Rotating equipment achieves optimum performance and longevity with proper installation and proper maintenance. As a member of the predictive maintenance product family, state monitoring devices are increasingly being applied to devices to closely monitor the operating state of the device for optimal performance. Today's equipment monitoring tools, with hard-to-reach locations and hazardous areas, are equipped with a full suite of predictive programs that maximize machine uptime, reduce downtime and reduce costs.
These devices alert the user when they find a problem that requires attention. In this way, maintenance personnel can take planned measures without rushing to face unexpected component failures.
Decided to monitor content
The monitoring targets include various types of rotating components such as bearings, gears, motors, pumps, compressors, fans and other key mechanical components. When these components are worn, contaminated, damaged, or improperly lubricated, the components or the entire machine may experience increased vibration and temperature rise, which ultimately leads to costly failures.
Similar manufacturers such as Timken have introduced a range of predictive maintenance devices that are used in a variety of environments and industries to meet customer requirements for applications, budgets and resources.
Decide how you will monitor
To choose the right device or system, the tool chosen must meet the return on investment expectations. Therefore, the facility must consider the number of points to be monitored, the budget, the critical value of the equipment, and the professionalism of the maintenance personnel to ensure that a predictive maintenance tool combination that meets performance expectations is purchased.
Careful discussion of needs and expectations can help customers refine their choices. Popular products include hand-held devices for periodic monitoring based on routing, wired and/or wireless systems required for continuous monitoring. The key to choosing is to understand the strengths and weaknesses of each of the two products.
Portable instrument
Portable machine status detector
Portable data acquisition and analyzer
Portable instruments depend on the critical nature of the machine being operated, the availability of readings, and the budget range, and are often the basis for an effective reliability program. From simple RMS vibrometers to advanced spectrum analyzers with data acquisition, portable instruments come in many configurations to choose from.
Timken offers a wide range of portable instruments including bearing testers, machine condition testers and data acquisition and analyzers. These instruments can be used for machine sampling or periodic data collection based on routing.
The Timken Bearing Tester is a portable pocket status monitor. It is reliable, affordable and easy to use. The bearing tester is designed to be compact and lightweight, and evaluates the health and lubrication of ball and roller bearings in industrial environments.
Bearing testers are an economical solution if frontline maintenance personnel or machine operators want to regularly monitor bearings and critical equipment. It uses shock pulse analysis to make early detection of bearing damage and insufficient lubrication. The built-in microprocessor of the bearing tester can analyze the impact pulse diagram of the bearing, and the LED instantly evaluates the green yellow red heat map. In addition, it comes with an infrared sensor for measuring the surface temperature and a stethoscope for detecting irregular sound through headphones.
The machine status tester can be used with vibration or shock pulse sensors. The vibration sensor measures the total vibration (in seconds) to detect trace skew, imbalance, and slack. The shock pulse sensor measures 32KHz and is ideal for detecting insufficient bearing lubrication and internal mechanical damage. With a route-based approach, service personnel can download measurement results, generate alarm lists and graphical trends for early detection of points of failure.
From testers to diagnostic tools, data acquisition and analyzers are a more advanced handheld monitoring instrument. Data acquisition and analyzers provide advanced analysis of baseband signals while measuring shock and total vibration. Signal analysis can be performed in the time domain and the frequency domain, respectively. The time domain analysis plots the amplitude of the signal on the time axis and determines the relationship between time and/or phase. For example, an event occurs during one revolution of the axis. Frequency domain analysis can plot the amplitude of the signal on the frequency axis, called the spectrum. The spectrum is often used to identify complex mechanical sources of vibration in the presence of bearings and/or gear damage.
In summary, the bearing tester and the machine condition tester are front-line tools that prompt the operator (basically without training) to run poorly. Data acquisition and analyzers provide trained technicians with the information they need to better identify the root cause of potential problems.
Wireless monitoring system
StatusCheck ® wireless monitoring device
For hard-to-reach locations, hazardous environments, remote or satellite operations, wireless solutions are ideal for operators to perform quick, real-time evaluation of monitored devices.
The advantage of the wireless device is that it is easy to install, can monitor the device around the clock, and can monitor areas where portable devices are difficult to access. The prepaid cost of a wireless system is higher than that of a route-based handheld device, but lower than a wired monitoring system.
Wireless systems come in a variety of options with great flexibility. Such as Timken ® StatusCheck ® , the unit is designed to detect and monitor excessive temperatures and vibrations. The system has a wireless transmitter and receiver that measures the total vibration on both axes. The wireless transmitter has an accelerometer and a temperature sensor that can be permanently mounted on the monitored device or attached to it. The acquired data is transmitted to a designated sensor, which can be located half a mile away to display vibration and temperature values.
The data provided by the wireless monitoring device allows equipment operators and maintenance personnel to establish a baseline for the acceptable range of vibration and temperature for a particular rotating equipment. This baseline will be used to set warning and alert thresholds. If the temperature and / or vibration level exceeds the threshold, the operator will receive a status alert. As thresholds are gradually adjusted in the future, wireless monitoring devices will become increasingly accurate and reliable tools to track fluctuations in the process, alert them, and avoid unplanned downtime.
Hardwire continuous monitoring device
When a handheld device or wireless device does not meet your needs, a hardwired monitoring solution will be your choice. This is the most expensive type of monitoring device due to the high installation costs. If customers want 24/7 monitoring, they can choose an independent monitoring device that is hardwired to critical equipment. The device is capable of receiving two shock pulses and/or two vibration signals simultaneously.
This type of monitoring provides easy access to device status and provides analog and digital signals to programmable logic controllers (PLCs) or other systems as long as they are installed correctly.
The continuous monitoring tool has two vibration channels and/or two shock pulse channels, making it ideal for monitoring multiple components. For example, it can be used to monitor critical motors and / or fan shafts, bearings, and monitor the imbalance of the fan.
If you need to monitor in multiple locations, get multiple results, and need multiple capabilities, the online monitoring system can provide an all-in-one solution. Such systems provide on-line inspection of thousands of measurement points, including bearing damage, lubrication status, vibration severity, spectrum analysis, and other process parameters. The condition monitoring system uses advanced software to generate reports and trend results, requiring additional training and analysis by the operator.
Choosing to monitor critical equipment is a step in extending the life of bearings, gears and other power transmission components. For more information on Timken's condition monitoring solutions, or to have a targeted assessment of your challenges and needs, please contact your local Timken sales representative or visit / conditionmonitoring
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