5 conditions you can monitor by using monitoring systems available in machine condition monitoring market.
Machine condition monitoring is a method of monitoring the condition parameters of large-scale machines used in industries. This method is used to track different parameters of machines like temperature and vibration to trace the potential faults that may lead to machine failure or downtime. Condition monitoring is more effective than reactive maintenance because faults can usually be inhibited.
The utilization of machine condition monitoring enables management authorities to tackle potential chances of machine failures by scheduling predictive maintenance. Condition monitoring helps industries by reducing machine downtimes, lowering expenses, and extending machine durability. Monitoring solutions available in machine condition monitoring market help in maintaining normal operation of machines by data processing, data acquisition, and data comparison with similar machines.
What conditions are monitored on a machine?
One machine can have numerous conditions that require monitoring. By directly connecting to a machine's PLC, machine condition monitoring solutions provide access to a wide range of machine data. You can also integrate external sensors or connect older equipment with digital and analog IO to ensure that all equipment is monitored.
By analyzing the data collected through machine condition monitoring, you can gain a better understanding of machine health and take necessary steps to maintain equipment when a given variable indicates a future machine failure. The following are some conditions that can be monitored to predict failures, identify trends, and implement condition-based maintenance activities:
- Vibration monitoring: High variations in vibration patterns indicate internal failures in machines. By monitoring these patterns operators can gain insights into machine reliability and operational efficiency. Machine failures can be detected by monitoring systems, which can give an early warning of up to 15 minutes or more before a human operator is able to notice the issue.
- Bearing wear monitoring: During startup and shutdown times, machines can be damaged due to ball bearing wear, as the machine’s fluid pressure is not high enough to assert proper lubrication. If the lubricant levels are low and the wrong type of lubricant is used, it may also cause bearing wear. Integrating a monitoring device to track the condition of bearings can avoid expensive maintenance and downtime, thereby helping minimize critical failures and reduce expenses.
- Load monitoring: Components of machines may sometimes become dull due to continuous contact with raw materials. The force applied by machines on these dull components may lead to a threat of damage, which can be tackled by machine condition monitoring devices.
- Temperature monitoring: Machine temperature is a significant indicator of potential problems. By monitoring machine temperature, production employees can be alerted to impending machine failure. In some manufacturing environments, where conditions are more hostile, monitoring temperature can even help prevent risks such as machine breakdown or fires.
- Tool failure: By integrating a machine condition monitoring system you can easily predict when a tool may break down or stop functioning. Monitoring systems help operators to implement preventive measures to timely fix these issues.
