2022-06-28 Company, News
Many machine builders are facing the challenge of having to digitalize their machines. The difficult question is what this should actually look like in practice. A comprehensive solution can be very costly, and the risk of betting on the wrong technologies or trends is high. So what can be done? A digitalization approach in relatively low-risk but fast steps can help.
For rotating machines such as pumps or compressors, major successes have been achieved in mechanical optimization over the past decades. However, it is becoming apparent that limits are being reached here, and that new paths must be taken to tackle new tasks such as further energy savings, optimized maintenance or additional revenue through services: the digitalization of machines is now on almost everyone’s agenda.
But what is the best way to approach this in concrete terms?
Equipping a machine with extensive sensors, electronics and connectivity is expensive. Of course, you can install a complete Linux-based computer in a compressor, measure many different data points and send everything to the cloud. However, such a customer-specific development quickly incurs high six-figure development costs – and who wants to take responsibility if, in the end, a different technology prevails or customer acceptance falls short?
But what is the alternative?
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But what is the alternative?
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Ignoring digitalization will not help either. Booksellers, taxi drivers and hotel owners have learned from their own experience how disruptive and brutal the changes brought about by digitalization can be for established business models.
Step by Step Instead of Costly All‑in‑One Solutions
Instead of investing in complex and expensive digitalization concepts right away, machine builders can start with small, low-risk steps: selectively digitalize existing components, collect data, gain experience – and then develop tailored solutions on that basis.
Digitalization in steps
Startups often take a different approach: tech companies in Silicon Valley have shaped the concept of Minimum Viable Products. This refers to early prototypes that are minimally functional and bring the core function of a new product to market quickly. In further steps, improvements are made and the products then “mature” in the market. This approach works well for consumer products. We all experience this regularly with online services or consumer electronics. For capital goods, this approach has to be adapted, but the basic idea can also be applied in high-quality and long-life products. The key point is to get into the market quickly with an initial product, gather experience and then develop further. This makes it possible to secure market positions. The big difference to consumer products is that customers are not willing to live with reduced product quality and continuous troubleshooting (bug fixing).
So what could a path towards Minimum Viable Products for capital goods look like?
Many machines such as pumps, blowers or compressors still generate no data at all. They are simply switched on and off and maybe controlled by a frequency inverter. However, no operating data is available. Established components such as protection relays or frequency inverters were not designed for this.
In recent years, Kriwan has digitalized various established standard components for compressors or pumps in such a way that they can replace existing components without major effort or risk – and, in addition to their well-known basic function, now also generate relevant data about the machine’s operating state. The portfolio includes pump protection relays, phase monitors, oil level regulators, compressor protection devices and much more.
With these products, a machine can be made “digital” in a first step: it stores its own data about operating conditions and can send this data to a smartphone, laptop or controller. Thanks to the wide range of simple customization options, this is not a one-size-fits-all solution for the entire market. Even at this initial stage, individual advantages and business models can already be created.
Using gateways, the collected data can be transferred all the way to the cloud and evaluated centrally. This means that individual systems can be digitalized to a greater or lesser extent depending on customer requirements, and it is possible to start with a first step and then gradually network systems in the field more and more over time. Digitalization can therefore grow in line with customer and market demands – without undue risk. There is no single fixed path: different gateways and modules make it possible to adapt to technological trends and changes. Digitalization thus becomes faster and less risky than a complete, monolithic solution. And because all products have been developed as fully certified products, they also meet the high demands of the B2B market in terms of quality and service life.
In this way, it becomes possible to gain experience with the collected data and to define more and more clearly what an individual digitalization solution should look like. New business models can then be supported even better, or cost advantages can be realized.
Summary
When digitalizing machines, boundary conditions such as speed, reliability and minimal financial misinvestment must be combined. A good approach is therefore to first use configurable, digitalized standard components, gain experience with them and then, if necessary, develop an individual solution. Further details can be found in the book “Digitalization of Compressors, Pumps and Fans” (VDE Verlag, 2018).
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