通过维护软件实现隧道工程领域的突破

巨人的力量： 运行中的隧道盾构机

Herrenknecht 的隧道盾构机长度可达 150 米，直径达 17 米，是真正的巨无霸。无论是阿尔卑斯山的布伦纳基线隧道和哥达基线隧道，还是中国、卡塔尔和美国的地铁线路，它们被应用于全球的许多基础设施项目，进行着快速、高效的隧道掘进任务。盾构机由大量组件构成，由于需要巨大的作用力，因此主要采用液压驱动。这些机器还承担隧道外的重要任务，例如，将挖出的碎石自动运走，同时进行粉碎，然后打成框架再次应用于隧道工程中。钻孔凿岩过程中，隧道盾构机承受极端作用力，从而产生磨损。

维护至关重要

要让像隧道盾构机这样复杂的设备平稳运行并避免发生昂贵的停机，就必须深入了解机器的内部状况，实现无停机的维护保养。然而，维护保养工作既耗时又繁琐。隧道盾构机的维护还有另一个特殊作用：它能够让设备保值。在新的商业模式下，隧道盾构机经常被生产公司回购。如果按规定持续对机器进行维护并妥善记录维护情况，某些隧道盾构机的部件就可以再利用，那么客户可以获得一定的优惠。然而，维护工作往往导致停机时间过长、费用过高。此外，纸质归档记录缓慢、费力且复杂。“对此我们并不满意，因此一直在寻找一款可以优化维护工作、改善保养管理的软件。”Herrenknecht 公司物联网系统工程师 Maximilian Vollmer 解释道。

通过 Herrenknecht.Connected 实现数字化转型

Herrenknecht 公司通过数字平台 Herrenknecht.Connected 推动技术数字化，实现隧道工程的创新和数字化转型。该平台可为 Herrenknecht 的客户提供从隧道盾构机运行到废水处理等几乎所有施工现场系统的状态和数据。这一创新为客户带来很多便利，他们可以通过基于网络的可视化和分析工具获取数字性能报告，并查看机器操作员驾驶舱内部的监视器。该软件的核心作用，是让施工现场和项目管理人员能够随时监控掘进相关的所有数据。它具有各种自动分析功能、清晰的主页面和详细的传感器数据分析。Herrenknecht 公司现在希望将一套现代化且用户友好的维护管理软件集成到这一平台中。

Maintenance in the digital age

"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."

The advantages of maintenance software: they are intuitive and easy to use

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.

Everything in sight with the right maintenance software

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.