VM-03 VIBRATION MONITORING AND DIAGNOSTICS

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Brian Baldwin
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1 VIBRATION AND DIAGNOSTICS NEWUCT D O R P EMO 01

2 MACHINE VIBRATION AND TEMPERATURE PREDICTIVE MAINTENANCE COMMUNICATION Visualization (TCP/IP) 1 VIBRATION AND TEMPERATURE Via accelerometer signals of machines, motors, drives (axes), conveyors, gearboxes, etc. Increase machine availability Detection of vibrations over limit - e.g. caused by fatigue, wear or bearing problems Detects temperature over limits FFT analysis Data transfer of.csv-files s (automatic or manual) INTEGRATION CONTROL Input/Output contacts INTEGRATION CAN-BUS COLLISION AND CRASH DETECTION GENIOR MODULAR System COLLISION AND CRASH DETECTION FOR MACHINE PROTECTION Rapid alarm <1ms allows fast stop Alarm memory (Black Box) for more than 1 events ACCELEROMETERS AND TEMPERATURE SENSORS x Acceleration, x Temperature (PT100) CUTTING PROCESS OPTIMIZATION VISUSCOPE (OPTION) FOR MACHINE CONDITION Individual data evaluation of recorded signals Software option for Windows Data Acquisition (DAQ) Visualization and analysis Signal linking Individual analysis for process optimization COMING SOON! SOLUTION Intelligent stand-alone (all-inone) module for installation on DIN-Rail into cabinets or field housings All necessary interfaces are available for an easy and perfect integration into existing controls and network environments Sensor connections: Accelerometer (x IEPE inputs) x PT100 temperature sensors Available signals x vibration velocity (mm/sec) x acceleration (g) 1x FFT (1 points up to 8KHz) x temperature x gravity (only via VA-D MG sensor) Data connection TCP/IP» visualization» VisuScope».csv export CAN-Bus» GENIOR MODULAR integration

3 STAND-ALONE Blackbox entries STAND-ALONE OPERATION OF Physical I/O interfaces ( inputs outputs) 8 diﬀerent operating scenarios diﬀerent static alarms for each scenario Fast alarm messages (< 1ms) Alarm event data recording 1 analog output 0-10 V Signal value log ﬁle 1 Visu PlugIn C BENEFITS VIBRATIONS OR HIGH TEMPERATURES OF TOOLS OR MACHINE ELEMENTS CAUSE: Vibration Monitoring unit OON! GS OMIN Available signals: x vibration velocity (mm/sec) x acceleration (g) 1 x FFT (1 points) x temperature x gravity (only with dedicated sensor) Features: independent accelerometer inputs (IEPE standard) limits deﬁnable for each graphic independent temperature sensor inputs (PT100 standard) 1 limit deﬁneable for each temperature sensor 10 Hz...10 khz frequency range (IEPE standard) X, Y, Z gravitiy values (only with dedicated sensor) 1 khz sampling rate 1 bit resolution 1 ms resolution Visu 0, ms resolution VisuScope Visu Scope VISUSCOPE OPTION CONDITION Quality problems of work pieces Machine downtimes Spindle bearing damages Axis wear Tool wear or damages Unplanned maintenance DYNAMIC COLLISIONS OF TOOLS OR MACHINE ELEMENTS CAUSE: Consequential losses Machine downtimes Spindle or axis damages Unplanned repair Tool damages Part damages DIAGNOSTIC TOOLS: Improve cutting parameters Improve cycle time Optimize machine uptime (MTBF) Document improvements Document anomalies Increase productivity (OEE)

4 WITH SMART SENSOR VA-D MG INTEGRATED INTO PROCESS GENIOR MODULAR VDC CAN-Bus Microcontroller MEMS D OON! GS OMIN C MODULARITY: EASY INTEGRATION IEPE Flash Memory Fieldbus ICP Interface VA-D MG SAVE BLACK-BOX DATA ON DEVICE: USE IN THE GENIOR MODULAR PROCESS : Smart Sensor x vibration velocity x acceleration x gravity Flash Memory BENEFITS: Black-box on device Small and duarable Resistant to cooling lubrication (IP/IPx) D gravity signals enhance monitoring Vibration Monitoring unit All functions remain active The raw data of the signals will be used in the monitoring strategies The visualization can be integrated into GEM Visualization Visualization Software PlugIn

5 OVERVIEW VIBRATION AND DIAGNOSTICS SUMMARY Windows PlugIn VM0 Rapid stop function <1ms fast output Machine control integration Ethernet (TCP/IP) PT100 - Interfaces Temperature Up to x... 1 Network-Integration.csv-Data Transfer Up to x... Fingerprint Signal Diagnostics Acceleration...or 1x D-sensor (X-Y-Z axis)... DIN-Rail Connection CAN-Bus and VDC IEPE Fieldbus...or Smart Sensor VA-D MG Visu Scope Process Monitoring GEM MultiView PlugIn (integrated) Vibration Monitoring unit COMMUNICATION Visualization (TCP/IP) INTEGRATION CONTROL INTEGRATION INTO MACHINE TOOLS AND PRODUCTION SYSTEMS VIBRATION AND TEMPERATURE OF stand-alone unit for installation on DIN-Rail into cabinets or ﬁeld housings The visualization can be used on Windows based PCs / controls The stand-alone module contains all necessary interfaces for a perfect integration 8 Machines Motors Drives and axis Gearboxes Conveyors COLLISION AND CRASH DETECTION FOR MACHINE PROTECTION VISUSCOPE (OPTION) FOR MACHINE CONDITION Rapid alarm output Alarm memory Individual data evaluation of recorded signals INTEGRATION INTO PROCESS GENIOR MODULAR Input/Output contacts INTEGRATION CAN-BUS Raw signals can be used for process monitoring strategies. All functions remaining active GENIOR MODULAR System ACCELEROMETERS AND TEMPERATURE SENSORS x Acceleration, x Temperature (PT100) 9

GENIOR MODULAR (GEM) TOOL-, PROCESS- AND MACHINE CONDITION SYSTEM MODULAR CONCEPT In the factory of

GEM is an autonomous intelligent Tool and Process Monitoring System which provides an automatic

Safe and reliable metal cutting processes are essential for economically-efficient mass production.

speed or special values are needed, and then evaluates the data based on multiple criteria and

The (big) collected data are converted into smart data (information) which can be stored locally or on

The modularity of the system is one of the core features needed to adapt the monitoring system to

PERFORMANCE PROCESS AND CONDITION TOOL PLUS TMU GEM CPU 0 CTM V GEM UPGRADE TOOL PLUS UPGRADE BUS-0

tool utilization by evaluating the set wear limits Modular structure, scalable system Additional

6 GENIOR MODULAR (GEM) TOOL-, PROCESS- AND MACHINE CONDITION SYSTEM MODULAR CONCEPT In the factory of the future, there is a permanent exchange of information. GEM is an autonomous intelligent Tool and Process Monitoring System which provides an automatic real-time image of a current production process. Safe and reliable metal cutting processes are essential for economically-efficient mass production. The system captures the measurement data digitally via fieldbus interface or via sensors when higher speed or special values are needed, and then evaluates the data based on multiple criteria and visualizes the processes in a transparent way. The (big) collected data are converted into smart data (information) which can be stored locally or on network devices for further evaluations like analysis, trend curves, statistics or reports. The modularity of the system is one of the core features needed to adapt the monitoring system to dedicated systems and machines. PERFORMANCE PROCESS AND CONDITION TOOL PLUS TMU GEM CPU 0 CTM V GEM UPGRADE TOOL PLUS UPGRADE BUS-0 GEM UPGRADE Benefits: Up to real-time measuring channels Adjusts the alarm levels autonomously Optimum tool utilization by evaluating the set wear limits Modular structure, scalable system Additional analytic functionalities Adaptive Control (AC) Option Data processing for Industrial Internet of Things (IIoT) surroundings Interconnection with other systems MultiView Visualization PlugIn (APP) -technology Expert Mode for individual adjustments Machine Condition Monitoring Etc. BASIC FUNCTION Dynamic Collision VM-0 Dull Collision CMS-0 Vibration Monitoring 10 11

7 A detailed address list is available at Other brochures for downloading available 09/01

Protect your machine and tooling. Minimize damage resulting from collisions. Monitor and analyze your machine behavior

Machine Tool protection and condition monitoring Protect your machine and tooling w w w. d i g i t a l w a y g r o u p. c o m Minimize damage resulting from collisions Monitor and analyze your machine