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Predictive Maintenance
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Predictive Maintenance
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Preventive Maintenance - Software and Strategies Table of ContentsPredictive Maintenance ImplementationHow is Predictive Maintenance Implemented? The Machines to be analyzed must be PLC controlled and additional sensors or devices may be needed. Next a computer program using SCADA software is employed which will communicate with the PLCs. Then Predictive Analysis Programming is added to the PLC programs and the SCADA Software. The machine parameters and normal operating tolerances must be recorded and input. Predictive analysis includes many parameters:
Lets look at each of these parameters. Increase in The Number Of Failures Analyzing the Increase In The Number Of Failures of a machine is only the beginning of the analysis.
Here an oven loader’s quantity of failures is charted and an alarm warning red line set point is set for 50 failures per week. Meantime Between Failures The Meantime Between Failures must be concurrently recorded and compared each day or week. Should the meantime decrease below an allowable set point this would predict a failure.
Deterioration of Individual Machine Operations The Deterioration Of Individual Machine Operations such as the cycle time of an oven loader, the opening and closing time of a flour diverter or an ingredient valve, or the times for the individual movements within a palletizer are all examples of signs of machine or component wear. Increase in Motor Amperages The increases in motor amperages are indicative of the rise of machine friction, failing motor stator insulation or failing electrical connections and devices.
Changes in Sonic Resonance/Increase in Vibration Tolerances Changes in Vibration and Sonic/Acoustic Resonance are very good prediction indicators. Studies have shown that over a third of all money spent on Preventive Maintenance is a result of unneeded shutdowns and early replacement of parts. Equipment misalignment, imbalance, bad bearings or gearing problems are directly related to vibration and sonic resonance levels.
Increase in Component Temperatures such as large motors, gearboxes, hydraulic transmissions, compressors, and even control panels should also be monitored.
Here are some pictures showing examples of online and manual thermo graphic monitoring. However, most devices can be monitored with the use of temperature probes connected to a PLC. Preventive Maintenance - Software and Strategies Table of Contents Predictive Maintenance - Preventive Maintenance Software |
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COGZ Systems, LLC
Phone 203-263-7882 Fax 203-263-7885 Woodbury,
CT 06798 USA |
