Smart Condition Monitoring
Servo drive with integrated condition monitoring — without sensor
Condition monitoring solutions allow the condition of many machines to be tracked regularly. Motor and machine wear can therefore be detected early and machine downtimes avoided. However, if this function is performed via sensors, it can quickly become very costly, depending on the type of machine and the number of motors used, such as in a textile machine.
Baumüller has developed a software solution with which the mechanisms can be monitored completely sensor-free. The smart condition monitoring software is integrated directly in the servo controller and is therefore easy to retrofit. The drive-based software solution thus increases productivity without further hardware and wiring.
Sensor-free monitoring function in the drive
The function uses previously recorded and analyzed process parameters from the current and speed signal as reference values for monitoring the mechanical elements, such as the motor, fan, and hydraulic pump. In this way, with the help of FFT analysis and other statistically calculated indicators, deviations between the measurement and the stored reference can be identified. Among other things, the calculated data can be traced back to unbalance or faulty alignment.
If a significant deviation from the reference value is detected during operation, a warning signal can be output in good time. This allows planned maintenance for the motor and prevents further damage to or the failure of the machine. The comparison measurements can be timed to take place at fixed intervals or on demand, depending on the customer’s requirements and the application. Monitoring is based on adjustable warning and error thresholds. Machine builders can use the measurements for new business models for data-driven additional services.
The smart condition monitoring software solution is integrated directly in the servo controller and analyzes the current and speed signal. If a significant deviation is detected, this can be used for a fault signal, thereby preventing damage
Monitoring function with sensor
In addition to the software module without sensor, a variant with sensor can also be integrated. The functional scope can thus be extended, for example, to include the evaluation of existing vibration sensors. These can be freely positioned on a mechanism. The values measured provide further information and can be additionally analyzed for a more precise fault pattern.
Intelligent drive solutions enable new business models
The smart condition monitoring software solution allows machine manufacturers to offer their customers conditioning monitoring with or without sensor link. The software is integrated directly in the servo controller via the b maXX softdrivePLC, making it easy to retrofit. Machine manufacturers thus have new options, such as offering runtime models for additional machine functions.
b maXX softdrivePLC
The drive-integrated PLC runs as part of the firmware in the b maXX servo converters.
Your benefits at a glance:
- Cost and space savings: No need for external hardware, reduction of wiring work and hardware costs
- Reduction of standstill times: Faults and deviations are detected by continuous monitoring
- Ready-to-use: Validated and tested software package saves development time and costs
- Engineering as a service: We will also solve your challenge!
Readable characteristic values
The smart condition monitoring software can be integrated in different variants. One possible variant could combine the results from the speed and current measurement with a temperature energy measurement to form a signal. This can be illustrated in the visualization, for example in the form of a red/green display.
For more in-depth information, the software can provide further values, such as the historical progression, the crest factor (ratio of peak to effective value) as well as the kurtosis factor for the number of transients/outliers in the vibration signal and standard deviation. Upon a change in the current oscillations, the exact value that has deviated from the reference value is then output. The range of functions can also be extended to include the evaluation of an external acceleration sensor. This can be freely positioned on a mechanical system and the measured values can be additionally analyzed.
The damage characteristics can also be optionally output on a clearly organized dashboard.
All data can be displayed compactly on the machine visualization
