Condition monitoring solutions ensure regular condition monitoring in many machines. Wear on motors can thus be detected in good time and machine downtime avoided. However, if this function is performed via sensor, this can quickly become very costly, depending on the machine type and the number of motors used, such as in a textile machine. The drive and automation specialist Baumüller has now developed a new software solution with which condition monitoring can be implemented entirely without a sensor.
The Drive-based Condition Monitoring software is integrated directly into the servo controller and can therefore be easily retrofitted. The drive-based software solution is another intelligent
function from the Baumüller SmartValue modular software system. This helps to improve the energy balance in production and reduce manufacturing costs. With Baumüller SmartValue, Baumüller offers numerous drive-integrated solutions, for example, to record, document and optimize the energy consumption of the drive system.
Monitoring function in the drive without sensor
The new function uses pre-recorded and analyzed process parameters from the current and speed signal as reference values for monitoring the mechanics such as the motor, fan and hydraulic pump. An FFT analysis can then be used to detect changes in the vibration spectrum. These vibrations can be due to imbalance or faulty alignment, among other things.
If a significant deviation from the reference value is detected during operation, an error signal can be output in good time. This enables planned maintenance for the motor and prevents further damage or failure of the machine. The time intervals for the comparison measurements can be carried out at a fixed interval or on demand, depending on the customer's requirements and application. Monitoring is based on adjustable warning and error thresholds. The machine builder can use the measurements for new business models in the area of data-driven additional services.
Drive-integrated PLC enables condition monitoring
The inverters of the b maXX 5000/6000 family are equipped with the integrated high-performance b maXX-softdrivePLC control platform. This enables control functionalities and an individualized API to be loaded directly into the drive. Programs can thus run highly synchronously with the controller clock. Baumüller has also used this intelligence in the drive for its new condition monitoring solution and runs the function in the firmware. The intelligence thus migrates into the drive. Depending on the application, an external sensor is not absolutely necessary. This saves the effort of separate wiring and reduces costs.
Readable characteristic values
The new Drive-based Condition Monitoring software can be integrated in different variants. In a simple version, the inverter provides a collective value from the temperature, power and vibration analysis of the motor. This can be clarified in the visualization, for example as a red/green display. For more in-depth information, the software can provide further values, such as historical curve, crest factor (ratio of peak to rms value) as well as kurtosis factor for the number of transients/outliers in the vibration signal and standard deviation.
When the current oscillations change, 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 values measured can be additionally analyzed. The damage characteristics can also be optionally output on a clear dashboard.