Loading system
With connected loading dock equipment, every loading system, whether door, dock or material distribution, continuously reports its condition to a platform. Operators detect wear early, carry out maintenance as needed and shorten repair and downtime.
Loading system at a glance
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Cloud-based maintenance solutions for automated door systems
Determining the optimal maintenance time – predictive filter monitoring of a material distribution system
Loading dock equipment: connected doors, docks and conveying
At Novoferm, a Bluetooth mesh network links the door controllers. A central gateway connected to drives and controllers collects the data and sends it to the cloud via MQTT. A digital twin brings together usage cycles, error codes and maintenance information, and the platform detects wear on ball bearings or belts from current curves. In its material distribution system for plastic granulate, WAGO measures the pressure upstream and downstream of the filters. The data is captured by a 750 series I/O system and analysed on a local edge computer, with maintenance orders sent to SAP automatically.
The examples come from construction and automation. Novoferm, a manufacturer of door and ramp solutions for logistics, developed Novo ServiceHub Live together with Smartsquare: technicians analyse faults remotely, and customers benefit from shorter repair times. WAGO now cleans the filters in its housing production as needed rather than at fixed intervals, and machine learning models cut the time spent on troubleshooting by more than 50 percent. In podcast episode #151, WAGO and AVEVA discuss optimising tank loading and monitoring with the WAGO I/O system and the AVEVA PI System.
Podcast episodes featuring Loading system
Loading dock equipment: frequently asked questions
How does dock door monitoring connect door controllers to the cloud?
Via a wireless network between the controllers and a central gateway. At Novoferm, a Bluetooth mesh network links the door controllers of the door and dock systems. The gateway is connected directly to the drives and controllers, collects all relevant data and sends it to the service cloud using the IoT protocol MQTT. There, the operating data is combined with customer and asset data.
How does predictive loading dock maintenance work?
The platform analyses the doors' operating and usage data and reports wear before a defect occurs. In Novo ServiceHub Live, current curves give early indications of wear in ball bearings or belts, so maintenance intervals can be set more precisely. A mobile app records every maintenance step on site. In future, an API will allow maintenance orders from ERP or field service systems to be created automatically and assigned to technicians.
How can a loading system for material distribution be maintained as needed?
With sensors that measure the pressure upstream and downstream of the filters, and a forecast of how fouling will progress. WAGO conveys plastic granulate to its injection moulding machines using vacuum pumps. The filters used to be cleaned at fixed intervals, which meant shutting the system down. Today, analytics trigger a maintenance order in SAP in good time, before conveying performance drops too far. Cleaning heavily soiled filters earlier also saves pump energy.
How does a connected loading dock speed up repairs?
Technicians analyse faults remotely using usage cycles, error codes, configuration and maintenance status of the door and dock systems. Novoferm brings this data together in Novo ServiceHub Live for all installed doors and drives. Technicians see the complete maintenance history including inspection reports and configuration changes. In logistics centres, reduced downtime improves operations, and customers benefit from shorter repair times.
More assets in “Machinery and Equipment”
Pump
Pump monitoring with IoT records vibration, temperature, pressure and energy consumption of running pumps. Operators detect damage and faults before a pump fails and plan maintenance by condition rather than at fixed intervals.
Compressor
With IoT, compressor maintenance follows actual condition: sensors record current consumption, pressure, temperature and running times. Operators detect creeping damage and unused running time early and cut energy and service costs.
Electric motor
Motor condition monitoring with IoT continuously measures the vibration, temperature and current draw of electric motors. Operators detect imbalance, bearing damage or winding faults early and replace motors based on condition rather than after a failure.
Packaging machine
OEE software automatically records run times, downtime, speed and rejects on packaging machines from the machine signals. Operators see where their lines lose performance, and machine builders use the same data for remote access and digital services.
Refrigeration system
A refrigeration monitoring system makes service plannable: temperatures, refrigerant circuit pressures, compressor status and energy consumption flow into a platform in real time. Operators and service partners detect faults early, avoid unnecessary site visits and reduce excess consumption.
Air conditioning system
Commercial air conditioning systems in offices, retail branches and data centres can be monitored remotely with IoT. Operators see energy consumption, temperatures and faults in one place, detect failing compressors or refrigerant shortages early and plan service visits precisely.
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