Many of our customers operate individual machines or small machine fleets. Until now, they often had to decide between procuring costly tools designed for large fleets or reverting to in-house solutions in order to meet ECM requirements. The Machine Maintenance Module provides the necessary fix. It is a sleek Plasser Datamatic add-on which allows users to prepare and document both regular and unscheduled maintenance. The focus lies on the roles of fleet management as well the ongoing development of the maintenance plan, with the latter requiring high-quality service documentation that is easy to analyse. The expert article “New ways in maintenance management” (EI 07/2024) details its potential.

Reporting and analytics

Generally speaking, a high degree of transparency is becoming more and more of a competitive criterion. On the one hand, it is about customers identifying potential solutions within the company that optimize processes and, as a result, improve performance. On the other hand, external contractors have to provide documentation of multiple things, such as a chronological shift log when there are discussions about delays, or proof of compliance with CO₂ emission limits. With its standardized and customer-specific reports, Plasser Datamatic can help a great deal in meeting these needs. These tailored reports, which are automatically generated at regular intervals (e.g. per shift, weekly, etc.), provide machine operating companies with high-quality analyses without them having to invest their own resources in the beginning and continue to spend time and money on these analyses. A sample report with real machine data is available on our website.

Furthermore, specific reports may contain various modules for condition monitoring and predictive maintenance; when taken together, they are referred to as Analytics-as-a-Service. The article “Step by step to sustainable added value from machine data” (EI 03/2024) illustrates specific examples of this service. Early detection of anomalies makes it possible to take action proactively and to minimize downtime and follow-up costs. Based on the characterization of how single modules and components operate, it is possible to optimally align maintenance intervals with actual conditions.

Remote to the rescue

If there is a disruption, it is essential to have a detailed overview early on if help is to be provided efficiently. Thanks to the Remote Assistance infrastructure (VPN) integrated into Plasser Datamatic, Plasser & Theurer’s Field Services staff or staff of certified service partners can connect to the machine network remotely after receiving authorization from on-site operating staff. Assistance staff can directly see active errors and sensor values: most issues can be easily resolved from the office. If, however, it is necessary to go to the machine, the exact description of the problem beforehand makes it possible to use the time on-site as efficiently as possible (organizing spare parts, consulting with specialists, etc.)

Unfortunately, the features described cannot prevent causes of external damage. Thanks to the Shock Detectionfunction which acts independently of the machine control system, it is possible to run diagnostics right away and determine the cause of any potential damage caused by buffing impacts, for example, during transfer travel (towing) or while shunting (marshalling work). The sensor system installed is always ready for use. In the event of impact, it automatically generates a notification and an accompanying report detailing the acceleration that occurred along with the time and location. This information is immediately sent to defined recipients.

The variety of aspects described above demonstrate that a holistic view of digitalization is necessary for fully realizing its potential. Therefore, it is important to focus both on the machine and its underlying operating sequences. An example of this is the File Exchange feature for synchronizing data between the machine and the office and vice versa. As standard, communication on the machine can be supported with the SmartALC and the DRP: the report from a completed measuring run can be transmitted directly to the office over the mobile network. Conversely, work instructions or target track geometries and correction data can be transmitted to the machine.

One size does not fit all

In addition to the advantages in daily machine operation described above, Plasser Datamatic is also conducive to our portfolio’s ongoing development. Real operating data optimize the design of machine components such as motors, engines, and work units. Recorded data prove the positive effects of the electric drive concept. The article “Energy-efficient, low-emission tamping“​ (EI 01/2024) compares and contrasts the different drive concepts of two Unimat 09-8x4/4S Dynamic machines. In this case, the concepts were diesel-electric vs. diesel-hydraulic.

Is there anything else you’d like?

This article does not completely detail all aspects of digitalization in machine operation. There are still many things that could be said about its challenges and opportunities. If your thirst for knowledge hasn’t been quenched just yet, the webinar “Unlocking the Power of Track Machine Data” offers a compact overview with further considerations. Are you ready to invest in a digital future together? If so, we are happy to advise you on ways to digitalize your machine fleet.

Get in touch with us at digital.services@plassertheurer.com
Further information is available at www.plassertheurer.com/datamatic

We care about your machine!