Predictive Maintenance Automation Software for Robots in Vehicle Manufacturing

Did you know that both old-school car manufacturers in Mexico and new electric vehicle makers are betting on robots for their production lines? Yes, they're a significant investment, but the benefits are enormous: from increased precision and safety to more efficient and adaptable production.

And since these companies are betting big on Collaborative robots in the automotive industry, it makes perfect sense in the world to take care of those investments, don't you think? That's why, at ULTATEK, we focus on ensuring those assets are always in optimal condition and have a prolonged lifespan, with top-notch maintenance practices!

But be aware, traditional time-based maintenance is no longer the height of efficiency. This is where predictive maintenance comes in: can you imagine being able to predict when a robot will need maintenance based on its own condition and performance? It's like a superpower for your machines!

At ULTATEK, we're all about that smarter, more cost-effective approach. We're all in on predictive maintenance, which not only ensures your assets are in their prime but also saves you time and money in the process. It's a win-win for everyone!

 

Predictive maintenance in the automotive sector

First, to understand the business case for predictive maintenance, I believe it's best to start with its definition. Predictive maintenance is the maintenance strategy that utilizes sensors and monitoring systems to continuously capture operational data. These data are, in turn, used to assess the asset's performance and condition to identify operating patterns and anomalies that may indicate potential failures.

More importantly, maintenance is triggered by insights derived from data showing the asset's performance deviating from its normal operating condition or deviating from specific parameters to suggest an impending failure. Technicians and maintenance managers in the automotive sector can schedule and perform crucial maintenance tasks only when there are indications of a potential asset failure.

Now that you know what predictive maintenance is, let's look at how manufacturers in the vehicle industry can achieve this strategy. The key is a combination of using artificial intelligence (AI) and predictive analytics, such as Mitsubishi Electric's MaiLab data science tool, and ICONICS automation software that can assist with predictive maintenance.

CONTENIDO ÚTIL – Aplicaciones IoT industrial para mejorar el mantenimiento productivo total

 

How Mitsubishi Electric's AI Predictive Analytics and ICONICS Automation Software Enable Predictive Maintenance

Imagine this: to predict when a machine will fail, our predictive maintenance solutions analyze tons of data, for example, how it's running, how long parts have lasted, and even how often it moves. But the coolest part is that our AI doesn't just do boring calculations; it also detects suspicious patterns that could indicate imminent problems!

And so that all of this doesn't drive you crazy, we use software that shows you all this data in a super easy-to-understand dashboard. This way, you can see at a glance how your machinery is doing and what actions to take to keep it in good condition!»

The value of this technology is the actionable data-driven insights it provides. Vehicle manufacturers can achieve predictive maintenance through a combination of Mitsubishi Electric's first-tier AI predictive analytics and ICONICS' automation software. Let me explain.

Fortunately, the Mitsubishi Electric industrial robots for the Mexican market they are now designed with embedded AI functionalities on the company's MELFA SmartPlus card for its FR series intelligent robots. The card integrates various artificial intelligence functions in line with Industry 4.0 trends. The smart extension allows for compensation of thermal expansion of the robot arm in production environments with temperature fluctuations, while maintaining positioning accuracy. The solution provides:

• Calculation of consumption level – que determina cuándo es probable que las piezas robóticas, como tornillos de bola y splines de bola, engranajes, rodamientos y correas, necesiten ser reemplazadas y envía notificaciones cuando se necesita mantenimiento.
• Maintenance simulations – que estiman la vida útil del robot, considerando las condiciones operativas del robot y las actividades realizadas, y sugieren un programa de mantenimiento que optimiza los costos de mantenimiento.

This is where ICONICS' automation software comes into play for predictive maintenance in the automotive sector, providing value on many levels but specifically at these levels for predictive maintenance:

1. Data collection, integration, and visualizationICONICS automation software can collect and integrate data from various manufacturing and operational sources, including sensors, assets/equipment, and production lines, into a centralized dashboard to provide a holistic view of the entire operating system.
2. Alerts and NotificationsICONICS automation software will contextualize and visualize predictive information from the MELFA SmartPlus card into easy-to-understand dashboards and generate alerts and notifications when performance or asset condition deviations or anomalies are detected. With rapid notification of potential issues, maintenance teams can act quickly, significantly reducing response times.
3. Through predictive maintenance, suppliers for the electric vehicle industry can optimize operational efficiency and productivity, which means a considerable increase in time to market.

 

Benefits of Adopting a Predictive Maintenance Strategy in the Automotive Sector

Some of you might be wondering why you should invest in predictive maintenance. You probably know that predictive maintenance is the way to go. But still, you might be on the fence, especially if you are using extremely reliable, high-quality robots, such as industrial robots from Mitsubishi Electric. These assets are excellently engineered and robustly designed, so breakdowns or even failures don't happen frequently. So, what's the point?

Well, the point is that even the highest quality vehicles still require oil changes, replacement windshield wiper blades, air filters, and other routine maintenance at certain intervals. Robots and robot parts are quite similar, so predictive maintenance pays dividends with many solid benefits. Here are several of those benefits:

• Minimizing downtime and maximizing productivityRobot controllers provide telemetry data, such as robot axis positions, servo motor loads, controller temperatures, etc., and automation software for predictive maintenance displays this information on centralized dashboards. It also sends alarms for any abnormal conditions, for example, if the servo load is higher than a set value or has been higher than a set value for too long. Maintenance technicians can be alerted to inspect the robot and take action if necessary. And for predictive maintenance, a robot controller can be equipped with a MELFA SmartPlus card that can provide predictive information, such as grease usage per axis or timing belt wear per axis. The automation software for predictive maintenance on robots for the automotive industry can then deploy logic to present this information visually. This approach allows maintenance teams to address any issues before breakdowns that can lead to costly unplanned downtime.
• Profitability and resource optimizationRobot assets and systems are intricate and require specific maintenance procedures. Predictive maintenance alerts maintenance teams to components needing service or replacement rather than time-based maintenance, which could lead to unnecessary parts replacement or servicing when components are still in good working order. As a result, predictive maintenance lowers operational costs and unnecessary consumption of valuable resources.
• Improvement of security and quality controlFor any manufacturing industry, including the electric vehicle industry and its suppliers, product safety and quality are paramount. Unexpected asset failure during production can lead to unsafe conditions and low-quality vehicle/component assembly. Predictive maintenance allows operations teams to proactively address potential failures to minimize safety risks and ensure product consistency and quality.

CONTENIDO ÚTIL – 5 formas de aumentar la eficiencia de la producción con tu equipo de técnicos de mantenimiento

 

Transform your operations through Predictive Maintenance and Automation Software Technology

The Mexican automotive industry is booming and is projected to continue growing, especially given increasing environmental concerns, government incentives, the development of electric vehicle infrastructure, advancements in technology, and rising consumer awareness and interest. This means that industry suppliers are tasked with meeting the growing demand.

One way to ensure these vendors can rise to the occasion is by performing predictive maintenance. As a data-driven strategy that uses real-time insights to predict failures, predictive maintenance optimizes maintenance efforts by allowing teams to perform maintenance only when needed. And this strategy has an incredible ROI with clear advantages.

Ultimately, adopting predictive maintenance means that suppliers are taking care of their asset investments. The technology and expertise exist for EV suppliers to transform their operations through predictive maintenance. And the time is now.

 

Solutions for predictive maintenance of robots in vehicle manufacturing

ULTATEK is a leading provider of automation software for predictive maintenance of robots in vehicle manufacturing. Our innovative solution helps manufacturers optimize operational efficiency, reduce maintenance costs, and improve product quality.

• Reducing unplanned downtime: Our software for predictive maintenance automation can identify and prevent robot failures before they occur, significantly reducing unplanned downtime and increasing productivity.
• Maintenance Resource Optimization Our solution allows maintenance technicians to focus on the most critical tasks, which reduces labor costs and optimizes resource utilization.
• Product quality improvement: Predictive maintenance helps ensure robots function correctly, reducing manufacturing defects and improving overall product quality.
• Quick Return on Investment (ROI): Our solution offers a fast and significant ROI through reduced maintenance costs, improved productivity, and product quality.

ULTATEK is the ideal solution for Mexican vehicle manufacturers looking to:

• Optimize operational efficiency and reduce costs.
• Improve product quality and customer satisfaction.
• Increase worker safety and well-being.
• Stay at the forefront of manufacturing technology.

Contact us today to learn more about how we can help you transform your robot maintenance program.