Life extension of critical manufacturing systems

其背景是制造业，以及老化但关键的遗留生产资产，这些资产不可靠，需要频繁维护，不安全，并且难以达到世界级供应链所要求的性能。传统的做法是报废和更换工厂和设备；但是，这是昂贵的，破坏性的，对环境有负面影响。我们打算在生产系统中使用我们相当多的技能和知识来延长这些系统的使用寿命。可靠性提高，维护减少，运行安全，结合工业物联网技术，具有操作，技术和经济性能，使系统不再是负债，而是具有多年使用寿命的宝贵资产。设计和安装数据采集系统的第一项任务是全面监控资产、过程和产品的状态和性能。数据被提交进行分析、统计和机器学习，以揭示系统的行为和性能，并利用这些知识和用户输入，构建数字孪生，然后制定翻新或重新设计方案，以及预测性和规范性维护制度。该创新项目将开发一个强大、技术可靠、成本有效的理想数据采集和分析系统，该系统可以很容易地配置，以满足不同公司、不同行业的各种生产系统的特殊要求。它将基于开源技术，为数字化提供另一种方法，从而避免订阅成本，消除供应商锁定和技术日落，并在通信协议和数据格式方面给予自由。

The context is manufacturing industries, and ageing, but critical, legacy production assets that are unreliable, require frequent maintenance, are unsafe, and struggle to achieve the performance required by world class supply chains. The conventional approach is to scrap and replace the plant and equipment; but, this is expensive, disruptive, with a negative environmental impact.We intent to use our considerable skill and knowledge in production systems to extend the useful life of these systems. Reliability improved, maintenance reduced, operating safely, incorporating IIoT technologies, with operational, technical and economic performance such that a system is no longer a liability rather a valuable asset with many further years of useful life.The first task in the design and installation of a data acquisition system to comprehensively monitor the state and performance of an asset, process and product. The data is submitted for analysis, statistical and machine learning, to reveal the behaviour and performance of the system, and with this knowledge, and user input, build a digital twin, and then develop a refurbishment or re-engineering scheme, and a predictive and prescriptive maintenance regime.This innovation project will develop a robust, technically sound and cost effective ideal data acquisition and analytics system, which can be readily configured to satisfy the peculiar requirements of a wide range of production systems, in different companies, across various sectors. It will be based on an open-source technology to offer an alternative approach to digitalisation, thus avoiding subscription costs, eliminates vendor lock-in and technology sunsetting, and grants freedom in terms of communication protocols and data formats.