Our experience in running R & D projects for our clients prompted us to develop the DBE research department. In 2014, we established our internal R & D department, headed by Przemysław Kurylas, which mainly deals with: development of electronic metrology, research into the energy efficiency of technological processes, research in the field of diagnostics of machines and devices (DiagSys).

We consider the conclusion of the grant agreement with the National Center for Research and Development (NCBiR) on 22 June 2016 to be a significant moment in the history of our R & D department. The grant was awarded for the project entitled 'Development of an innovative diagnostic system of drives (DiagSys) based on the electrical measurement of signals typical of mechanical failures of the elements of rotating machines, including development of the specialized analyzer of the operating status and efficiency of machines (APPS 3)'.

The project is financed under the Operational Program Smart Growth 2014-2020, within the submeasure 1.1.1. 'Industrial research and development works conducted by enterprises'. Contest Number: 1 / 1.1.1 / 2015. The value of the project is PLN 5 974 021.85 (USD 1,706,863.39). The value of the grant is PLN 3 727 676.11 (USD 1,065,050.32).

A new product for diagnostics of rotating machines (motors and drive systems) used in industrial processes (DiagSys) will be developed as a part of the R & D work. It will be based on the use of power measurements and  the expert database accessible on-line.

Diagnostics of rotating machines seems to be a significant issue, if we take into consideration:

  • business continuity,,
  • downtime costs,
  • risk of losing markets and contractors in consequence of unplanned downtime,
  • costs of failure elimination and repairs,
  • energy consumed by machines which operate improperly,
  • the environment - since the control of machine efficiency leads to decreased emission and cleaner environment,
  • the cost of the diagnostic itself.

Our goal is to develop a system which will allow for remote diagnostics of propulsion systems in industrial processes. The system will have to fulfill two major tasks:

  • control the work of machines, prevent machine failures and remove them quickly (the average cost of failure ranges from several hundred thousand to several million zlotys per day of the downtime in a medium or large company in Poland),
  • reduce energy consumption (industry is responsible for 41% of electric energy consumption in the world, industry in Poland consumes 24% of electric energy and the numbers are still growing; drives are responsible for the consumption of 70% of the energy used by the industry - DiagSys will reduce the consumption by 0.9-7.5%).

The main advantages of DiagSys include:

  • the cost of the system is lower than the cost of vibroacoustic analysis and thermal imaging which are currently used,
  • on-line continuous measurements are performed - continuous machine monitoring is provided,
  • there is no need for the data to be interpreted by an expert- intelligent database is provided,
  • you may take advantage of the online expert advice,
  • integration with automation devices is possible - control of production process efficiency is guaranteed.

In the result of this project, an innovative product will be created - DiagSys, i.e. the diagnostic system of mechanical failures of rotating machines (motors and complete drive systems) which are used in manufacturing processes. DiagSys is the comprehensive system based on the analysis of spectra, with measurements of power performed. The system provides the online access to the intelligent expert empirical database, as well as  the database of failure spectrum models (peripheral field), used for the purpose of validation of collected data. DiagSys will enable cheaper and faster detection of changes in the parameters of a drive, including the use of consumable items, mechanical and electric failures, procedural irregularities and overloading. That, in turn, will allow a company to avoid downtime and related costs and to reduce energy consumption. Technological systems with electric drives account for even up to 70% of electricity consumption in industry.

Business areaWorking with energy around the world

We have been successfully conducting energy efficiency audits in big and medium scale industries achieving significant energy savings for our clients. So far, according to our team's projects, modernizations have been carried out at a total cost of over USD 730 million, which allowed to reduce energy consumption by at least 3.9 TWh and save over USD 215 million.

Working with energy around the world