Festo Diagnostics and Condition Monitoring (PDF)

Diagnostics and condition monitoringAbteilung/Name Projektname 11.11.2011 1

What is Condition-Based Maintenance?Maintenance only when need arisesPerformed after indicators show that equipmentis going to fail or that equipment performance is deterioratingPrerequisitesNeed real time data from condition monitoringExtensive instrumentation of equipmentBetter tools for analyzing condition dataMaintenance personnel trained to decide the right time to perform maintenanceBenefitsMaintenance personnel only do the right thingsMinimise system downtimeMinimizing spare parts costLess time spent on maintenanceImproved Diagnostics capabilityAbteilung/Name Projektname 11.11.2011 3

Diagnostics and condition monitoring have different aimsDiagnostics• For detecting an exisitingmalfunction• For fast fault finding• For reducing downtimesCondition monitoring•For Product and Plant Safety• For detecting faults, before theycause downtime• For Planned PreventativeMaintenance• Increasing machine availabilityAbteilung/Name Projektname 11.11.2011 4

Benefits of diagnostics and condition monitoringFood and Drink Manufacturers• Product Safety: Traceability ofbatch production conditions• Improved Process Control• Increasing safety• Plant Safety: Improved monitoring ofsafety-relevant movements andprocessesAbteilung/Name Projektname 11.11.2011 5

Benefits of diagnostics and condition monitoringFood and Drink Manufacturers• Fast fault identification in the eventof a malfunction• Data for long-term evaluations• Information before stoppage enablingPlanned Maintenance•Increasing system availability• Input for measured variable – overallequipment effectiveness (OEE)Abteilung/Name Projektname 11.11.2011 6

Benefits of diagnostics and condition monitoringFood and Drink Manufacturers• Reduction in operating costs viaenergy saving• Assignment of energy costs to "costaccounts“• Increasing productivity• Avoidance of unnecessarymaintenance work• Intelligent maintenance planningAbteilung/Name Projektname 11.11.2011 7

The importance of diagnosticsHow can damage be detected in due timeby inspections?Mechanicalcomponents 30%Electricalcomponents 36%Can be detectedin due time 34%Condition Monitoring &Preventative MaintenanceCannot bedetected in duetime 66%Electricalcomponents 4%Fast diagnosticsvery importantMechanicalcomponents 30%% shares: percentage of the total ofall fault times caused by damageSource: H.GrothusAbteilung/Name Projektname 11.11.2011 8

Enabling Condition-BasedMaintenance:Insight into technology that facilitatesefficient methods of collecting andinterpreting performance dataAbteilung/Name Projektname 11.11.2011 9

Trend: More intelligence at field levelThe integration of electronicsfurther down the control hierarchyAbteilung/Name Projektname 11.11.2011 10

Enabling condition based maintenance:Intelligent air supplyBasic AirPreparationVisual InspectionAdjustableVisual InspectionRed/Green DisplayRed/Green zones SCADA FeedbackIntegrated air supplyControl, Isolationconsumption monitoring& EN 954-1 Cat. 4 SafetyAbteilung/Name Projektname 11.11.2011 11

Enabling condition based maintenance:Intelligent actuatorsNo sensing =Uncertainty& RISKEnd position SensingConfirms positionEnables cycle counting and“Watchdog timers”Full stroke sensingenables Positioning& Motion profilingPneumatic & Electrical AxisAbteilung/Name Projektname 11.11.2011 12

Enabling condition based maintenance:Intelligent SensingPosition SensingPosition MeasurementColour recognitionMonitor packagingMaterialsVision SystemsInvestigationQuality ControlMeasurementAbteilung/Name Projektname 11.11.2011 13

Enabling condition based maintenance:Intelligent Solenoid ValvesBasic SolenoidNo monitoringIntegrated cycle countEnables Condition basedReplacementProportional solenoidEnables positioningMotion profiling &Force controlAbteilung/Name Projektname 11.11.2011 14

the diagnostic core in valve terminalsDistributionof programming effortProcess programmingDiagnostic programmingVisualisation programmingSavingspotential withCPX/MPASavings potential dueto integrated diagnosticsand visualisationIntegrated diagnostic functions:• Saves programming work andthus costs• Increases productivity andsystem availability• Simple access to diagnosticfunctionsAbteilung/Name Projektname 11.11.2011 15

CPX diagnostic concept integrated functionsAbteilung/Name Projektname 11.11.2011 16

CPX diagnostic conceptFieldbus4-stage diagnosticsULRCBAPSPLSF[1][1] LEDs in the bus nodes/modulesfor on-site diagnosticsBenefit: Fast and simple diagnosticsBit7RDBit6System status (ST)Bit5Bit4MBit3Bit2Bit1Bit0[2][2] System status via 8 inputs in the imagetable or system diagnostics via 16 inputs and16 outputsBenefit: Simple diagnostics via the I/O level[4][3][3] Diagnostics via service data channel(DP V1, PCP, SDO, explicit message)Benefit: Full access to the entire system data[4] Diagnostics via handheld terminalBenefit: Plain text diagnostics on siteAbteilung/Name Projektname 11.11.2011 17

CPX diagnostics via LEDs (1)ULRCBARDPSPLSFMTRDiagnostic LEDs:[1] – Bus-specific LEDs:Profibus: SF, DeviceNet: IO, MNS, INTERBUS:UL, RC, BA, RD and TRetc.[1] [2][2] – Valve terminal-specific LEDs:PS: Power electronics/sensor power supplyPL: Power valves/outputsSF: System errors. Differentiated display,depending on the type of fault (warning, fault e.g.sensor short circuit, hardware error)−M: Modify/force: indication of the type ofparameter storage, indication of the force statusAbteilung/Name Projektname 11.11.2011 18

Enabling Access to informationModern communicationtechnology:•Ethernet interface TCP/IP•System information via Web server•Secure Bidirectional access to datavia Intranet•E-mail directly from the valve terminal•SMS messaging facility•Own website/HtmlAbteilung/Name Projektname 11.11.2011 19

diagnostics via handheld terminalPlain text on-site diagnostics fortechnicians•Interogate control components•Diagnostics•Diagnostic memory•ParameterisingAbteilung/Name Projektname 11.11.2011 20

Festo Energy MonitoringSaving energy during operationVisualisationDiagnoseControllerwith softwareFlowsensors• Determination of pressure and flow rate• Teach-in functionality• Time and batch-dependent references…• Flexible process or time triggers• Visualisation of the status, current values…• CoDeSys-based (library)Abteilung/Name Projektname 11.11.2011 21

Diagnostics and condition monitoring summaryDiagnostics• For detecting an exisitingmalfunction• For fast fault finding• For reducing downtimesCondition monitoring•For Product and Plant Safety• For detecting faults, before theycause downtime• For Planned PreventativeMaintenance• Increasing machine availabilityAbteilung/Name Projektname 11.11.2011 22

Diagnostics and condition monitoringAbteilung/Name Projektname 11.11.2011 23