AI-Powered Asset Monitoring with the Digital Twin Starter Kit

The Digital Twin Starter Kit consists of various components. The hardware includes powerful 12 kHz vibration sensors, an ICE2/3 IO-Link master, and the BTC22 embedded PC from Pepperl+Fuchs. Together, they enable communication from the field level directly to a Bosch cloud instance running a variety of cloud applications, such as a digital twin, AI and ML analytics applications, and a data history. In addition to the vibration sensor currently included as standard for detecting vibrations in machine parts, other sensors from the Pepperl+Fuchs portfolio can also be used as required, including variants specially designed for hazardous areas. The IO-Link master collects the sensor data from the field via IO-Link and initially transfers it to the BTC22 industrial box thin client serving as Edge gateway. The BTC is particularly powerful and designed for 24/7 operation in industrial environments. With the “Intelligence Core” software from Bosch preinstalled, it is able to process the sensor data from the field and then forward it to the cloud in aggregated form. 

The actual analysis and derivation of measures take place in real time on the Bosch Digital Twin platform. It is based on established cloud platforms such as AWS or MS-Azure and evaluates the transferred data using machine learning algorithms and AI models. “Our algorithms can use the digital twins of machines to predict anomalies and potential failures,” explains Matthias Wieland, Global Partner Manager at Bosch Digital Twin Industries. “We can predict and visualize mechanical problems in detailed 3-D models. This enables our customers to take preventive action and ensure the smooth operation of their production facilities.” This predictive maintenance significantly reduces the likelihood of unexpected downtime. At the same time, it creates a high degree of transparency and avoids the premature replacement of machine parts, which in turn increases cost efficiency.

The Digital Twin Starter Kit is particularly quick and easy to put into operation. The sensors and the IO-Link master are installed on the system component to be monitored and the BTC is connected to the network. After switching on, an initialization process starts automatically in which the system configures itself. This is followed by a short learning phase. Once this is complete, the process and device data is immediately transferred to the Bosch platform.

Once up and running, users can see the operating status, energy consumption, and general condition of their systems in real time on their dashboard—from anywhere in the world. Since the Bosch platform is in the cloud, the information can be viewed anytime, anywhere—whether you are working from home or at the office, on a desktop PC, or on a smartphone. In addition, responsible persons receive notifications of critical situations via email, text message, or any other preferred communication channel, so that they can intervene directly or initiate the necessary measures.

The partner companies involved combine their expertise in sensor technology, data processing, and AI in the Digital Twin Starter Kit, providing customers with a complete solution. “From capturing the necessary sensor data, to data transmission and processing, to AI-based analysis and the resulting recommendations for action, we have considered every step in the Starter Kit. We have tightly integrated Bosch’s AI and software expertise with Pepperl+Fuchs’ IO-Link communication platform. If required, our partner company Syntax can also integrate the data directly into our customers' ERP system,” summarizes Brad Beale, Director Global IIoT Solutions. “This allows operators to focus on their own core business while significantly increasing plant efficiency, ensuring operational uptime and availability with little effort.”

• High productivity and efficiency: ready-to-use plug-and-play solution enables AI-supported analysis in real time
• Accurate maintenance forecasts guarantee significant resource and cost savings
• Maximum transparency due to a wide range of scenario simulations and early detection of anomalies, including recommended actions
• Easily scalable: complete solution can be expanded and extended as required
• Accessible from anywhere: cloud platform allows access from any location
• Optional: integration into ERP system via Syntax