Advantech’s Machine Condition Monitoring and Predictive Maintenance Solution
Predictive and preventive machine maintenance have become indispensable parts of Industry 4.0. Machine condition monitoring (MCM) systems upgrade consumable and damage replacement practices, as well as periodic maintenance activities, to preventive maintenance, or even predictive maintenance. This prevents situations in which machines are halted without warning for parts replacement, which causes additional overhead.
The MCM system visualizes machine status, enabling instantaneous monitoring over the life of key components in the machine. Massive volumes of data are recorded in order to analyze and optimize the production line and minimize machine shutdowns, hence maximizing production efficiency and simultaneously increasing machine safety and reducing the cost of equipment maintenance.
Palm-size Embedded Computer Provides Cost-effective Preventive
Maintenance for Industrial Band Saws
|Based on the concept of Industry 4.0, intelligent factories should not only strive for manufacturing technology innovation but also focus on machine monitoring and preventive maintenance, which is an important part of optimizing the production process. Unlike traditional periodical maintenance or emergency break-down repair, preventive maintenance can detect and troubleshoot hidden faults in advance.|
|Taking the metal-cutting band saw as an example, equipment manufacturers can perform preventative maintenance by collecting data that predict that saw blades or other components may wear out after performing thousands of cutting operations. Meanwhile, plant managers do not have to urgently call their suppliers to arrange for repairs on damaged machines, thus reducing equipment downtime and increasing overall plant productivity while also improving the quality of finished goods.|
Advantech Provides an Economical Automatic Spindle Calibration and
Chatter Measurement Solution that Increases CNC Machining Accuracy
|In the manufacturing sector, increased productivity and product quality are constant goals. Additionally, Industry 4.0 is driving the vision and realization of intelligent manufacturing. In response to this trend, CNC machines, which are key production equipment for the manufacturing industry, are undergoing continual improvement. With equipment manufacturers actively improving machine performance and precision to better satisfy customer needs, the precision of machine calibration is a significant factor that influences processing accuracy.|
|In traditional factories, all equipment must be checked and calibrated by an experienced mechanic before operation. To resolve calibration issues caused by human error and prevent machine chatter from affecting machining accuracy, the company implemented spindle calibration and chatter measurement functions at their existing machining centers in order to increase efficiency through consistent calibration and automated monitoring.|
WebAccess/MCM Machine Condition Monitoring Software
WebAccess/MCM is Machine Condition Monitoring software that provides easy sensor signal acquisition, signal analysis, feature extraction, data management and interpretation, and sends alerts. Engineers or system integrators can configure settings to meet the needs of different applications.
Programming is not required for WebAccess/MCM in which a simple setup page is configured for data processing, and interfaces are provided for user-defined inspection and analytic conditions. The system issues warnings and records data when any warning limit is exceeded.
This software solution effectively and substantially reduces the R&D resources invested, improves automation levels, saves human resource costs, and delivers a visual display of equipment and production line status.
When beginning to implement a measurement system, the user needs to verify and observe the sensor signal. The scope helps users analyze signals, and provides oscilloscope-like functions, including cursor measurement tools, trigger capture functions, automatic measurements of amplitudes, frequencies, average values, and peak-to-peak values, as well as real-time display of time-domain data and spectrograms.
Intelligent Inspection Mode
This mode provides an easy way to develop an inspection system for a production line. Wizard guides are provided for easy setup, along with customized algorithms for optimizing signals, and data analysis. The system also outputs signals to link other equipment to the SCADA/PLC system as monitoring nodes, and generates quality inspection reports.
Condition Monitoring Mode
Provides plenty of algorithms for signal processing and data analysis to convert large amounts of data into useful information. Through the data management function, data is uploaded to an IIoT cloud. With MCM, the user can realize real-time online condition monitoring, predict key component lifespan, minimize machine shutdowns, and increase productivity.