The power of giants: tunnel boring machines in action
With lengths of up to 150 meters and diameters of up to 17 meters, Herrenknecht tunnel boring machines are true giants. They are used for quick and efficient tunneling in many infrastructure projects around the world – from the Brenner and Gotthard Base Tunnels in the Alps to metro lines in China, Qatar and the USA. Tunnel boring machines comprise a large number of components – predominantly driven by hydraulics due to the large forces required. They also perform important tasks outside the tunnel, where, for example, the removed gravel is automatically transported away, crushed in parallel and reintegrated into the tunnel construction process as formwork. During the drilling process, tunnel boring machines are exposed to extreme forces and therefore wear.
It all comes down to maintenance
In-depth insights into the internal condition of tunnel boring machines, combined with seamless maintenance and servicing, are essential in enabling such complex machines to function smoothly while avoiding expensive breakdowns. However, this is time-consuming and involves a lot of work. There is also another special dimension to maintenance of tunnel boring machines: it is necessary to maintain their value. Tunnel boring machines are often bought back as part of new business models. For example, customers might be in line for discounts if their machines have been properly and continuously maintained (and this maintenance has been documented in a qualified manner), since parts of a tunnel boring machine can be reused. However, in the past, maintenance work often resulted in excessively long and expensive downtimes. In addition, paper documentation was slow, laborious and complex. "We simply weren't satisfied with this, which explains why we were looking for software for optimized maintenance and improved maintenance management," explains Maximilian Vollmer, System Engineer IOT at Herrenknecht.
Digital transformation with Herrenknecht.Connected
With its Herrenknecht.Connected digital platform, Herrenknecht is driving digitalization forward, thus ensuring innovation and digital transformation in the field of tunnel construction. This platform provides Herrenknecht customers with data and insights into almost all systems on the construction site – from the tunnel boring machine during operation to wastewater treatment. Customers benefit from this innovation because they can obtain digital performance reports and insights into the cockpit monitors of their machine operators using web-based visualizations and analysis tools. The core function of this software is to allow the construction site and project management to monitor all data relevant to tunneling from anywhere at any time. This includes a wide range of automated analysis functions, clearly laid-out dashboards, and detailed sensor data evaluations. Next, Herrenknecht wanted to integrate modern and user-friendly maintenance management software into this platform.
Maintenance in the digital age
"However, we rejected the idea of developing our own CMMS software (Computerized Maintenance Management System) after a few tests," adds Vollmer. CMMS is a computerized system that helps companies plan, track and document maintenance tasks to maximize 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 fulfills 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 machine operators. Maintenance tasks and schedules can be flexibly created, duplicated and then evaluated. Intelligent machine management improves fast teamwork and boosts the efficiency of maintenance management.
"What we found impressive was the fact that Festo developed the AX Smartenance software itself for its production processes and systems, and also uses it there," says Vollmer, adding: "That means the AX Smartenance CMMS software was not written by software developers from a non-specialist system house, but specifically where it was needed."
The advantages of maintenance software: intuitive and easy to use
On site at the tunnel construction site in London, people are also impressed by the CMMS software. Carlos Plata from Herrenknecht Field Service says: "It is easy and intuitive to use. In fact, only simple solutions are really accepted by users in the long term." It was precisely this simple and intuitive operation that was a major advantage and the reason why Herrenknecht decided to integrate AX Smartenance. Only minor adjustments were necessary to the special features of the tunnel boring machines and Herrenknecht's corporate design. 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 on a large construction site.
Everything in view with the right maintenance software
For construction site and project management, the Herrenknecht.Connected platform offers the function of monitoring all data relevant to tunnel construction, independently of the time and place. With automated analysis functions, clear dashboards and detailed evaluations of sensor data. Thanks to the integrated AX Smartenance CMMS software from Festo, transparent monitoring and rapid responses to problems relating to maintenance and servicing are possible. This improves processes, reduces downtimes, minimizes the time required for maintenance, and thus 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 deep insights into the condition of the tunnel boring machines. This enables maintenance managers to identify problems at an early stage and rectify them in a targeted manner. Functions such as improved remote diagnostics lead to more efficient maintenance and servicing. In addition, such a digital platform opens the door to integrating new Software-as-a-Service business models. "Maintenance staff and mechanics on the machine also benefit from AX Smartenance. This is because the teams on site can now process, report and track routine tasks and incidents directly via 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 tunnel construction offers considerable advantages. 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, it is important to recognize the opportunities of digital transformation not only in tunnel construction but also in many other industries and sectors, and to take appropriate measures to benefit from new technologies and tools.
