One of the primary conclusions of the Design News Machine Controller Reader Survey from October 2012 is that there is an opportunity to unify different and new machine functions on a single controller.
To explore interest in what machine controller functions users might be more likely to implement in new designs, the survey asked respondents how likely they would be to utilize specific new capabilities. The answers were not necessarily surprising but they did confirm recent initiatives to provide more tightly integrated solutions. Condition monitoring (bearings and temperatures, etc.), for example, was mentioned by 24.6 percent of respondents as very likely to be adopted.
One of the keys, of course, is how much work it is, and the cost to add a function such as condition monitoring to an application, but automation control suppliers are very aware that these tools need to be easy to implement if they are going to gain traction especially among OEM machinery builders.
The B&R System Diagnostics Manager is a powerful tool that provides mobile condition monitoring for operators, technicians, and supervisors. (Source: B&R Automation)
B&R Automation has recently introduced an intelligent X20 module that offers an integrated approach to evaluating vibration patterns, offering onboard intelligence for vibration analysis that can make condition monitoring an integral standard feature on machines. In the past, preventive maintenance based on data from permanent condition monitoring has been rarely practiced due to the high cost of conventional systems. The X20 module claims to remedy this by maximizing machine availability while minimizing the time and money spent on maintenance. Preventive maintenance control based on the condition of the machinery can be planned more efficiently and performed during breaks in production.
With the X20CM4810 module, B&R has also introduced a new dedicated condition monitoring tool for machine builders and end users that enables operators to continuously monitor the status of an entire system. With a width of two slots, the module provides four input channels and an IEPE interface (integrated electronic piezoelectric) for querying acceleration sensors. This interface supplies the sensors with power, samples their signals, and processes them internally to generate more than 70 condition parameters like configurable damage frequency values, which are then transferred directly to the CPU via Ethernet POWERLINK or any other standard fieldbus system.
Optimizing machine availability
One effective way to optimize the ratio of machine availability to maintenance costs is to replace fixed maintenance intervals with condition-dependent, predictive maintenance. This involves scheduling maintenance when changes in monitored parameters indicate impending failure. The advantage of this is that components can continue to provide value until much closer to the actual end of their useful life, which is typically much later than the conservatively estimated maintenance interval.
But there is also no impact on manufacturing planning, since the required maintenance can be performed during regularly scheduled breaks in production. The risk of maintaining a stock of replacement parts is also minimized since only the affected components need to be replaced. This is also a way to reliably avoid failures that result from neglected maintenance.
This approach to condition monitoring machinery would be a boon to Plane Engineers with the resposibility for maintaining machinery in a production plant. Now,as the article states, separate pieces of equipment are required to monitor temperature, pressure and vibration. All inclusive instrumentation would be a great advance in maintaining production and increasing the bottom line.
This approach to condition monitoring machinery would be a boon to Plane Engineers with the resposibility for maintaining machinery in a production plant. Now,as the article states, separate pieces of equipment are required to monitor temperature, pressure and vibration. All inclusive instrumentation would be a great advance in maintaining production and increasing the bottom line.
William, I can understand your reservations about integrated safety. But the incentives to eliminate the separate Safety PLC from the total system cost point of view, redundancy features plus implementing safety software using the same development tools as the rest of the machine seem to be winning among users. Suppliers will need to prove that these systems with multiple applications running on a single machine controller will operate reliably over the long haul.
"The answers were not necessarily surprising but they did confirm recent initiatives to provide more tightly integrated solutions."
AI, yes peoples are looking for single point solutions. They don't want to refer different data set or devices for analyzing, instead they prefer a single point solution where they can get all in a capsulated form.
I have a concern and a caution about putting any safety controls on the same controller as condition monitoring code or data acquisition code, and really, any other code. My reason for concern is that sometimes programs lock themselves into conditions that prevent the rest of the program from executing. That could cause a disaster if it inhibeted some safety function that was needed urgently. Perfect code would have no problms, of course, but not all code is perfect. So while there mnay not be any problems arise from running all of the code, including safety functions, on one controller, it is leaving an opportunity for problems available.
Al, Thanks for reply and the investigation into the module supporting development of Control Charts. Look forward in the hearing B&R Automation response.
Not sure if the B&R package provides the specific data for Control Charts or not. Will see if I can check on that. The goal of these condition monitoring modules from B&R is to precisely detect cases when service work may be needed-- along with being very easy for the user to configure. Back of Chuck's question, that makes implementing the feature easier because most of the specific software functionality is already provided.
Chuck, I think the issue with Preventive Maintenance is both hardware and software. What vendors are working toward are standard packages within their development tools which allows users to very easily implement software solutions using standard tools. In the case of wind turbines for example, where reliability is critical and detecting problems can save big $, vendors are offering optional add-ons to their systems to provide advanced functionality.
Al, Interesting article and survey results. With this module that B&R Automation developed to monitor machine performance, is it possible to obtain data for creating Control Charts?
I'm curious, Al -- you mention that preventative maintenance was rarely practiced due to the high cost of conventional systems. Is it the high initial cost of the systems or the cost of implementing them?
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