How ROHRDORFER is initiating digital monitoring at its aggregate plant in Pichlern, Austria.
It is a rainy day. The soaked material sticks together and blockages occur. A large slab of rock has cheated its way through the grate and is now blocking an opening in the gravel processing plant. Fixing such unplanned incidents is one of the everyday tasks that aggregate plant managers are confronted with.
“With hundreds of tons of throughput per hour, every minute counts. A short standstill of the processing plant of just 10 minutes can cause high costs,” reports Stephan Auböck, Operations Manager of the ROHRDORFER aggregate plant in Pichlern, Upper Austria. Every year, 300 000 tons of sand, gravel and grit are blasted and processed from the conglomerate rock here. Consistent machine monitoring along the process chain and direct access to documentation and spare parts without time-consuming searches are therefore absolutely essential.
An IFE circular motion vibrating screen with a capacity of 130 t/h and a double-deck flip-flop screen TRISOMAT with a capacity of 90 t/h have been working reliably at the plant since 2008. Apart from a maintenance period in winter, there are no planned shutdowns. The processed fractions are used, for example, in the neighboring asphalt plant.
The 1.6 m x 5 m circular motion vibrating screen with 3.5 screen decks and oil bath lubrication (IFE standard!) delivers 5 different grain sizes. It was equipped with i-STEP Vibrosense sensors in 2023, which have been continuously recording essential vibration data ever since. Other sensors also record the current oil temperature and oil quality.
This data is evaluated and clearly displayed in machine dashboards on the i-STEP platform. Whether desktop PC, tablet or smartphone, the platform can be accessed from any end device in the browser. Immediately after logging in, the user has access to meaningful evaluations ranging from current live data to in-depth long-term analyses.
i-STEP Operator: The next evolution is in the starting blocks
Following the initial successes in the field with the i-STEP Workbench, the next development step is now imminent: the i-STEP Operator. Building on the proven system, it offers a comprehensive set of practical functions.
“For optimal machine operation and sustainable cost reductions, we offer operators live data, immediate access to documents and spare parts lists as well as a direct line to IFE. The possibility of machine learning models and AI will soon make the i-STEP Operator a central tool for smart and future-oriented machines,” explains Reinhard Hochstrasser, who is driving i-STEP forward as part of the IFE after-sales team.
The integration and querying of the i-STEP Vibrosense and other sensors is one of the most basic features. These are supplemented by a central document management system for operating instructions, tools for spare parts management and maintenance planning, for example.
The i-STEP Operator
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Real-time condition monitoring of machines - including automatic detection of deviating operating conditions
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Intelligent maintenance planning based on actual machine running times
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Spare parts management with specific lists for direct spare parts inquiries and contact to the IFE service team
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Central access to documents such as operating instructions, technical documentation and maintenance manuals
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Integration of a wide range of sensors, e.g.: Vibration (i-STEP Vibrosense), oil quality and temperature, speed, engine current, air pressure and much more
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Device-independent use via browser - in the office or mobile
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Data-based process optimization through evaluations and connection to machine learning models
“The rapid availability of spare parts is essential for the efficient operation of our plant. Digital support in the form of predictive planning, timely notifications, clear spare parts lists and online services is of course very welcome,” says Operations Manager Stefan Auböck. In general, the plant is constantly investing in the digitalization of machine monitoring. This saves unplanned downtimes and valuable working time and enables machine service life to be maximized, predictive maintenance to be carried out and rapid responses to be made.
"With the i-STEP Operator, we offer our customers not only our proven machine technology, but also digital solutions – for continuous machine monitoring and more efficient workflows. This creates real added value." Reinhard Hochstrasser concludes. In future, the i-STEP Operator including the Vibrosense sensor technology will be available as a demo. Accompanied by IFE, valuable insights into vibration machines can be gained and optimisation options identified.
