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Vibration monitoring on the fans of an extraction system with moneo RTM

Visualisation and analysis of vibrations of an extraction system to ensure air and process quality in the production environment

In various production processes of ifm prover gmbh, an exhaust air system permanently guarantees and secures the quality of the products, machine uptime and high air quality.

The fan capacity is therefore a relevant factor in the entire production process.

The initial situation: no permanent fan monitoring

At the beginning of the digitisation project, there was no comprehensive, continuous fan condition monitoring.In the worst case, a defect that was detected too late would result in a complete standstill of the entire production area because a failure of this system would have meant that

  • the product quality would be reduced due to problems with automatic marking, among other things, because fine dusts were not adequately extracted.
  • Machine defects and downtimes occur due to overheating if waste heat is not sufficiently dissipated.

Goal of the project: permanent assurance of the production process

In order to permanently ensure product quality and to avoid machine downtimes and production losses, permanent, software-supported monitoring of the fans should be implemented. This should also make it possible to abandon inefficient, time-based maintenance intervals in favour of demand-oriented, flexible and predictive maintenance planning.

The implementation: moneo RTM in combination with IO-Link

Due to the existing IT infrastructure at ifm prover gmbh, moneo could be installed directly on the existing hardware to activate the moneo RTM module. In case of insufficient system capacity, the software package could have been made available alternatively on the moneo appliance. moneo appliance is the IPC solution whose hardware components and computing power are precisely tailored to the software. An IO-Link master has been connected to the server via an internal VLAN. Via the IO-Link master, the data of the connected process sensors is transferred to the moneo world for evaluation.

The success: Advantages of vibration monitoring with moneo RTM

With the help of the modular IIoT platform moneo, fan monitoring has become more efficient and reliable. Thanks to the early detection of imminent damage to the fans, a failure of the extraction system can be prevented. In addition, necessary maintenance can be planned in such a way that plant downtimes will be reduced to a minimum. Software-supported maintenance documentation also makes it easy to identify excessive recurring wear and tear and to initiate appropriate measures.

Bottom line: These features and services of moneo RTM ensure efficient fan monitoring

  • Calculated values: conversion of sensor values into process-relevant information using data modelling
  • Cockpit functions: comprehensive and individual visualisation of all sensors in the process
  • Detailed information about the machine status by acquiring sensor values
  • Integrated alarm management: Fast reaction to changing process parameters
  • Early warning: Avoidance of unplanned downtimes thanks to early detection of faults

System setup

  1. IO-Link Vibration sensor
  2. Temperature sensor
  3. Speed sensor
  4. IO-Link Master

Dashboard

The dashboard provides the user with an overview of the relevant process values for fan monitoring.

  1. Overview of vibration characteristics v-Rms, a-Peak and a-Rms in a line chart
  2. Crest factor (ratio a-Peak to a-Rms) for the assessment of the bearing condition
  3. Traffic light display of the crest factor (green = OK, yellow = > 10, red = > 12)
  4. Traffic light display of the temperature value (green = OK, yellow = > 50°C, red = > 60°C)
  5. Current surface temperature of the motor
  6. Traffic light display of the speed (green = OK, yellow = > 3000 rpm, red = > 3500 rpm)
  7. Current speed of the motor

Analysis

The analysis offers the possibility to access the historical data. In the event of a warning or alarm, the status that led to the message can be directly observed here.

  1. Curve of the motor speed
  2. Trend in motor speed
  3. Peak value of the VVB

From the analysis, it can be deduced that the motor does not rotate when the peak occurs, which may indicate, for example, that it is a manually triggered fault.

Tasks & tickets

As soon as a defined limit value has been exceeded or not reached, a ticket will be created for the corresponding process value. This can be taken over and processed by the responsible employee. Via the comment function, implemented measures and descriptions of solutions can be documented immediately.

Calculated values

Using a template to calculate the operating hours, an operating hours counter can easily be set up by means of five options. In the case of a fan, the speed of the motor can be used as a measurement variable for counting up.

  1. Name of the operating hours meter for clear identification in the topology
  2. Data source used to count the operating hours
  3. Threshold value to define when the counter will count up
  4. Preselection of the current operating hours
  5. Option to count backwards