Optimizing combustion air supply through predictive maintenance with Bosch Digital Twin Industries
The challenge
The multistage centrifugal blower, responsible for supplying combustion air to the reactor, was plagued by repeated coupling ring breakages. These failures were caused by a metallurgical deformation, leading to fractures in the coupling rings. As a result, the company experienced frequent unplanned downtimes, occurring up to four times a month, significantly impacting the efficiency of the combustion process and the overall capacity utilization factor (CUF).
The solution
Bosch Digital Twin Industries deployed its Integrated Asset Performance Management (IAPM) solution powered by digital twin technology to address the root cause of the issue and optimize the performance of the multistage centrifugal blower.
The result
The frequency of unplanned downtimes has been reduced from four times per month to zero, significantly improving operational efficiency.
Key features and benefits
Root cause identification
BDTI’s hybrid models, which include kinematic models, bending force analysis, torsional models, and base excitation, combined with pressure signal telemetry from various points near the surge onset, successfully pinpointed the root cause of the coupling ring breakages.
Finite element analysis integration
Reduced Order Models (ROMs) of finite element analysis for the machine foundation were integrated into the data model, allowing the diagnostic and prognostic modules to proactively detect and address potential issues before they escalate.
Root cause mitigation
The deterioration of the machine foundation, which led to resonance phenomena under specific loads, was identified as the primary cause of the coupling ring breakages. This discovery allowed for targeted maintenance and repairs to directly address the underlying problem, thus preventing future failures.
Scalable solution
The templatized solution facilitated easy scaling and adoption across multiple deployment scenarios, enabling the company to replicate the benefits across its operations.
Staying ahead with predictive maintenance
Bosch Digital Twin Industries' innovative solution has helped the industrial company improve productivity and efficiency and thus avert failures. Utilizing digital twin technology and predictive sensor data analytics, it has secured a competitive advantage in their fast-changing industry.
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