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In the era of industrial Internet, industrial manufacturing equipment has become more efficient, intelligent and sophisticated, which also brings a lot of challenges to the maintenance of the equipment itself.At present, industrial equipment maintenance can be divided into three categories: repair maintenance, preventive maintenance and predictive maintenance.
Post-fault maintenance or scheduled maintenance in traditional maintenance modes such as repair maintenance and preventive maintenance can affect production efficiency and product quality, and significantly increase the cost of manufacturers.In today's intelligent age, predictive maintenance technology, a "killer" application, arises as The Times demand, based on the mature application of sensor technology, data acquisition, big data analysis, cloud service and other technologies.Predictive maintenance based on condition monitoring is more convenient and less costly, so it is a technology development direction with broad application prospects.
The services provided by predictive maintenance also extend the profitability of the equipment manufacturer from the sale of the equipment to the long-term maintenance of the equipment. It is also a manifestation of the continued competitiveness of the enterprise brought by the new value-added services.The intelligent sensor of mechanical predictive maintenance is the core component of predictive maintenance system.
According to the relevant research data, the predictive maintenance technology using mechanical predictive maintenance intelligent sensor makes the following contributions to the factory:
● Reduce maintenance cost: 25-30%
● Eliminate production shutdown: 70-75%
● Reduce equipment or process downtime: 35-45%
● Increase productivity: 20-25%
From this contribution, we can see that predictive maintenance using mechanical predictive maintenance intelligent sensor has a significant productivity improvement ability for the factory. The above parameters are a direct quantified contribution, and its potential contributions also include:
● Quality improvement: obviously, reduce the production line and equipment when the machine is conducive to reducing the rate of defective products
● Continuation of the use value of the equipment, due to the predictive maintenance of the intelligent sensor of mechanical predictive maintenance, the potential problems of the equipment can be monitored and timely improvement, such as:The installation adjustment, reasonable equipment speed and distribution will extend the original life of the equipment, which is also a good protection for the investment of the production enterprises. Especially for important high-value equipment, an extra 6 months of use often means millions of savings.
● For worker safety issues, good equipment operation and predictable failures contribute to safe operation.
Mechanical predictive maintenance intelligent sensor (wired) features:
A) Power supply: DC5V
B) Frequency response range: 12KHz (maximum)
C) Getting weak signals
D) Get the original signal
E) Range: ±200G
F) Communication mode: RS485, Modbus protocol
G) The system can be updated and the software can be upgraded
H) Collection parameters can be configured (for specific equipment)
I) With status indicator light
J) Working temperature: -40℃ to +85℃
K) Installation method: fixed thread
L) Overall dimension: diameter 32mm, height 47mm
Mechanical predictive maintenance smart sensor (wireless) features:
A) Power supply: DC5V
B) Frequency response range: 12KHz (maximum)
C) Getting weak signals
D) Get the original signal
E) Range: ±200G
F) Communication method: LORA protocol (need to buy gateway)
G) The system can be updated and the software can be upgraded
H) Collection parameters can be configured (for specific equipment)
I) With status indicator light
J) Working temperature: -40℃ to +85℃
K) Installation method: fixed thread
L) Overall dimension: diameter 32mm, height 47mm
Mechanical predictive maintenance intelligent sensor technology advantages:
Can collect original signal and weak signal, through the weak signal can know early fault characteristics of equipment, through the original data can predict the future movement of the fault, at the same time to the life of the future forecast provides the reliable data to support fully, make data analysis complex, no longer only accurate and reliable data, only the most valuable.
Mechanical predictive maintenance intelligent sensor alarm mode:
1: direct alarm, output vibration value, normal mode.
2: Cloud alarm, output vibration value, health value and fault characteristics, advanced mode.
Mechanical predictive maintenance intelligent sensor application industry:
Paper industry: paper machine stick, auxiliary machinery, ventilation, dust removal.
Steel industry: converter, continuous rolling, straightening, sizing, spinnetting machine, ventilation
Petrochemical industry: pump station, ventilation, oil and gas pipeline.
Shipbuilding Industry: Generator, Port Hoist.
Wind power industry: wind power gearbox, generator, main bearing, support bearing, tower drum.
Railway industry: axle box bearing, motor bearing, gear box, tread.
Mining industry: miner hoist, shovel, bucket wheel excavator, tunneling machine, shearer.
Cement industry: vertical mill, rolling machine, rotary kiln.
Automotive: Gearbox Testing, Drum Testing, Ventilation.
Textile industry: setting machine, needling machine.
Thermal power and hydropower industry: pumping station, ventilation.
Machine tool industry: spindle, reducer, lead screw.
Mechanical predictive maintenance intelligent sensor is suitable for unmanned vehicles, pumps, rods, motors, compressors, machine tool bearings, gear boxes, robots and other types of equipment rolling bearings, gear box gear, bolt loose, other vibration parts of the fault monitoring and customer needs to monitor the signal.
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