Predictive maintenance & condition monitoring
Keep shafts turning with bearing condition monitoring
E
ngineers constantly seek solutions to minimise machine downtime without risking costly or perhaps dangerous
breakdowns. It is a dilemma faced by engineers and designers worldwide, especially in sectors like heavy industry, mining, marine engineering, oil and gas, green energy and rail operations where rotating machinery is common-place and the machinery is often remotely located or inaccessible. Bearing failure is a significant risk in
equipment with rotating elements and it is generally sign-posted in its early stages by increased levels of vibration and a rise in bearing temperature. Typically, this risk is managed by frequent
inspection and maintenance of bearings, but condition-based monitoring (CBM) has become the preferred approach for cost- effective maintenance operations. CBM uses sensor technology to extract real-time data from machinery, developing a performance profile that identifies potential failures before they bring operations to a ‘grinding halt’. Designers have to balance the desire to
collect as much data as possible, on vibration, deflection, temperature and operating hours, which might all help predict an imminent breakdown, while keeping cost and complexity to a minimum. Specifying multiple sensors meets the data-
collection needs, but is a costly approach, often requiring significant compromise in mechanical design. Contrinex Multi-Mode Smart Sensors,
available from PLUS Automation, fulfil the application’s requirements without compromise, using their multi-function technology. A single Smart Sensor can monitor multiple parameters including deflection, vibration, temperature, linear position, angular displacement and cycle count. Each of these measurements may be reported as process data or event data, while
cumulative operating parameters are recorded in the sensor’s on-board storage. The user-defined operating modes enable a
single sensor to provide a range of functions. On the rotating machinery, it is mounted in either a bearing housing or adjacent to a shaft to monitor for unexpected levels of vibration, increased bearing temperature or irregular radial deflections of the shaft. The sensor’s IO-Link functionality provides plug- and-play replacement of damaged sensors, without any loss of functionality and without any need for configuration. Dual-channel operation is another valuable
feature of the Smart Sensor range. Should a critical event occur, the sensor delivers a high- speed notification directly to the control system, bypassing the IO-Link communications channel and initiating a shut-down sequence immediately. This avoids further, costly damage and minimizes subsequent process downtime. Smart sensors are exceptionally reliable, making them ideal for installation in remote locations where day-to-day access can be impossible. In wind turbines, rail cars, drag- lines, marine powerplants, paper mills, drilling platforms, construction equipment, heavy-duty pumps and a host of similar installations, these highly versatile sensors tick all the boxes. Contrinex inductive Smart Sensors are
designed with the needs of OEMs and system integrators in mind to provide an unobtrusive fit-and-forget solution. For flexible, cost- effective CBM solutions that maximise data availability without adding complexity, Contrinex Multi-Mode Smart Sensors deliver complete peace of mind The sensor’s high corrosion resistance has
contributed to excellent reliability providing the customer with a cost-effective solution for a simple, fit-and-forget system.
PLUS Automation
www.Smart.PLUSAx.co.uk
34
October 2021 Instrumentation Monthly
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