Instumentation • Computing • Control
Of course, companies can protect their plant without using condition monitoring or predictive maintenance systems, for example, by holding more stock of a particular component such as a gearbox, bearing, pump, coupling or shaft. Tis means when a breakdown occurs in the plant, the component that caused the breakdown is available to hand, ready for the maintenance team to fix the problem. In order to help companies monitor vibration
levels on critical rotating plant or machinery, including electric motors, drives, bearing arrangements, gearboxes, pumps, generators, ventilators and fans, Schaeffler (UK) Ltd has developed the ‘FAG ProCheck’ online monitoring system. Tis system enables maintenance teams to monitor vibration levels and diagnose faults on critical rotating plant, preventing machine breakdowns and eliminating problems before they occur. Omce set up the sytem can operate automatically without further intervention from the user, to measure, record, analyse and issue alerts on vibration data from rotating plant. By continuously monitoring a machine or piece of rotating equipment, FAG ProCheck can detect changes in their behaviour early and alert maintenance personnel to a potential problem before it actually occurs. Maintenance teams can therefore improve their planning and scheduling and production downtime is significantly reduced. Te FAG ProCheck system can be expanded and customised through a new expansion slot system and digital filter algorithms.
So how does it work? Te data recorded by sensors on rotating plant is subjected to initial assessment by FAG ProCheck and if defined alarm limits are exceeded, alert warnings are automatically generated and sent to defined interfaces, where they undergo further assessment. Te system can be configured and adapted either by the end user customer or by Schaeffler’s maintenance and asset management service division, FAG Industrial Services (F’IS). Te stored algorithms process the data to extract the necessary information on the condition of the machine. Tis initial check is independent of connection to a server PC, which holds the configuration and analysis software. Tis means all FAG ProCheck systems in a network can operate independently of a server connection and store their data on a permanent memory medium. Depending on system configuration, the data can be held locally for up to several weeks. Te system can accommodate up to 16 sensor channels plus additional analogue and digital
inputs and outputs, and so can be expanded from monitoring an individual machine, right up to monitoring complete production plant systems. Multiple FAG ProCheck units can be connected to a network and managed using the same database. FAG ProCheck uses ‘broadband parameter monitoring’ to determine changes in the overall vibration behaviour of rotating plant at an early stage, in combination with ‘selective frequency monitoring’. Tis is used to detect changes in the behaviour of individual components and therefore enables precise analysis of component damage. Monitoring parameters include time and frequency domains, measuring velocity, acceleration and envelope signals, both broadband and frequency selective. As well as vibration, further parameters such as temperature, pressure, load, speed, torque, oil status and oil quality can be recorded and correlated with the vibration data. For communication with high-level plant operating data systems, various inputs and outputs are available. Extra signals can be received via digital or analogue inputs and used for triggering or validation of messages. Tey can therefore be used as ‘command’ variables for dependent signal analysis such as alarm threshold control. Tese signals can also be used to initiate time-controlled or event-controlled measurement tasks, for example, to control automatic data logging for specific applications. Communication with FAG ProCheck can be carried out via network (TCP/IP), serial or modem links.
“Plant managers and maintenance managers need to justify any expenditure on condition monitoring systems and services, to their finance director or MD.” Kate Hartigan, Managing Director, Schaeffler (UK) Ltd.
Schaeffler also supplied its ‘FAG Motion Guard Champion’ automatic lubrication system. Tis is a robust, electromechanically driven unit that operates on replaceable batteries. Te device is electronically controlled and has a back-geared motor that enables the unit to discharge lubricant at adjustable intervals of one, three, six or 12 months. A lubricant canister is screwed to the drive unit, holding 60, 120 or 250cm3
of lubricating grease. Automatic pressure
control at 5 bar is provided and the unit operates in temperatures from -10°C up to 50°C. Te device is also protected against dust and splash water and is immune to electromagnetic interference. ●
www.engineerlive.com 41
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56