machinery | Maintenance Right: Feddem’s barrel cooling
system concept uses straight through holes to allow easy channel cleaning without the need for
disassembly
independent maintenance software program, the timers can be disabled.
Century Extrusion’s
Below: Entek’s integrated Maintenance IO system allows the user to set timed alerts for all key
servicing and maintenance tasks
Bessinger also stresses the importance of preventative maintenance (PM). “A formal PM programme should be designed to monitor, treat, repair or replace compo- nents of a system in order to maximise performance and to prolong the life of the extrud- er,” he says. The benefits of such a programme easily out-weigh the costs: producers should factor in the cost of replacing failed parts; the cost for replacing additional parts dam- aged as a consequence of the failure; the cost of increased labour (when shutdown is unplanned); and the cost of lost production. “A PM programme will incorporate all of the individual equipment service requirements into one comprehensive PM task list, which can then be subdi- vided into specialised task lists (electrical, mechanical, and the like) to finally provide an overall maintenance schedule for the complete system,” Bessinger says. Like numerous other equipment suppliers today, Century Extrusion lists remote access to its machines via industrial VPN routers among its PM products and services. “Remote access will significantly reduce the time it takes to diagnose problems and therefore gets our customers up and running faster,” says Bessinger. The routers can be connected to a company’s internal network, with access through an IT-controlled portal. Another solution is using a router with cellular network
connectivity. This enables customers with stringent rules on network access to have remote machine support without the risking their corporate network. Bessinger’s list of PM tips includes keeping gearbox oil in good condition. “This can be done by changing the oil according to the OEM’s oil change schedule, but lately customers are sending oil samples for analysis,” he
says. “These tests are valuable as increased levels of certain properties
can indicate increased wear and this enables customers to diagnose the failure of a bearing or
gear before a catastrophic failure occurs.” Bessinger cites the GearControl-Oil multi-parame-
ter sensor offered by Eisenbeiss, which continuously monitors six oil condition parameters. LEDs indicate the condition of the oil. Further analysis can be done to pin-point the time at which parameters started changing by downloading the log file from the sensor.
Focused on service ICMA’s Colombo points to the company’s PM program, OrangeService. This is offered in different modules covering mechanical, electrical and electronics, and is designed to allow checking of the general operative conditions of the line. “One of our expert engineers can spend time at the customer to make a number of checks using [for example] special internal inspection tools to monitor wearing etc.,” he says. “The objective is to make sure that the line works at peak efficiency and make sure potential failures are anticipated.” The OrangeService package can be combined with a planned supply of spare parts in order to avoid any rush when a replacement is finally required. Colombo points to various in-house services at ICMA such as screw dismantling with special machine tools engineered and built by the company to treat units with shafts up to eight metres long. ICMA also has its own division dedicated to gearbox dismantling and refur- bishing, with “a very rich spare parts inventory from screws to shafts and parts to provide a safety cushion for customer requirements.” At KraussMaffei Berstorff, Automation & Electrical Engineering Head Peter Fröse says the trend to globally networked machines and production processes that characterise Industry 4.0 gives plastics processors of any company size tremendous opportunities to optimise their output rates and take advantage of potential
22 COMPOUNDING WORLD | April 2017
www.compoundingworld.com
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