideal person to talk to about the current status quo at Omron.

What new fields of application do you see in drive technology against the backdrop of digitalization?

Foreman: The discussion about the implementation of the Industrial Internet of Things (IIoT) and Industry 4.0, from smart devices to artificial intelligence in production, is gathering pace. Among other things, this is a result of increasing computing power and the availability of growing data volumes as well as the increased use of devices with IoT functions. In addition, implementation is being further accelerated by the introduction of artificial intelligence on the factory floor. In terms of control and drive technology, machine control systems equipped with adaptive algorithms offer enormous potential for further developments. This includes predictive maintenance and networked and efficient production, which are necessary in the context of Industry 4.0. In this context, manufacturing companies are realizing that these developments offer them the opportunity to increase overall equipment effectiveness (OEE), reduce costs and increase productivity.

The Internet of Things is about connected devices that respond to circumstances based on the data they collect. Without an efficient way to interpret the data and define actions, the devices simply collect information that cannot be used. When implementing smart devices for IIoT or Industry 4.0, many manufacturers are faced with a situation where they are limited by their existing infrastructure of outdated machinery and equipment and lack standardization of system architecture.

Do you already have intelligent drive solutions for networked production with regard to Industry 4.0 in your product range or in development?

Foreman: Omron's Sysmac Studio is designed to give machine builders complete control from a single environment. Sysmac Studio integrates configuration, programming, simulation and monitoring in one simple interface. This advanced software tool is the only software required for NJ Series machine automation control, bringing logic, motion and vision together on a single platform. Real-time communication to and from devices at field level, for example via open manufacturer protocols such as IO-Link, enables the devices to exchange data with the machine controller. Bidirectional communication is established so that parameters can be transferred from the controller to the devices and the status can be read out.

Omron offers the capability of artificial intelligence (AI) in a machine controller that works "on the edge" and thus enables predictive maintenance in real time. In addition to the micro-second response time to potential failures, the risk of potential safety threats associated with the use of AI is easier to control than with AI in the cloud.

In your opinion, what challenges does drive technology still have to face in the near future?

Foreman: Machines and devices within a factory are a potential source of valuable data. But how can users access and analyze the data that a machine could provide? How can a production plant then use this data as effectively as possible? Manufacturers need to ask themselves: do I have enough data, which data is the most relevant and how will it be used? And how much will the infrastructure cost? Following this, they then need to implement a system that allows them to monitor the effectiveness of machines or equipment. Once real-time communication is established between devices, field devices can be monitored and maintained before they fail and cause a line interruption. Another level of predictive maintenance can be achieved with artificial intelligence "at the edge". AI at the edge, for example using a machine controller with an AI library, enables companies to capture, process and respond to data collected at the production line level in real time.

Danfoss Drives: "The standardization of data exchange will be the basis for digitalization"

Michael Burghardt is Head of Product Marketing for Danfoss Drives.

© Danfoss

Since the development of electric motors is part of Michael Burghardt's CV, he knows drives from the ground up. It is therefore easy for him to assess current and future developments in drive technology and predict their respective requirements. His assessments.

What new fields of application do you see in drive technology against the backdrop of digitalization?

Burghardt: The original task of drive technology will not change. It consists of the safe, precise and efficient control of motion sequences.
Modern drive controllers already record a large amount of data and often forward it to the higher-level controller via a fieldbus. This can lead to a high volume of data that needs to be transported securely and processed by a central location with high computing power.
We can see that intelligent frequency inverters can offer both relief and added value here. On the one hand, they have a large number of sensors that provide valuable data and, on the other, high computing power that, if used correctly, processes this data into valuable analyses, messages and processes.

Do you already have intelligent drive solutions for networked production with regard to Industry 4.0 in your program or in development?

Burghardt: We have already implemented these intelligent solutions in our drives. For example, in the VLT AutomationDrive, a frequency inverter that has been on the market for many years and is constantly being adapted to the needs of customers with new software functions. With the latest update, we have implemented functions for status monitoring. For this purpose, the inverter performs a so-called baseline measurement. This measurement records defined data of the drive in "good condition". If deviations occur during operation, for example due to wear, the inverter issues a warning message. For example via the fieldbus. Thanks to its edge intelligence, the inverter provides event-oriented monitoring, relieves the higher-level control system and reduces unplanned downtimes. In addition to the monitoring of the system characteristic curve just described, the VLT AutomationDrive can also monitor the stator winding of the motor and evaluate external vibration sensors.

In your opinion, what challenges does drive technology still have to face in the near future?

Burghardt: The greatest potential of digitalization lies in the networking of system components. This means that system data from different applications and areas can be exchanged and used for analyses. For this to succeed, standardization is required for cross-manufacturer data exchange. Defining the characteristics and the way in which they are exchanged is currently one of the biggest challenges. This standardization of data exchange will form the basis for the digitalization of entire plant systems, regardless of their processing in the edge device, a controller or in the cloud.

Lenze: "The supreme discipline of digitalization is machine learning"

Dipl.-Ing. Frank Maier, CTO at Lenze

© Lenze

In his role as CTO, Frank Maier plays a key role in deciding on paths and investments in the Lenze Group's product and solution portfolio. Observing and evaluating social and technical trends, and in particular technological leaps, is naturally an integral part of his role in order to ensure that the company is positioned in line with the market and is fit for the future.

What new fields of application do you see in drive technology against the backdrop of digitalization?

Maier: Digitalization naturally has a lot to do with data. And in this respect, a drive controller is a real treasure. Depending on the complexity of the device, a modern inverter processes several 100 to several 1000 parameters. Our Lenze Servo Inverter 9400, for example, knows around 5000. It's easy to imagine that many of these provide a lot of information about the device itself as well as about the connected devices, for example the geared motor - about its status, any defects plus lots of operating data.

So there is no shortage of data. Logging these parameters and making them available via a bus, field or diagnostic bus, is not a problem in itself. The much more exciting question is: what exactly are they and what can they be used for? Data itself is of little value. The added value lies in condensing it into information or, even better, into expert knowledge. It's like in semiconductor technology: sand has a very low value, crystalline silicon has a much higher value and as a microprocessor, sand is suddenly worth a fortune.

Tapping into this potential is naturally a joint task between the drive manufacturer and the mechanical engineering customer. Which data can help the machine manufacturer to increase the performance of the machine, more throughput, higher yield, ...? How are machine problems reflected in the drive technology data, how can I recognize them at an early stage? The variety seems almost limitless to me. I believe that this field will be less of a product business in the next few years and more of a service that we will have to provide for our customers.

Do you already have intelligent drive solutions for networked production with a view to Industry 4.0 in your product range or in development?

Maier: As always at this point, I would like to emphasize that intelligence in the drive is really nothing new. With the PLC in the drive and the possibility of operating drive-based automation via our system bus, we have been contributing to intelligent and networked production for many years.

We have now expanded these possibilities with our x500 IoT gateway and the associated X4Remote data service to include networking right up to the cloud. We also provide a very simple tool with which our customers can quickly and pragmatically familiarize themselves with the cloud world. Solutions of this kind are indispensable for remote access to machines. The lockdown due to the coronavirus pandemic has shown us very clearly how quickly this can suddenly become important.

We use our Asset Administration Shell (AAS) to abstract our solutions into the RAMI 4.0 administration shell, which was defined in the German government's National Platform Industry 4.0. We are certainly a pioneer in the industry here.

In my opinion, however, the supreme discipline of digitalization in drive technology is machine learning, for example to preventively detect faults in the machine. We are working intensively on this topic and are involved in the it's OWL research landscape, among other things. We have already attracted a lot of attention at various trade fairs with our demonstrators. Of course, these projects also pay particular attention to the new fields of application that we have already discussed.

In your opinion, what challenges does drive technology still have to face in the near future?

Maier: Above all, we should not forget that there are other topics that are not sold under the label of "digitalization", but are nevertheless of great importance for our customers and even for our society.

A key example of this is the issue of sustainability. Intelligent, controlled drives with energy-efficient solutions can and must make an important contribution here. With the European Eco-Design Regulation 2019/1781, the next stage of legal regulations was published on October 1, 2019. It will come into full force on July 1, 2021 and will require our customers to make a considerable effort to switch to more efficient motors.

However, concepts such as the DC industry also play an important role in this context, albeit not quite so soon. This is a project funded by the German Federal Ministry for Economic Affairs and Energy, which has been given the title "Energy transition meets Industry 4.0". It combines the two major topics that are currently occupying us. The aim of this research project is to redesign the power supply for industrial plants via a smart, open DC grid and to digitalize the industrial energy supply architecture. In phase 2 of this project, 33 companies and 6 research institutes have been working together since October last year to research the DC power supply of an entire production hall. In this project, Lenze is contributing the drive technology for this revolutionary architecture. More information on the DCIndustry project.

ebm-papst: "Integrated electronics optimize the overall system"

Johannes Moosmann is head of the Industrial Drive Technology division at ebm-papst.

© ebm-papst

As head of the Industrial Drive Technology division, Johannes Moosmann's responsibilities include sales and development of components. As a result, he is able to work closely with product management to identify trends based on demand and adapt the ebm-papst company to them in a targeted manner and develop overall concepts.

What new fields of application do you see in drive technology against the backdrop of digitalization?

Moosmann: Decentrally controlled and regulated drive systems relieve the central control system and can provide valuable information about the status of the application. This is the basis for intelligent optimization of availability and product safety within machines and applications.

In this context, we are also experiencing increased demand for drives in the low-voltage protection range, i.e. products with a power supply < 60 V DC. The advantages of these DC drives can be seen in general automation technology and particularly in the use of battery-powered applications, which can be connected directly to the power supply without voltage converters and without losses. The high efficiency of the drive systems reduces energy consumption and therefore also contributes to the optimization of the overall system. In automated guided vehicle systems (AGV) and other mobile applications, the low weight of the compact drives also helps to optimize the overall system.

Do you already have intelligent drive solutions for networked production with regard to Industry 4.0 in your product range or in development?

Moosmann: Our drives come with integrated intelligence - if required - and have been for quite some time. A motor with integrated electronics records and calculates internal states, such as position, temperature and speed information, torques and current values - if required, this information can also help the customer to better understand the overall system and thus optimize it. This means that topics such as condition monitoring and predictive maintenance can be supported very well with our compact drives.

In your opinion, what challenges will drive technology have to face in the near future?

Moosmann: In the course of digitalization, the volume of data and its exchange is constantly increasing. First and foremost, intelligent drives must correctly process the valuable data available and then deliver it to a higher-level unit via the network. In drive technology, there are few standards in terms of data exchange and no uniform bus system, but a large number of different solutions. It would be nice if standards were to become as widespread as possible in the future. This would make it easier for our customers to use the available data.

The trend towards compact and efficient drives continues. From a purely technical point of view, we can implement even more efficient drive systems - there are many ideas - but unfortunately the costs of such concepts quickly spiral upwards. For this reason, we must keep an eye on maintaining a marketable price-performance ratio with every optimization.

Ziehl-Abegg: "Digitalization will enable a higher level of service"

Peter Fenkl is Chairman of the Executive Board of Ziehl-Abegg SE.

© Ziehl-Abegg

Ziehl-Abegg's wide-ranging portfolio means that CEO Peter Fenkl can take advantage of the synergy effect of different industries and their different areas of application for motors and apply digitalization processes to each other. The prospects.

What new fields of application do you see in drive technology against the backdrop of digitalization?

Fenkl: Ziehl-Abegg mainly develops and builds electric motors for elevators, city buses and fans, so I only want to look at these areas of drive technology. I see completely new areas of business in these areas: from local craftsmen to special service providers and support for complex machines and systems. Digitalization will enable a higher level of service and improve the reliability of complex systems. It also provides better information on the functioning of entire systems and individual components.

Do you already have intelligent drive solutions for networked production with a view to Industry 4.0 in your product range or in development?

Fenkl: We have been offering networkable electric motors and fans for several years. Depending on customer requirements, via Ethernet or with an IP address or even with a Bluetooth module. Our own cloud solution is now new.

What challenges do you think drive technology will have to face in the near future?

Fenkl : Drive technology must be easily integrated into cloud solutions across all providers. Security against access by third parties will be a key issue here. For this reason, we have chosen Deutsche Telekom as an experienced partner for our ZAbluegalaxy cloud solution.

Nord Drivesystems: "Condition monitoring and predictive maintenance for system efficiency"

Jörg Niermann is Head of Marketing at the Nord Drivesystems Group

© Nord Drivesystems

With a degree in production engineering and his current role as Head of Marketing for Nord Drivesystems, Jörg Niermann is able to view trends from a technological perspective as well as recognize and evaluate opportunities and potential for the industry and, accordingly, for his own company.

What new fields of application do you see in drive technology against the backdrop of digitalization?

Niermann: The focus is primarily on topics such as condition monitoring and predictive maintenance - in other words, concepts that can be used to optimize the operational reliability and efficiency of machines and systems. If you take our drive solutions, for example, drive and condition data can be recorded permanently or at regular intervals. This enables continuous condition monitoring and thus lays the foundation for predictive maintenance concepts. Equally important: communication options for drive technology. Our inverters have condition monitoring solutions for predictive maintenance systems and are optimally equipped for use in IIoT and Industry 4.0. Communication interfaces transmit threshold values or general status information to the outside world. Service calls can be better planned by using the data provided. This is complemented by mobile solutions such as our Nordcon app. One highlight of the app, for example, is the dashboard-based visualization for drive monitoring and fault diagnosis.

Do you already have intelligent drive solutions for networked production with a view to Industry 4.0 in your product range or in development?

Niermann: Yes, we offer our customers condition monitoring for predictive maintenance concepts. Our inverters are equipped with a PLC as standard. This can process the data from connected sensors and actuators, initiate sequence controls and communicate with other system components. The periodic or continuous recording of drive and status data allows unacceptable operating states to be detected and avoided at an early stage. Unplanned downtimes can thus be significantly reduced and condition-based maintenance (predictive maintenance) takes the place of time-based maintenance. Machine or system downtimes can be planned. This is precisely the aim of predictive maintenance.

In your opinion, what challenges will drive technology have to face in the near future?

Niermann: Digitalization has long since ceased to be a trend and is now a reality. One thing is clear: in order to meet customer requirements, digital images of products must become part of the entire process chain. All drive technology manufacturers must face up to this reality. At Nord, we have been working on digitalization at process and product level for years. In Nord's own application test field, we have the opportunity to gain precise insights into the operating behavior and control of drive technology and to put new products and technologies through their paces. All of these results are incorporated into our product strategy.