Jaguar Presentation

VIBRATION ANALYSIS ON STAMPING PRESSES

PROBLEMS NEED SOLUTIONS

• Identify the problems• Understand the impact to the facility• Engineer out repetitive/critical problems• Design monitoring measurements to

detect the onset of other problems in a timely manner

We want to monitor the condition of our machinery

• How do we start?• We carry out a

POTENTIAL FAILURE ANALYSIS

Base Cause Failure TypeExternalManifestation Technology Parameter Interval Set Up

Dry/Markedbearings

Bearing Failure High frequency resonance @ bearing defect frequency intervals

Vibration Demodulation(Ultra Sound)

Time Waveform

On Line Fmax = BPFI x 8

On Line = 3 revs

RadialG acceleration

Spalledbearings

Bearing Failure Harmonics of bearing defect frequencies

Vibration Velocity

Time Waveform


On Line = 3 revs

(higher if not usingresonance parameter)Radial

G acceleration

Press Main Drive Motor PFA Tree

Misalignment Bearing Failure/Shaft Failure

High axial vibration Vibration Velocity On Line Fmax = 10 x rpmAxial

Looseness Bearing Failure/Shaft Failure/Structural Failure

Run speed harmonics & subharmonics

Vibration Velocity On Line Fmax = 10 x rpmVertical

c. Ron Frend - PreDiCon

Analysis

Spikes @ Brg defectfrequencies (20 dBG)See sect. 2.5

Peaks in waveform

Spikes @ Brg defectfreqys. & harmonicsand/or sidebands. See sct. 2.5

Peaks @ 12 G (roller)7 G (ball brg)

Multiples of run speedaxial > radial

Multiples of run speedup to 15x. Possiblesub-harmonics

Bad S.C.R.s Reduced PowerMotor Burnout

Vibration @ SCR Frqys Vibration Velocity On Line Fmax = 120 kcpmDrive End

Changes in SCR temps.

Different current / input phase

Thermography

Current Draw

Thermal Image

Amps

6 month

6 month

Compare SCR to SCR

Compare phase to phase

Windingdefects

Motor burnout Stator temp. rise/Uneven temp. distribution

Thermography Thermal image(spot temp)

Megger

6 month 1 baseline

6 month Motor de-energizedEarth current leakage Insulation test

Rotordefects

Rotor failure Line frequency +sidebands

Motor loadcurrent analysis

Motor currentfrequency

Velocity

6 month Press idling

On Line Fmax = RBPF x 3Radial

Vibration @ rotor barpass frequency

VibrationMotor burnout

240 Hz, 1/3 DC pulse,s/band on DC(Sect.2.5)Bad SCR is colder

Unbalanced supply

Hot spot on stator

Should be > 1.5 M

Sidebands of slip x No.of poles around 60 Hz(Sect. 2.2)Sidebands of 1x (Sect 2.2)

PFA for an electric motor

We first decide what the possible failures could be

For example, spalled bearings will lead to

a bearing failure

We then identify how that failure mechanism will show

itself as something we can measure

This example will requirea measurement based ona vibration technology

The applicable parametersfor detecting spalled bearings

are velocity spectrum andtime waveform in G’s

Using our experience, wenow decide on the specifics

when carrying out the analysisThe detection of spalled

bearings should be carried out continually (On-Line)

In the last column we specifysome of the finer details to

ensure good, practical failure detection


Dry/Markedbearings



Time Waveform


On Line = 3 revs

RadialG acceleration

Spalledbearings

Bearing Failure Harmonics of bearing defect frequencies

Vibration Velocity

Time Waveform


On Line = 3 revs

(higher if not usingresonance parameter)Radial

G acceleration

Press Flywheel PFA Tree

Looseness Bearing Failure/Shaft Failure/Structural Failure

Run speed harmonics & subharmonics

Vibration Velocity On Line Fmax = 10 x rpmVertical 1 Baseline


Analysis


Peaks in waveform

Spikes @ Brg defectfreqys. & harmonicsand/or sidebands. See sct. 3.5

Peaks @ 12 G (roller)7 G (ball brg)

Multiples ofBPFO or BPFI in velocitySect. 3.5


Dry/Markedbearings



Time Waveform


On Line = 3 revs

TriggeredG acceleration

Spalledbearings

Bearing Failure Harmonics of bearing defect frequencies or rise in low frequency vibration

Vibration Velocity

Time Waveform


On Line = 3 revs

(higher if not usingresonance parameter)Triggered.

G acceleration

Press Crown PFA Tree

Loosebearing capor cracked key slots

Bearing Failure/Shaft Failure/Structural Failure

Harmonics of press runspeed and gearmesh vibration.

Vibration Velocity On Line Fmax = 25 Hz400 lines, 4 avg.


Analysis


Peaks in waveform

Spikes @ Brg defectfreqys. & harmonicsand/or sidebands.or high amplitude L.F.

Peaks in waveform

Multiples of pressspeed. Increase in gear mesh amplitudesIncrease in resonance

Gearing tooth defects

Broken teeth/catastrophicfailure

Vibration @ gear meshand / or run speed.

Vibration Velocity Spikes @ GMesh frqySidebands @ run speedResonant frequenciesSee sect. 2.4.4

On Line 1) Fmax = G/mesh x 5800 lines, 1 avg, triggered2) Fmax = 500 Hz,800 lines, 10 avg, no trig.3) Famx = 25 Hz,400 lines, 4 avg, no trig.

Wear particle contamination in oil return

Tribology Spectrographic

Ferrography

Increase in Fe, Cr, orCu, Ni, Pb for bush brgWear mode analysis indicates severity

Monthly Clean sampling absolutelyessential.Use a reputable labAs

required

Wear particle contamination in oil return

Tribology Spectrographic

Ferrography

Increase in Iron

Wear mode analysis indicates severity

Monthly Clean sampling absolutelyessential.Use a reputable labAs

required

GET TO KNOW YOUR MACHINERY GET TO KNOW YOUR MACHINERY BETTERBETTER

GATHERING THE DATA

TURNING THE DATA INTO INFORMATION

SHARING THE INFORMATION

MAKING IT WORK

USING VIBRATION ANALYSIS

TYPES OF CONDITION MONITORINGTYPES OF CONDITION MONITORING

WALK AROUND SPOT CHECKINGHAND HELD DATA COLLECTORS

ON-LINE SURVEILLANCEMULTI POINT NETWORK SYSTEM

CONTINUOUSMULTI CHANNEL MONITORING

WHEN TO USE AN ON-LINE SYSTEMWHEN TO USE AN ON-LINE SYSTEM

24/7 INFORMATION REDUCES RISK TO PROCESS

INACCESSIBLE / UNSAFE MACHINE AREAS - PRESSES

MANPOWER IS AT A PREMIUM

HIGH DOWNTIME COST PROCESS

HAZARDOUS ENVIRONMENTS

The vibration changes during the stroke

Clutch Engages

Die Operatio

n

Brake Engages


GATHERING THE DATA



MAKING IT WORK FOR YOU

USING VIBRATION ANALYSISUSING VIBRATION ANALYSIS

Hub

LINKING UP THE SYSTEMLINKING UP THE SYSTEM

Office PC

Hub

Drop

Existing PlantEthernet Highway

(100Mbps)

Nodes

MeasurementPoints

MeasurementPoints

MeasurementPoints

Line 43

Nodes

MeasurementPoints

MeasurementPoints

MeasurementPoints

Line 49

MONITORING NODE “ITA-1”MONITORING NODE “ITA-1”

16 MULTIPLEXED ANALOG INPUTS ACCEL ICP INTERFACE PER CHANNEL BEARING CONDITION MEASUREMENT BIAS VOLTAGE CHECK PROGRAMMABLE GAIN AND FILTERS FLEXIBLE TRIGGER/TACHO FUNCTIONS 10BaseT ETHERNET INTERFACE

ITA-1 - 16 CHANNELS MULTIPLEXEDDYNAMIC AND STATIC DATA ACQUISITION

TACHO / SYNC FEATURESTACHO / SYNC FEATURES

FOUR ISOLATED TRIGGER INPUTS FOR:

EXTERNAL TRIGGER SYNCHRONISATION

TACHO (SPEED) READING

PHASE-LOCK FOR ORDER ANALYSIS AND PHASE

GATED MEASUREMENTS (HARDWARE ENABLE/DISABLE)

THROUGHPUT PERFORMANCETHROUGHPUT PERFORMANCE

UPDATE RATETYPICAL INSTALLATION (100-200 POINTS):

ONE MINUTE TO READ ALL POINTS

“… CATCH FAST DEVELOPING PROBLEMS”

LIVE MODEVIRTUALLY “REAL-TIME” UPDATE RATE

NETWORK USAGETYPICALLY ONLY A FEW PERCENT OF NETWORK

BANDWIDTH USED


GATHERING THE DATAGATHERING THE DATA




WHY USE VIBRATION ANALYSISWHY USE VIBRATION ANALYSIS

GUARDIAN APPLICATION SOFTWAREGUARDIAN APPLICATION SOFTWARE

FEATURES MIMIC BASED VISUAL INTERFACE SUPPORTS VIBRATION AND PROCESS MEASUREMENTS FULL TRENDING, SPECTRAL DISPLAYS AND ARCHIVING NETWORK AND TRANSDUCER DIAGNOSTIC FACILITIES HIGH SPEED “LIVE” SPECTRUM ANALYSIS VIRTUALLY INFINITE EXPANSION CAPABILITY

MIMIC DISPLAYMIMIC DISPLAY

43-2 43-3 43-4 43-5 43-6

Legend:

Guardian Node:

Network 8-port switching hub:

Plant Network drop:

10-BaseT Cat5 cable:

10-twisted-pair analogue signal cable:

ALERTS / ALARMSALERTS / ALARMS

43-2 43-3 43-4 43-5 43-6

Legend:

Guardian Node:


Plant Network drop:



Alerts and AlarmsAlerts and Alarms

VISUAL: POP-UP AND TRAFFIC LIGHTS REMOTE: AUTOMATIC EMAIL TO MACHINE OWNER

PROBLEMS PINPOINTEDPROBLEMS PINPOINTED

43-2 43-3 43-4 43-5 43-6

Legend:

Guardian Node:


Plant Network drop:



TRENDSTRENDS

ANALYSISANALYSIS



TURNING THE DATA INTO INFORMATIONTURNING THE DATA INTO INFORMATION




ON-LINE: WHAT YOU GETON-LINE: WHAT YOU GET

24/7 SURVEILLANCE INSTANT AND HISTORICAL

INFORMATION “LIVE” DATA FROM ANY POINT/MACHINE PRO-ACTIVE, NOT REACTIVE, ENVIRONMENT

“We don’t let our Machinery make our Plans for us”

HOW INFORMATION CAN BE SHAREDHOW INFORMATION CAN BE SHARED

LOCALREAL-TIME GUARDIAN UPDATING

PLANT-WIDEINTRANET ACCESS TO GUARDIAN

GLOBALINTERNET ACCESS USING EXPLORER/NETSCAPE

INFORMATION DATA PATHSINFORMATION DATA PATHS

Main Computer

Local Viewer PC Local Viewer PC

Laptop Computer(with browser)

IE5

Web Server(could be existing resource)

DatabaseMimosaOPCModbusetc



TURNING THE DATA INTO INFORMATIONTURNING THE DATA INTO INFORMATION

SHARING THE INFORMATIONSHARING THE INFORMATION



SOME POSSIBLE MEASUREMENTSSOME POSSIBLE MEASUREMENTS

WE CAN MEASURE

VIBRATION (ACCELERATION, VELOCITY, DISPLACEMENT)

PHASE BEARING CONDITION

(DEMODULATION / ENVELOPING) TEMPERATURE MOTOR CURRENT

etc

DETECTIONDETECTION

WE CAN DETECTFLYWHEEL BEARING PROBLEMS, INTERMEDIATE SHAFT BEARING PROBLEMS, GEARING DEFECTS, CRACKED SHAFTS, BROKEN TEETH, LOOSE COUPLINGSRESISTANCE, BROKEN ROTOR BARS, DAMAGED STATORS, HOT BEARINGS, POORLUBRICATION PRESSURE, FLOW RATE, LOOSE MOUNTINGS, BENT SHAFTS, PITTED BEARINGS, WORNCOUPLINGS

… and lots more ...

TECHNOLOGY IS A TOOL ...TECHNOLOGY IS A TOOL ...

… … INFORMATION IS A NECESSITYINFORMATION IS A NECESSITY

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Jaguar Presentation