TEST & MEASUREMENT FEATURE
Good vibrations P
Turck Banner looks at the benefits of preventative over reactive maintenance
reventative maintenance uses sensors to detect when a machine is having an
issue, such as worn bearings or a fault. Without this type of detection, manufacturers must wait for a failure to occur to then organise repairs, known as reactive maintenance. Reactive maintenance is inefficient and
can lead to downtime during production hours, costing valuable time. Using sensors to predict when there is beginning to be wear, or an issue with a machine, allows for planned downtime and repairs
CM SERIES WIRELESS NODE Turck Banner offers a range of products to monitor machines, including the CM series wireless node. The CM series wireless nodes are used
to collect vibration, temperature and current draw data from electric motors and machines. It combines wireless radio, antenna and
battery power supply in one compact and easy to install device. The battery power supply makes it ideal for remote and hard to access locations. There are 20 amp and 150 amp split core current transformers included with the node for simple set up. The device is preconfigured for plug and
play with the VT1 vibration and temperature sensor, and is DIP switch configurable. Once connected, the device can start communicating straight away. The nodes’ wireless design makes them
ideal for retrofitting and hard to reach places, while removing the expense of altering existing wired infrastructure. Monitoring machine health and
performance in real time is critical and the CM series node detects changes in
the three critical indicators of this, enabling machine performance issues to be detected, as well as allowing for a more strategic scheduling of equipment maintenance. Users can monitor the general health
and performance of their equipment as well as specific components, such as motor bearings, brushes and windings. The node can also be used to verify that equipment is on or off, track energy use, and identify power surges. The condition monitoring nodes can be
used with Turck Banner’s wireless solutions kit for vibration and current monitoring, for an easy to install IIoT solution. Customers can also create their own IIoT solution using the condition monitoring nodes, a DXM Series wireless controller, and the Connected Data Solutions cloud software. With easy to access data, the customer can establish thresholds, trends and issues in order to make better decisions.
CASE STUDY A large commercial printing and advertising distribution company collected a sample of vibration data monthly on machine cooling fans located over the main printing machines. Several catastrophic failures still occurred, costing the company over £25,000 in replacement costs and downtime for each failure. The printing press fan cantilevered above
printing machines requires continuous monitoring to identify issues prior to catastrophic failure. Access to the fans is difficult and installing or relocating the sampling systems is arduous and costly.
QM42VT1 vibration detection motor
CM series wireless node
The main way that worn bearings were
identified was when the bearing was completely worn and the fan stopped. This is an ineffective solution as a failure in the middle of a print run is unacceptable and causes downtime during production. To solve this problem, Turck Banner
installed the QM42VT vibration sensors connected to DX80 nodes, which collect continuous vibration values of the cooling fan motors. This data is wirelessly transmitted to a DXM100 controller containing action rules that define thresholds. Should these thresholds be exceeded, third party monitoring data notifies the customer for immediate corrective action. The customer can choose to be notified by email or SMS as well as local indication. Identifying bearing and blade issues prior
to failure is critical to reducing downtime. In January 2018, one of the Banner wireless vibration systems detected an anomaly. The customer was able to replace the fan unit prior to failure, avoiding another £25,000 repair situation. By monitoring motor functions continuously, potential failures can be detected and repairs can be scheduled, thus preventing two days of downtime for the customer. This vibration system solution had easy
retrofit installation, and paid for itself in the first few months. Removing the need for manual sampling saves time, while the new system saves costs associated with failures and needs less access to out of the way installations
Turck Banner
turckbanner.co.uk ELECTRICAL ENGINEERING | OCTOBER 2019 37
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