RUD Chains Link Conveyor Systems in the IoT Cloud
Without RUD's conveyor chains, many power plants, industrial facilities, and mines would come to a standstill. To prevent failures, the chains can now be monitored via Telekom's IoT cloud. The last coal-fired power plant in Germany is to be shut down by 2038 at the latest; and the current federal government has even stipulated in its coalition agreement that the coal phase-out should ideally be brought forward to 2030. However, around 130 coal-fired power plants will still be in operation in Germany in 2023, partly to meet the industry's growing demand for electricity. That is why the industry continues to invest in innovative solutions such as the Internet of Things (IoT).
In brief
- RUD connects its conveyor chains via Telekom's IoT cloud to monitor plant status and wear data remotely in real time.
- Operators receive automated alerts when critical values are reached and can prevent downtime and plan maintenance more efficiently thanks to predictive maintenance.
- The scalable solution increases plant safety, reduces costs, and opens up new business models for RUD as a digital service provider.
Extreme Strains on the Material
Enterprises such as RUD, the market leader in high-performance chains and industrial conveyor technology based in Aalen, Baden-Württemberg. The hidden champion’s special products are subjected to extraordinary strains in, say, coal-fired power stations where powerful forces are at work when coal is converted into energy. Tons of sedimentary rock flow along conveyor belts from stockpiles into coal storage to be burnt at temperatures of around 1,300° Celsius after heavy machinery has ground them into dust. Steam is generated that powers turbines and generators. The power generated is fed into the grid and the hot coal ash is disposed of beneath the boiler.
Non-stop operation in these hostile environments imposes a serious burden on the material that is used. If conveyor belts are defective and no longer transport the combustion waste, work in the entire power station can in the worst case grind to a halt. That is why well-functioning conveyor systems are essential to ensure a smooth flow of material, especially the removal of coal ash.
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Expensive On-site Material Testing
Founded in 1875, RUD Ketten Rieger & Dietz GmbH & Co. KG is specialized in industrial conveyor systems of this kind and manufactures robust system components like high-performance chains, rollers or wheels. Usuall operating in extreme conditions, these components require regular status checks and maintenance.
These checks used to be based on sensors and an on-site traffic light system. RUD customers could only check the chains of their conveyor systems when a regular on-site inspection was due. Remote maintenance or continuous status analysis of the chains was not possible.
Potential Reasons for Outages:
- Impermissible heat
- Overfilled outlet hoppers
- Unusual speeds
- Blocked rollers
- Exhausted span width
How Does the Cloud Help with Remote Analysis?
That is why RUD, a midrange enterprise, was on the lookout for a digital solution in order to constantly check its customers conveyor chains remotely and always have access to the latest data. RUD opted for an Industrial Internet of Things (IIoT) solution based on Telekom’s IoT Cloud. Within three months Telekom succeeded in connecting to the Cloud the sensors already fitted to the conveyor systems. It was an instance of fast-track Industry 4.0.
Dozens of RUD conveyor systems are now connected on the IoT. Sensors transmit data on total operating time, average and current strain and wear and tear of the chains as well as heat development or blocked rollers. This data is sent encrypted via a smart box with a robust industry-grade SIM card by 2G to the Telekom Cloud, where it is evaluated and visualized. This technology enables RUD customers to access the processed data via a secure online cockpit. Without needing to be on-site, digital data enables the company and users to check the latest status reports or follow the strain on or wear and tear of chains live on the cloud-based system.
Maintenance Planned Better with the Internet of Things
A further function based on indidual alarm settings is that customers are notified immediately by text or e-mail if a value no longer complies with the standard. IIoT application. revent outages. Possible outages are identified in advance by the IIoT application. Predictive maintenance also enables RUD and its customers to plan on-site inspections better, including maintenance personnel and replacement material. Unnecessary routine maintenance is eliminated. Predictive maintenance enables RUD to offer its customers a new service and thereby expand its business model.
Telekom’s IoT Cloud can also be scaled flexibly so that users are able to add and connect new facilities fast. RUD has already connected several systems in Europe and overseas. Further conveyor systems in other countries are urrently at the planning stage.
Annalena Rauen
Marketing Manager IoT
Back in 2016, Anna worked on IoT topics at Deutsche Telekom for the first time. Since then, she has been supporting customer best practices in a wide range of industries – always focusing on the benefits that the Internet of Things can provide. Her IoT blogposts describe real use cases and the value these innovations add to market players, their business models, and even entire industries.