Continuous Process Monitoring Using Vibration Analysis:
Continuous monitoring of industrial processes or manufacturing equipment using vibration analysis opens a unique and extremely effective method of identifying process variation or failing equipment. Its effectiveness is based in the fact that a vibration spectrum is unique to a specific process and it is immune to background/ambient noise. Low cost monitoring equipment is programmed to view the spectrum (peaks in the data) and monitor for changes in frequency and/or amplitude that is indicative of a change in process performance. Examples of successful monitoring projects that eliminated adverse failures include:
- Early identification of rolling element bearing failure of large critical equipment
- Enunciation of excessive imbalance of large material transfer blowers. In the past the shaft failed in fatigue with catastrophic results. Now an alarm signals the fault as well as the condition of the rotating equipment
- Prevention of “choking” of hammer mills in grain processing equipment that results in fires
- Enunciating cracked or worn tooling in very high volume automated assembly machines
- Enunciation of machining irregularities such as chatter, loss of lubricant, and cutter wear
- Monitoring of assembly line finished product for production defects using acoustic or vibration input. Defects that have routinely been captured include porosity in castings, improper sintering, inspection of manufactured gear boxes in high volume production, dimensional variation of finished parts
- Gear boxes in high volume production, dimensional variation of finished parts
Continuous monitoring reduces process variation, improves product quality and safety, and reduces labor content in identifying and managing failures.
Machine condition and product quality are tracked using vibration analysis of key components. Permanently mounted sensors provide input into a simple signal processing system that simultaneously monitors multiple, independent machine components and provides alarm if a problem arises. Each possible failure mode is easily identified by its unique frequency and associated amplitude which can be reliably distinguished from other machine vibrations and background noise.
- Provides a baseline of machine performance and TRENDS machine performance
- Monitors critical components in the system and warns of imminent failures
- Provides valuable troubleshooting data