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360° machine monitoring

Smart maintenance for machine tools, from intelligent condition monitoring and failure forecasts to maintenance support for service technicians – Fraunhofer IPK’s exhibit at Hannover Messe 2021 comprises all these aspects.

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Interactive 3D Model

Experience the Fraunhofer IPK Smart Maintenance Testbed! Rotate, zoom in, zoom out, jump between scenes – the interactive exhibit invites you to try it out and discover.

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Smart Maintenance explainer

In an entertaining cartoon, we explain in detail how our Smart Maintenance solution works.

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Fraunhofer IPK was there | Hannover Messe April 12 - 16

Smart Maintenance for Machine Tools

© Fraunhofer IPK / Katharina Strohmeier

Wear and tear threatens the smooth operation of machine tools. The total failure of a machine is only the worst-case scenario. Modern production systems work so precisely that even the smallest deviations from good condition, such as imbalances in a spindle, can turn a workpiece into scrap. In addition, production processes are so tightly scheduled that malfunctions and unplanned machine downtimes can prevent on-time delivery and may result in compensation claims.

At Fraunhofer IPK, we are developing a solution for intelligent machine tool monitoring and maintenance which not only detects signs of impending failures during operation, but also interactively supports maintenance. With the help of inexpensive sensor technology and machine learning, even the smallest irregularities are identified before they become serious problems.

Previously available smart maintenance systems only monitor the machine status. Fraunhofer IPK‘s solution goes much further. The system addresses three scopes of tasks:

  • Early detection and classification of irregularities and damage using machine learning and depiction in a traffic light system.
  • Even smallest irregularities are detected before they cause damage.
  • Service technicians are automatically notified and receive intuitive instructions to support service calls.
  • This prevents a longer-term standstill in production.

The solution is interesting for these industries:

  • Mechanical and Plant Engineering
  • Automotive
  • Railroad (e. g. train manufacturers)
  • Aviation (e. g. turbine producers, Aircraft manufacturers)
  • Energy (e. g. turbine producers)

You are looking for:

  • Predictive Maintenance
  • Condition Monitoring
  • Context sensitive assistance
  • Retrofit
  • IoT system architecture
  • Process modeling
  • Dashboard development

Further Downloads

For additional information on our exhibit please click here:

We were also involved in these Hannover Messe exhibits:


EPIC Centre of Excellence in Production Informatics and Control

EPIC is a long-term cooperation between the Fraunhofer Institutes IPK, IPT, IPA, Fraunhofer Austria and the Hungarian partners of EPIC Inno Labs, SZTAKI and BME. The cooperation's goal is to establish a center of excellence for Cyber Physical Production Systems. At Hannover Messe, the partners presented an interactive map showing an overview of joint pilot CPPS use cases.


Fraunhofer Smart Maintenance Community

At this year's Hannover Messe, the Smart Maintenance Community presented opportunities and challenges in establishing necessary maintenance strategies. Through virtual interaction, you can digitally follow a production scenario, try out various technologies for real-time detection of damage during operation, and see for yourself the need for predictive maintenance.

AdWiSe – Research on Advanced Systems Engineering

The AdWiSe partner institutes are jointly researching and shaping the engineering of the future by networking and supporting Advanced Systems Engineering (ASE) activities in science and industry. The BMBF-funded project involves acatech, IPEK at the Karlsruhe Institute of Technology (KIT), and the Fraunhofer Institutes IAO, IEM, and IPK.