AMMJ - Library

More documents

Recommendations

Info

Maintenance News Honda engine factory in China benefits from SKF on-line machine monitoring Sales of Honda cars in China increased by over 50% year on year during 2009. And with another joint venture factory being built in 2010 the company is very optimistic about delivering more of their fashionable and high quality cars to the Chinese market. Contributing to this success are the modern and reliable engines manufactured by Dongfeng Honda, a joint venture factory located right next to the Honda car assembly plant, in Guangzhou. Equipped with advanced manufacturing machinery the engine factory produces engines in the range 1.3 to 2.4 litres for Honda cars in China. And a central machine in each production line, critical for high productivity and quality, is the multifunction machining centre. These machining centres must operate for very long times in a range of speeds and loads, which often change very quickly, as they drill, cut and turn away the metal to form the finished products of engine block and engine head. So it is absolutely essential that the machining centre spindle operates within very tight tolerances to deliver the accuracy required of Honda engines. Key to spindle performance are the bearings that support and rotate the spindle across its tough work cycles. And bearing performance and reliability are therefore critical to keeping the very high cost spindles delivering high quality machining output at cost effective levels demanded of all modern manufacturing plants. This in turn means it is very important, to detect early indications of any bearing wear that could take the spindle outside its required tolerances or lead to bearing failure that would damage the spindle assembly and require very heavy costs to repair, as well as a long period of loss of production. Depending on a number of factors a typical machining centre spindle would have an operational life of 1- 2 years before replacement of bearings was needed. The actual life is difficult to determine and a lot of off-line measuring, requiring stopping production, is needed before taking the decision for a full spindle bearing replacement action. Dongfeng Honda maintenance manager, Mr. Chen Shi, was using off-line monitoring in this way for some years and was concerned about the amount of lost time needed to carry out this necessary maintenance. So, in the Honda tradition of challenging and trying new technology, he had the desire to upgrade to on-line monitoring. With on-line monitoring, sensors would track the spindle bearing’s condition 24 hours a day, and give a signal at any signs of bearing wear or drop in performance outside specified limits. But on-line monitoring of this sort had not been applied before by Honda in China, so he had no inhouse experience to draw on. So, looking for a partner in this challenge he invited SKF to propose a solution for his machining centres. An SKF inspection report led to a 5 months test and evaluation program of the TMU together with Honda engineers. In this period a number of factors needed to be determined; • best location of vibration sensors on the spindle • arranging cabling for good data transmission yet allowing spindle full uninhibited movement for all functional machining operations • getting accurate control points from Honda’s PLC for all machining operations • determining the spindle’s vibration spectrum and trend pattern for its machining operations for both the spindle head and the bearing, across a range of typical application speeds and forces. At the end of the test period the Honda engineers, now fully trained on the TMU, were enthusiastic about the potential and so Chen had 3 TMU’s installed on 3 different machining centres. Success was almost instant with one TMU detecting a condition later diagnosed as poor lubrication and immediately rectified, and a second TMU detecting a bearing defect that could be allowed to continue until an optimum time for replacing at a scheduled machine maintenance stop. A further 19 TMUs have since been installed at the Guangzhou engine plant and 3 more have been ordered for the Honda plant in Wuhan. Commenting on this Chen says; “I have been very satisfied with the performance of the TMU and its ease of use by our maintenance personnel. And I am also very impressed with the professionalism of SKF’s engineers who gave fast and knowledgeable support whenever we needed it. Dongfeng Honda is safe in the knowledge that the spindles will not fail unexpectedly, with the corresponding catastrophic effect on production and costs. Furthermore we can optimize our production, as far as machining centre availability is concerned, by replacing any necessary bearings during planned maintenance stops” Features of the SKF Multilog Online System TMU: The TMU is a 3 channel 24 hour/day surveillance device designed to protect critical rotating assets in rugged manufacturing environments. It can warn of developing machine problems such as bearing damage, spindle or shaft imbalance, poor lubrication etc and provide diagnostic information for improving reliability and quality. Monitoring is done according to user-defined conditions, making it applicable in a wide number of industries. In addition it has a special feature which rapidly detects shocks, such as would occur with a spindle crash, and instantly shuts down the machine helping to prevent severe damage to machine components. It has a distributed architecture allowing easy and flexible expansion to cover small, medium or large machine or manufacturing systems. www.skf.com SEW delivers unmatched maintenance support When shut-down periods approach, and scheduled maintenance and repairs are carried out, it is important that Australia’s mines and industrial facilities have access to premium levels of motor and drive service and support—especially those in remote areas of the country. With an Australia-wide network of technical support, assembly and service facilities staffed by teams of engineers and technical experts, SEW-Eurodrive leads the way in this regard. According to SEW-Eurodrive Mechanical Service Team Leader, Frank Fedele, it’s the company’s extensive support infrastructure that allows the motor and drives expert to deliver such high levels of service. “Australia’s industrial and mining motor and gear-unit users are able to send repair and maintenance jobs to SEW’s strategically located service and assembly facilities in Brisbane, Sydney, Melbourne, Adelaide and Perth,” he said. “We provide the fastest turnaround possible to ensure end-users can Vol 24 No 1
Maintenance News get back into production as quickly as possible, after scheduled maintenance or emergency breakdowns.” By assembling locally, stocking a comprehensive range of spareparts and providing 24-hour around-the-clock technical support, SEW-Eurodrive has gained a reputation as Australia’s most dependable drive solutions provider. “SEW’s ability to supply total project lifecycle support throughout Australia sets us apart,” said Fedele. Importantly, SEW-Eurodrive recently expanded its Perth sales and service centre. The new facility is four times the size of the company’s previous premises and has been purpose-designed to accommodate the assembly and repair of larger-sized complete drive packages. Industry can also access a wide range of technical literature and product information via SEW-Eurodrive’s DriveGate online portal. Here, parts lists, CAD drawings and installation and operating manuals, along with online support, can all be accessed to aid product selection, installation, maintenance and commissioning. SEW-Eurodrive also offers motor and drive technology training courses via the company’s new DriveAcademy training program. www.sew-eurodrive.com.au Fiber Bragg Grating – new technology in optical fiber and semiconductor lasers Optical fibers provide a fundamental improvement over traditional methods offering lower loss, higher bandwidth, immunity to electromagnetic interference, lighter weight, lower cost, and lower maintenance. By applying a UV laser to “burn” or write a diffraction grating (a Fiber Bragg Grating – FBG) in the fiber it became possible to reflect certain wavelength of light, which used together with an interrogation analyzer precise sensing measurements could be taken. This technology is widely used for Dense Wavelength Division Multiplexing DWDM) applications, for real time fault detection and imbedded monitoring of smartstructures (stress measurement). Applied Infrared Sensing launches new Fiber Bragg Grating Analyzers (FBGA) from BaySpec (USA). These FBGA employ a highly efficient Volume Phase Grating VPG® as the spectral dispersion element and an ultra sensitive InGaAs array detector as the detection element, thereby providing high-speed parallel processing and continuous spectrum measurements. As an input, the device uses a tapped signal from the main data transmission link through a single mode fiber, then collimating it with a micro lens. The signal is spectrally dispersed with the VPG®, and the diffracted field is focused onto an InGaAs array detector. The control electronics read out the processed digital signal to extract required information. Both the raw data and the processed data are available to the host. www.applied-infrared.com.au Shaft Alignment and Geometric Measurements in New Package Solutions Elos Fixturlaser is launching two successors to its best-seller Fixturlaser XA; the Fixturlaser XA Pro – a complete shaft alignment tool, and the Fixturlaser XA Ultimate – shaft alignment and geometric measurements in an ultimate package solution. Fixturlaser XA Pro Fixturlaser XA Pro comes with an increased software and hardware package. The software package contains all you need for performing shaft alignment of rotating machinery, e.g. horizontal and vertical shaft alignment, alignment of machine trains, Hot Check, and Softfoot. A new function is the “Machine 59 Defined Data”, which makes it possible for the user to save machine configurations as templates. All machine data for each specific machine, such as machine dimensions, measurement distances, tolerances, and target values, are readily available in the Fixturlaser XA Pro alignment tool. The hardware package contains e.g. thin magnet brackets and an extension fixture, which are useful when working in narrow spaces. A magnetic base is also included which will facilitate the mounting of the measurement units on shafts with a big diameter. Fixturlaser XA Ultimate Fixturlaser XA Ultimate is a measurement tool with a complete software package for both shaft alignment and geometric measurements, such as flatness and straightness. Having a properly aligned machine starts already at the time of its installation, e.g. with checking if the machine foundation is skewed or warped in any way, which would influence the machine’s capability to work under optimal conditions. The Fixturlaser XA Ultimate tool gives the user access to all the software and hardware that is required for a successful machine installation and consequently ensuring optimal running conditions for the machine. www.fixturlaser.com PartsSource Releases ePartsFinder 4.10 PartsSource, the nation’s only multi-manufacturer, multi-modality, alternative supplier of medical replacement parts has released the latest version of its e-commerce platform, ePartsFinder. Based on user feedback, ePartsFinder 4.10 advances the procurement and management of medical replacement parts with the following features and benefits: • Consolidated Shopping Cart - One screen/one click parts order process reduces cycle time • Display Part Image - Digital imaging improves order accuracy and reduces wrong parts delivered and returns • Customer Notes/Enhanced Quoting - Dynamic text dialogue improves order accuracy • Printing Quotes - Instant quote documentation and printing from Part Detail screen speeds approval process • Duplicate Part/Frequently Ordered Parts - Past purchases via History tab can be easily researched avoiding duplicating orders and reducing time required to enter and submit parts orders. “ePartsFinder is used in over 600 hospitals by over 3,000 technicians. In addition to releasing ePartsFinder 4.10, we recently completed customer-driven integrations with leading ERP and CMMS software companies improving the utility of our asset management and parts procurement applications by our customers.” www.partssource.com Coatings and Automatic Lubricators Cut Maintenance Costs at Pequiven Based in Venezuela, Pequiven is a Government-owned company founded 30 years ago. The company produces petrochemical products, mainly for the domestic market. The company specialises in the production of fertilisers and chemical products, as well as olefins and other synthetic resins. At its phosphoric acid plant, which has a production capacity of around 250 tonnes of P2O5 per day, Pequiven wanted to improve the running time of a critical conveyor system that separates the solids from the phosphoric acid mixture. Vol 24 No 1
Page 3 and 4:
SKF Reliability Systems 2011 Traini
Page 5 and 6:
Do our people get smarter when they
Page 7 and 8: 8 14 16 22 28 34 AMMJ Laser Claddin
Page 9 and 10: info@infratherm.com.au Introducing
Page 11 and 12: Tough Times Demand Smart Solutions
Page 13 and 14: Reach new heights of production and
Page 15 and 16: Locate electrical problems Detect p
Page 17 and 18: AMMJ Strategic Maintenance Reportin
Page 23 and 24: Figure 1 Proactive Workflow Model Y
Page 25 and 26: AMMJ Asset Criticality Analysis Eve
Page 27 and 28: AMMJ strategies that accomplish thi
Page 29 and 30: AMMJ Maintenance and Reliability We
Page 35 and 36: AMMJ Mill Downtime Tracking 35 THE
Page 37 and 38: AMMJ Mill Downtime Tracking 37 The
Page 39 and 40: AMMJ Mill Downtime Tracking 39 C. B
Page 41 and 42: AMMJ Mill Downtime Tracking 41 Basi
Page 43 and 44: AMMJ Underground Cable Faults To fo
Page 45 and 46: AMMJ 2 Maintenance Approach Mainten
Page 47 and 48: AMMJ deemed critical, a reactive or
Page 49 and 50: AMMJ This type of measurement gener
Page 51 and 52: AMMJ 6.1 Bearing Characteristic Fre
Page 53 and 54: AMMJ zero. As the bearing radial in
Page 55 and 56: AMMJ the afternoon and night shifts
Page 57: Green CMMS The Engine of Sustainabi
Page 61 and 62: Mail this form to: EIT P/L, PO Box
Page 63 and 64: 8. PLANT MAINTENANCE MANAGEMENT ( 3
Page 65 and 66: MAINTENANCE BOOKS - ORDER FORM Pric
show all

AMMJ - Library

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?