Interrupted production can be costly!

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The IIot Motor Diagnostic System – Cracked Rotor Bar Defect

Interrupted production can be costly. Loss of production hours, output as well as the cost to repair mechanical faults or major machine breakdowns can severely impact production and maintenance budgets.

The IIot Motor Diagnostic System allows plant owners to prevent unplanned mechanical breakdowns through fault detection alerts enabling maintenance teams to act proactively.

The IIot Motor Diagnostic System installed at an international rubber and tyre manufacturer on a rubber-mixing mill saved the company many hours of unscheduled downtime and hundreds of thousands in production revenue.

The Roll Milling Machine applies a mechanical process to blend the ingredients into a homogeneous substance. Internal mixers fitted with two counter-rotating rotors in a large housing shear the rubber charge along with the additives.

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The IIot Motor Diagnostic System identified an existing Coupling/Bearing problem in the Roll Milling Machine. The system also flagged an immediate alert related to the Rotor Bar parameter.

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The trend visibly reflects how the Rotor Bar error advanced. Vibration measurements verified the presence of broken rotor bars, already identified by The IIot Motor Diagnostic System.

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The IIot Motor Diagnostic System in this instance demonstrated its ability to detect developing Rotor Bar faults, alerting the maintenance team. The necessary predictive and preventative maintenance actions were taken, resulting in no production loss recorded.

Can you imagine the impact on the production and maintenance budget if this fault were not detected?

CIS Industrial Services (Pty) Ltd – Plant Uptime, Plant Safety, Asset Reliability!

Unscheduled downtime affects your production​!

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The IIot Motor Diagnostic System – Unbalance and Misalignment

Faults going undetected in an industrial plant can have serious negative implications on production and often safety. It is of the utmost importance for the Maintenance Department to always be alert and aware of any technical issues no matter how big or small, that can result in unplanned downtime.

The IIot Motor Diagnostic System installed at a major international manufacturer in the automotive industry did just this. The IIot Motor Diagnostic System unit first gave a warning of a problem on 16 October 2015 and diagnosed a looseness problem. Due to pressure to meet production targets a decision was made by the maintenance team to wait for further indications.

On 19 November 2015, a new alert reflected, which initiated an inspection, resulting in the discovery of a loose attachment bolt on a Cooling Tower Fan, responsible for cooling the water circulated in the tower.

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Next follows the sequence of alerts by the IIot Motor Diagnostic System unit at the time, as an example of the operation of the unit.

OCTOBER 2015

The system indicates looseness, and then the problem disappeared. Numerous alarms flagged in the software that related to foundation issues, including unbalance as well as misalignment alerts.

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NOVEMBER 2015

Continuous monitoring of foundation problem followed.

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DECEMBER 2015

The IIot Motor Diagnostic unit continuously reported a unbalance, and misalignment problem.

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DECEMBER 2015

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FEBRUARY 2016

Scheduled maintenance took place in February 2016, where the foundation problem was corrected.

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RESULT: The IIot Motor Diagnostic System unit detected an Unbalance and Misalignment concern well in advance. Due to the early warnings provided by the IIot Motor Diagnostic unit an informed decision was made by the maintenance team to run and monitor the fans for any drastic changes that could affect production until the problem could be resolved during scheduled downtime.

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Making the correct maintenance decisions can be an easy task if you have access to accurate information to base your decision making on.

Can you afford unscheduled downtime?

CIS Industrial Services (Pty) Ltd – Plant Uptime, Plant Safety, Asset Reliability!