The Permanent monitoring of data lines in production

Not only motors and pumps are subject to wear and tear in production plants, but also the data lines of the machine and plant networks.

Constant alternating bending stresses, shocks, oxidation and corrosion allow aging and wear to run unobstructed on plugs and cables. While the mechanical wear and tear can be perceived analogously with the sensory organs, the wear and tear of a data line only becomes noticeable in the extreme case: failure. To counteract this, intelligent managed switches are required, where the physical condition of the data line is digitized and thus visible.

The question of availability and the knowledge of the plants and their condition in the company directly affects production and productivity; with predictive maintenance, premature wear can be detected and unexpected downtimes and the associated costs can be reduced. The awareness that a mechanical element like an engine can wear out is commonplace, but it is missing when it comes to the network: Because the network infrastructure with data lines and plug connections is also exposed to the environmental factors in production. Oxidation and corrosion on the plug connections are usually the results. Added to that are mechanical loads such as bending stress or torsion, for example on travel routes or in robot technology. Lines and structural components are therefore subject to wear and aging - a gradual process that is not immediately apparent.

The current VORTEX report (evaluation of service calls on machines and system networks) clearly shows that too little attention is paid to data lines during the operation of a system. Until commissioning, the cables are considered as a component and complex test reports and certification evidence are created according to CAT. However, all tests only relate to the cable, not the interaction of cable and socket. In addition, these tests are offline and do not say anything about the line quality in function of the system. Not to mention the degree of wear and tear or the interference reserve.

Conversely, the many data lines in machines and systems are to be regarded as components subject to wear and classified as such in the maintenance and repair concept. The material costs are negligible, but the consequences of a failure can hardly be estimated. The data lines thus represent an asset that needs to be protected and preserved through appropriate condition monitoring.

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