International Journal of Mechanical JOURNAL OF MECHANICAL 0976 INTERNATIONAL Engineering and Technology (IJMET), ISSN 6340(Print), ISSN 0976

6 6359(Online) Volume 3, Issue 1, January- April (2012), IAEME

ENGINEERING AND TECHNOLOGY (IJMET)

ISSN 0976 6340 (Print) ISSN 0976 6359 (Online) Volume 3, Issue 1, January- April (2012), pp. 142-149 IAEME: www.iaeme.com/ijmet.html Journal Impact Factor (2011): 1.2083 (Calculated by GISI) www.jifactor.com

IJMET
IAEME

NEW METHOD IN PREDICTIVE MAINTENANCE OF A MACHINE

N. RISHI KANTH Lecturer Dept of Mechanical Engineering University College of Engineeing Kakatiya University [email protected] 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.

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 1, January- April (2012), IAEME

One of the parameter to increase the quality is perfect maintenance of a machine. In adequate maintenance of a machine leads to production of a bad component, injury to worker and damage to machine. The commonly adopted procedures for running a machine are 1) Run to failure or Break-down or Reactive Maintenance. 2) Preventive Maintenance or Scheduled Maintenance. 3) Predictive Maintenance or Condition Based Maintenance. 1) Run to failure or Break-down or Reactive Maintenance: - In this Reactive maintenance we use to repair the machine when ever the sudden Brake-down occurs while running in this no prior maintenance is taken. 2) Preventive Maintenance or Scheduled Maintenance: - In this Preventive maintenance the machine is kept under maintenance in the in a particular schedule of time even though the machine is running smoothly. This is for prior safety for not to brake down occurs for the machine. 3) Predictive Maintenance or Condition Based Maintenance: - Predictive maintenance is also called as Condition based Maintenance. In this we use some sensors like vibration monitoring sensor, Temperature monitoring sensor, Noise monitoring sensor etc.for the maintenance of the machine and the machine is opened when ever required. Initially every machine has there own vibrations, if any disturbance or any damage occurs in the machine the frequency of the vibrations changes. If we continuously monitor that frequency of the vibrations then we can easily maintain the machine with out any sudden brake down I.e. If any change in frequency of vibration of a motor suddenly increases, the sensor will sense the change in frequency and it will give the perfect indication before damage occurs. From this we will go to that point and change the damaged part. The same principle was applied for all the other types of sensors. Predictive Maintenance Strategy can improve Plant Efficiency Reduction in Lost Production: - Predictive maintenance aims to identify problems in equipment so that necessary downtime can be scheduled. By identifying problems in their initial stages, the predictive maintenance system gives notice of impending failure, so downtime can be schedules for the most convenient and inexpensive time. Predictive maintenance minimizes the probability of unexpected failures, which would result in lost production. Reduced Cost of Maintenance: - As equipment is only repaired when needed (as opposed to routine disassembly), maintenance staff have more satisfying and worthwhile work and the costs of maintaining the machinery are reduced as resources (labor, equipment and parts) are only used when needed.

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 1, January- April (2012), IAEME

Less Likelihood of Secondary Damage: - By identifying potential failures in advance, the severity of these failures can be substantially diminished by reducing or preventing secondary damage. For example, a failing bearing in a motor can be identified and replaced before the winding and shaft are also damaged. Reduced Inventory: - Predictive maintenance reduces inventory costs because, as substantial warning of impeding failures is provided, parts can be ordered as required, rather than keeping a large backup inventory. Extending the Life of Plant Items: - Using a predictive maintenance program, machines are only dismantled when necessary, so the frequency of equipment disassembly is minimized, and thus the probability of infant mortality is reduced. Improved Product Quality: - Predictive maintenance requires data to be taken from the plant. That process, coupled with the collection of additional plant performance data (performed by many predictive maintenance groups), means that the efficiency of plant equipment is scrutinized constantly. By increasing the efficiency of your process, the quality of your product will be improved. With an improved product, and a renewed confidence in product supply, customer relations will also be improved. Secondary Damage: - It is difficult to develop a general rule for the savings due to reduced secondary damage. An estimate of a factor of ten has been suggested2. That is, the repair bill will be ten times higher if a machine is allowed to fail, rather than repairing it before failure. Other Benefits: - The benefits of increased product quality, improved employee relationships due to increased safety and job satisfaction, reduced inventory and extended plant life can only be assessed in your plant. 2 BRIEF WORKING OF SYSTEM It includes preparing of check list for all parameters which are important and continuous monitoring is required. Vibrotip is equipment used for checking 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. The Equipment used for taking the readings is VIBROTIP in this we have facility for taking for 5 readings 1) Vibrations frequency 2) Temperature, 3) Bearing condition, 4) RPM of any rotating parts, 5) pump cavitations. Vibrotip was used for monitoring of vibration frequency, Temperature, RPM of rotating parts of all important motors. Hydraulic motor, coolant motor, and spindle motor 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. Later it will be extend to take readings of bearing condition, pump cavitations also. In this work a check list is prepared for predictive maintenance of all machines in the machine shop. Operator will take the vibrotip equipment and go to the prescribed 144

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 1, January- April (2012), IAEME

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

VIBROTIP is rugged: its extremely robust, rubberized housing withstands hocks, chemicals, water spray and dirt. All sensors are already built into the instrument, with no cumbersome cables or fragile plugs. (If desired, however, external sensors may be plugged into a socket on the top of the VIBROTIP.) The patented Tandem-Piezo dual function accelerometer is ideal for both vibration severity readings as well as reliable shock pulse measurement (for bearing condition and pump cavitation); the contoured tip minimizes contact resonance. The non-contact contrast sensor measures RPM at distances up to 1 m (39"), with no need for a power-consuming light source of its own. The flexible temperature probe flips out of the way when not in use and maintains proper probe contact regardless of application angle. It can also be used to measure the temperature of liquids. 145

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 1, January- April (2012), IAEME

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

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 1, January- April (2012), IAEME

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 Temp at 32 Front Bearing Temp at 32 Rare Bearing Vibration 0.8 at Front Bearing Vibration 0.8 at Rare Bearing Checking Method 1st 7th 14th 21st 28th

Spindle Unit

Vibrotip

29

34

30

32

31

Vibrotip

27

34

32

33

32

Vibrotip

0.3

1.1

1.2

1.1

Vibrotip

0.9

1.6

1.5

1.4

1.5

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 1, January- April (2012), IAEME

Temperature of spindle at Front and Rear

36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 1 2 3 4 5

Temperature

Temp at Front Bearing

Temp at Rare Bearing

Month

Temperature of spindle motor at front and rear where at 32 is prescribed as standard by the machine manufacturer

Vibration at Front & Rear

1.8 1.6

Vibration mm/s

1.4 1.2 1 0.8 0.6 0.4 0.2 0 1 2 3 4 5

Vibration at Front Bearing

Vibration at Rare Bearing

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

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 1, January- April (2012), IAEME

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.

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