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T IoT

A breath of fresh air from the Internet of Things

No more thick air due to failed fans: the family-owned company Ziehl-Abegg uses the Internet of Things for predictive maintenance of its ventilation and air conditioning technology. This reduces machine downtime and unnecessary maintenance work.

Two engineers photographed through a gear shaft.

In brief

  • With IoT and predictive maintenance approaches, ventilation and air conditioning systems can be monitored automatically so that failures can be detected at an early stage and unplanned downtimes can be avoided.
  • The system from Ziehl-Abegg combines sensor technology, IoT gateways and a cloud-based platform to centrally analyse operating data such as vibration, temperature or energy consumption and predict signs of wear.
  • Optimised maintenance cycles, fewer breakdowns and data-based control reduce operating costs and resource consumption - a strategic advantage for companies in Industry 4.0.

From disruption to prevention: how IoT prevents downtime

At first it is a soft knock that develops into a thunderous rumble. Then the conveyor system in the assembly hall comes to a standstill. Three hours later, the service technician inspects the machine. The diagnosis: a defective drive shaft. But the right spare part has to be ordered first. The unplanned downtime not only disrupts the production schedule, it also costs the company several hundred thousand euros. A nightmare for any company.

Ziehl-Abegg is networking its fans via the Internet of Things (IoT) in order to avoid downtimes and plan maintenance work more predictively. The aim is for customers to use predictive maintenance to monitor their ventilation systems and respond more quickly in the event of a malfunction. An example calculation by the German Academy of Science and Engineering shows why predictive maintenance pays off: for every euro that companies invest in the maintenance of their machines, they save five times as much in follow-up costs for machine failures. Predictive maintenance makes this much more efficient.

Internet of Things: eliminate errors before they occur

Ziehl-Abegg is driving forward its digital transformation with predictive maintenance and developing a new digital business model at the same time. The medium-sized company is using predictive maintenance technologies to add digital services to its product portfolio for laboratories, agricultural operations and server equipment. At the same time, it is optimising the cost and timing of tightly scheduled maintenance cycles. A positive side effect: predictive maintenance projects strengthen the company's own competitive position - now and in the future. Automation plays an important role in the new solution.

The medium-sized company already had several solutions in place to digitalise the machines and collect machine data using sensors. However, it lacked a digital platform to store and visualise data from different sources. Together with Deutsche Telekom, Ziehl-Abegg developed a cloud-based IoT platform for predictive maintenance. About the Microsoft Azure Cloud, the family-owned company is now bringing its fans and third-party devices together with the Internet of Things. Deutsche Telekom implemented the cloud as well as interfaces to Ziehl-Abegg's product database and mobile apps. The result: a customer and administration portal via which manufacturers and customers can monitor all machine information and operating data in real time.

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Digitalisation helps to reduce operating costs

Because the service life of individual machine components can be predicted more precisely, customers save on maintenance costs and reduce equipment downtime. At the same time, operational data provided by the system helps optimize processes and production: sensors collect data on power consumption, temperature, or vibration and transmit it via Bluetooth to an IoT gateway. From there, the information is securely aggregated and sent to the IoT platform via local WLAN, LAN, or UMTS connections.

The key advantage: users can detect material fatigue or wear effects on production at an early stage. In the event of irregularities, maintenance work can be scheduled immediately – with technicians bringing the required spare parts on their first visit.

Industry 4.0: Will IoT create the new industrial revolution?

Predictive maintenance is an important component of Industry 4.0, but digital technologies for maintenance and servicing have so far been used by less than half of German industrial companies: according to a study by the German Engineering Federation and Roland Berger, only just under 40 per cent of the companies surveyed offer corresponding technologies and services. Analysing machine data increases efficiency and cost-effectiveness - and ensures that machines retain their value in the long term.

"As an innovation leader in our industry, we were looking for a solution that would also meet the challenges of the future," says Peter Fenkel, CEO of Ziehl-Abegg. "With Telekom, we have a competent partner at our side who fulfils our requirements perfectly."

Digitisation in the SME sector

The Internet of Things is playing an increasingly important role in driving digital transformation among German SMEs. With innovative IoT solutions, predictive maintenance projects based on advanced predictive analytics can be implemented quickly and efficiently. This is a crucial step to ensure that medium-sized companies – the backbone of the German economy – remain competitive and future-ready.

IoT Connectivity

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IoT Connectivity

The right IoT connectivity coordinates IoT connections across platforms, integrates devices and data via API, and enables global control with the highest security standards. You can manage your IoT projects flexibly, efficiently, and independently of manufacturers.

Potrait photo Ümit Günes

Ümit Günes

Marketing Manager IoT

Having been with Telekom since 2008, Ümit possesses a comprehensive understanding of various facets of the Internet of Things. He has a keen interest in the digital transformation of the business world. On this blog, he shares insights into the latest developments and trends in the IoT sector that provide genuine value to customers.

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