Mit bis zu 150 Metern Länge und Durchmessern von bis zu 17 Metern sind Tunnelbohrmaschinen von Herrenknecht wahre Giganten. Sie sind an vielen Infrastrukturprojekten auf der ganzen Welt daran beteiligt, Tunnel schnell und effizient vorzutreiben – ob am Brenner- und am Gotthard-Basistunnel in den Alpen oder bei Metrolinien in China, Katar und in den USA. Tunnelbohrmaschinen bestehen aus einer Vielzahl von Komponenten – überwiegend angetrieben mit Hydraulik wegen der großen benötigten Kräfte. Auch außerhalb des Tunnels erfüllen sie wichtige Aufgaben, wo beispielsweise der abgetragene Kies automatisiert wegtransportiert, parallel zerkleinert und aufbereitet als Verschalung wieder in den Tunnelbau integriert wird. Während des Bohrvorgangs sind Tunnelbohrmaschinen extremen Kräften und damit Verschleiß ausgesetzt.
Sollen komplexe Anlagen wie eine Tunnelbohrmaschine reibungslos funktionieren und teure Ausfälle vermieden werden, sind tiefe Einblicke in den inneren Zustand der Maschinen und eine lückenlose Wartung und Instandhaltung unerlässlich. Diese ist allerdings zeitaufwendig und umfangreich. Auch hat die Wartung bei Tunnelbohrmaschinen noch eine andere, besondere Dimension: Sie ist notwendig für die Werterhaltung. Tunnelbohrmaschinen werden im Rahmen neuer Geschäftsmodelle häufig zurückgekauft. Kunden könnten beispielsweise Vergünstigungen erhalten, wenn die Maschinen ordnungsgemäß und durchgehend gewartet (und diese Wartungen qualifiziert dokumentiert) werden, da Teile einer Tunnelbohrmaschine wiederverwendet werden können. Oft sorgten aber Wartungsarbeiten für zu lange und teure Ausfallzeiten. Außerdem war die Dokumentation auf Papier langsam, mühsam und komplex. „Damit konnten wir nicht zufrieden sein und suchten daher eine Software für eine optimierte Wartung und ein verbessertes Instandhaltungsmanagement“, erklärt Maximilian Vollmer, Systemingenieur IOT bei Herrenknecht.
Herrenknecht is driving digitalisation forward with their Herrenknecht.Connected digital platform, ensuring innovation and digital transformation in the tunnelling sector. This platform provides Herrenknecht customers with insight and data into almost all systems on a construction site, from the tunnel boring machine during operation to wastewater treatment. Customers benefit from this innovation because they can get digital performance reports and insight into the cockpit monitors of their machine operators using web-based visualisations and analysis tools. The core function of this software is to allow construction site and project managers to monitor all data relevant to tunnelling from any location and at any time. This includes a wide range of automated analysis functions, clear dashboards and detailed sensor data analyses. Herrenknecht wanted to integrate modern and user-friendly maintenance management software into this platform.
"However, we rejected the idea of developing our own CMMS (Computerised Maintenance Management System) software after a few tests," adds Vollmer. CMMS is a computerised system that helps companies to plan, track and document maintenance tasks in order to maximise the efficiency and service life of their systems. While researching the market, the IT specialists at Herrenknecht came across AX Smartenance, the maintenance software from Festo. The software meets the specific functional requirements and enables access to data via the mobile app or web application. It is a CMMS software for the entire team that enables paperless maintenance management for production managers, technicians and plant operators. Maintenance tasks and schedules can be flexibly created, copied and then evaluated. Intelligent machine management speeds up teamwork and increases the efficiency of maintenance management.
"What impresses us is the fact that Festo developed the software AX Smartenance itself for its own production processes and systems and also uses it," says Vollmer, adding: "That means the CMMS software AX Smartenance was not developed by software developers from a non-specialist computer company, but specifically where it was needed."
At the tunnel construction site in London, people are also impressed by the CMMS software. Carlos Plata from Herrenknecht Field Service says: "Operation is intuitive and simple. In fact, users really only accept simple solutions in the long term." It was precisely this simple and intuitive operation that was a major advantage and the reason why Herrenknecht decided on AX Smartenance. Just a few minor adjustments to the special features of the tunnel boring machines and Herrenknecht corporate design were necessary. Integrated into Herrenknecht's customer service platform, the CMMS AX Smartenance is responsible for the maintenance management of tunnel boring machines and all other maintenance-relevant machines and systems at large construction sites.
For construction site and project managers, the Herrenknecht.Connected platform offers location- and time-independent monitoring of all data relevant to tunnelling. This includes automated analysis functions, clear dashboards and detailed evaluations of sensor data. Thanks to the integrated CMMS software AX Smartenance from Festo, it is possible to transparently monitor and react quickly to maintenance and servicing problems. This improves processes, reduces downtime, minimises the time required for maintenance and significantly lowers costs. With the right data and information, the company can make well-founded decisions, which increases efficiency.
For Herrenknecht itself, AX Smartenance offers in-depth insights into the condition of the tunnel boring machines. This enables maintenance managers to identify problems at an early stage and rectify them. Functions such as improved remote diagnostics lead to more efficient maintenance and servicing. In addition, this type of digital platform opens up the integration of new software-as-a-service business models. "Maintenance staff and machine mechanics also benefit from AX Smartenance. The teams on site can now process, report and track routine tasks and incidents directly using the CMMS software. All maintenance-relevant documents such as circuit diagrams and drawings are available in one central location. This makes the work of the maintenance teams much easier and increases productivity," concludes Carlos Plata (Herrenknecht Field Service).
Overall, the digital transformation in tunnelling offers considerable benefits. It enables improved and transparent processes, makes work easier for employees and increases machine availability. By integrating maintenance software, it is possible to act proactively and develop new strategies for business models in order to increase efficiency and competitiveness.
However, identifying the opportunities of the digital transformation and taking appropriate measures to benefit from new technologies and tools is not just important in tunnelling, but in many other industries and sectors too.