Академический Документы
Профессиональный Документы
Культура Документы
IJMET
IAEME
Dr.C.V.MOHAN RAO
G. YEDUKONDALU
AssociateProfessor
Asst.Professor
Dept of Mechanical Engineering Dept of Mechanical Engineering
University College of Engineeing K.L.University
Kakatiya University
ABSTRACT
It has been established that for efficient and economic operation of manufacturing
systems, monitoring the condition of tool, work piece and machine, as well as adaptive
control of the system are required. This paper investigates the development of improving
life of a machine by implementing Predictive maintenance for achieving automation
manufacturing process. With this system we upgrade the Machine Maintenance technique
by providing Equipment called VIBROTIP and collect the data of the machine
(Vibrations, Temperature etc) and observes the condition of the machine it allow officers
located far from the Machine to monitor the machine health and give important warnings/
precautions to the worker for maintenance if required This paper gives knowledge on
predictive maintenance by using VIBROTIP.
Key words: Predictive maintenance, vibration, temperature
1 INTRODUCTION
The result of ineffective maintenance management represents a loss for a
company. Perhaps more important is the fact that our ineffective management of
maintenance dramatically impacts our ability to manufacture quality products that are
competitive in the world market. The loss of production time and product quality that
results from poor or inadequate maintenance management has had a dramatic impact on
our ability to compete with others. In order to overcome this problem a proper
maintenance method is implemented.
142
143
points in the checklist, take the respective readings of that element and enter in the check
list. After that he will plot a graph in which the limits are pre set in the chart. If the value
locates in between the limits means that machine is in proper condition, when ever the
reading locates beyond the limits then machine should opened for maintenance.
3 REQUIREMENT OF THE SYSTEM
1) One of the Basic requirements is to maintain good health for a machine.
2) Perfect monitor at important points in a machine
3) It will be ensured that the machine is running under safe limits and give prior
information if any maintenance requires.
4) If at any point the readings are exceeding the limits then immediate attention is to
be taken before it damages the machine and reduce any danger to the operator.
4 VIBROTIP
In this work equipment called VIBROTIP is used for predictive maintenance of
all machines in the machine shop. From the VIBROTIP equipment we can sense the
Vibrations frequency, Temperature, Noise, Bearing condition, RPM of any rotating parts,
pump cavitations. It is the non contact type of sensor which used as multipurpose
equipment.
Technicaldata
Charging duration approx. 14 hours
Power supply 115 / 230 VAC
(switchable)
Output voltage 24 VDC idle load
Charging current 10 mA at
10Vchargingvoltage
From this equipment the readings for the important parameters that affect the
quality of product in constant interval of time is collected and plot the readings in the
graph and then compare the varying of the graph. If the variations in the graph occur then
we go to that parameter and take the predictive maintenance before failure occurs.
5 EXPERIMENTAL PLAN
In this predictive maintenance with the equipment Vibro tip we will check the
important parameters prescribed in check list of all machines in cylinder block & cylinder
head line.
The over all machines in the cylinder block line are two HELLER Machines, one
NAGEL Machine. In cylinder Head line five makino machines.
Line diagram for collecting of data
146
The following 5 readings can be observed by using the Vibro tip equipment 1) Vibrations
frequency 2) Temperature, 3) Bearing condition, 4) RPM of any rotating parts, 5) pump
cavitations.
The data from Hydraulic motor, coolant motor, and spindle motor is collected
these are the some of the important parameters from which we have to keep continuous
monitoring to maintain the machine perfectly with out any sudden major brake down. For
example if spindle motor is not maintained in proper condition vibration may start and if
it exceeds to some limit it may brake if motor shaft brakes the tool may damage the
component or it may damage the machine if operator is not in aware it is danger to the
operator also
Fault diagnosis
With the help of vibrotip mainly we collected the data of temperature and
vibration at given points and updated in excel sheet. We can also use the related software
for plotting the points and get the out put automatically and with that we have to compare
those values with standard values prescribed by machine manufacturer and if it exceeds
that limit immediately we can go for maintenance for that respective motor before it
damages the machine
Predictive Maintenance Check sheet for Makino1
Sr.
No
Description
Parameter Std
to
be Readi
Check
ng
Checking
Method
1st
7th
14th
21st
28th
Spindle Unit
Temp
at 32
Front
Bearing
Vibrotip
29
34
30
32
31
Temp
at 32
Rare
Bearing
Vibrotip
27
34
32
33
32
Vibration
0.8
at
Front
Bearing
Vibrotip
0.3
1.1
1.2
1.1
Vibration
0.8
at
Rare
Bearing
Vibrotip
0.9
1.6
1.5
1.4
1.5
147
Temperature
Temp at
Front
Bearing
Temp at
Rare
Bearing
Month
Vibration mm/s
1.6
Vibration at
Front Bearing
1.4
1.2
1
Vibration at
Rare Bearing
0.8
0.6
0.4
0.2
0
1
Month
Vibration of spindle motor at front and rear where at 0.8mm/s is prescribed as standard
by the machine manufacturer
Similar to the spindle unit the data from Hydraulic motor, coolant motor also collected
and maintained in a tabular column so that we can get continuous monitoring on the key
points on a machine
148
6. CONCLUSION
Predictive Maintenance of machine gives the pre indication of the
health of the machine. It generates a graph by collecting of values like vibration,
temperature from VIBROTIP; if it crosses the limit specified by machine manufacturer
then immediate attention is taken at that point before major damage occurs.
7. REFERENCES
1. John S. Mitchell, Machinery Analysis and Monitoring, Penn Well,1981.
2 E. Downham and R. Woods, ASME paper, Toronto, September 8-10,1971.
3. P. Bradshaw and R. B. Randall, Early Fault Detection and Diagnosison the Trans
Alaska Pipeline, MSA Session, ASME Conf.,Dearborn, pp 7-17, 1983.
4. J. Howard Maxwell, Induction Motor Magnetic Vibration, Proc.Vibration Institute,
Meeting, Houston, TX, Apr.19-21, 1983.
5. R. B. Randall, A New Method of Modeling Gear Faults, ASME J.Mech. Design, 104,
pp 259-267, 1982.
6. J. Antoni and R. B. Randall, Differential Diagnosis of Gear and BearingFaults,
ASME J. Vib. & Acoustics, 124, Apr. 2002, pp 165-171.
7. P. D. McFadden and J. D. Smith, Model for the Vibration Producedby a Single Point
Defect in a Rolling Element Bearing, J. SoundVib., 96 (1), pp 69-82, 1984.
8. D. Ho and R. B. Randall, Optimisation of Bearing Diagnostic TechniquesUsing
Simulated and Actual Bearing Fault Signals, MechanicalSystems and Signal Processing,
14 (5), September 2000,pp 763-788.
9. W. A. Gardner, Introduction to Random Processes with Applicationsto Signals and
Systems, Macmillan, 1986.
10. R. B. Randall, Frequency Analysis, Brel & Kjr, Copenhagen,1987.
149