Condition monitoring – individual and systematic
Condition monitoring – individual and systematic
Condition monitoring is based on systematically determining the condition of all drive technology and drive automation.
We create and implement entire concepts for you, from initial consulting and designing of the optimal analysis method to installation and diagnostics. This approach includes measurement, interpretation and visualization of defined parameters that are then forwarded to your maintenance system. Targeted evaluations require the appropriate expertise and the right sensors – this is easy with SEW-EURODRIVE on your side. We compare the measurements to reference values we have collected throughout the years – this enables you to act instead of react.
The following services can be combined individually:
- Thermal imaging of control cabinets and drive components
- Examination with an inspection scope for gear unit diagnostics
- Visual inspection of drive technology
- Load state analysis
- Analysis of device-specific environmental conditions
- Current consumption measurement
and many others
Your benefits
-
Reduced storage costs
by reducing spare parts inventory and storage as well as by targeted material procurement. -
Increased productivity
by fully utilizing system capacity. -
High system availability
by wear-oriented maintenance and repairs as well as by being able to schedule downtime. -
Higher operational safety
by constant analysis and inspection of the machines and systems being monitored.
Diagnostic units
Time is money and maintenance is certainly no exception, so take advantage of the ideal product/service combination with drive technology diagnostic units from the modular system.
Diagnostic unit: DUO, Diagnostic Unit Oil Aging
Gear unit oil diagnostics through thermal analysis
Features:
- The perfect sensor to determine the remaining life of the gear unit oil and reliably indicate the right time for an oil change
- A thermal sensor installed in the gear unit measures the oil temperature and sends this information to an evaluation unit, which then calculates the time remaining until the next oil change for the specified oil type
- The diagnostic unit takes into account the oxidation characteristics of the different oils under thermal loading
Benefits:
- Reduces oil costs
- Full utilization of the oil service life
- Startup can be performed directly on the diagnostic unit (without PC)
- Simple identification and reading of the time remaining until the next oil change
- 5 different oil types can be configured
- A warning message is issued if predefined limit values such as the maximum oil temperature are exceeded
- Permanent monitoring of oil aging
- Maintenance intervals can be planned individually
NEW: Diagnostic unit option /DUE, Diagnostic Unit Eddy Current
Brake diagnostics through continuous functional and wear monitoring
Features:
- Ideal sensor to monitor the wear and proper functioning of the brake (BE../ BF.. / BT..)
- Measuring system for contactless monitoring of the working air gap
- A single sensor reliably monitors both the correct functioning of the brake and the wear of the lining
Benefits:
- Brake lining wear can be detected in good time
- Reliable brake function monitoring
- Contactless and thus wear-free measuring system
- Direct evaluation via an SEW-EURODRIVE frequency inverter with corresponding error protocol
- Can be used in damp conditions up to IP66
- Maintenance intervals can be planned individually according to wear
Diagnostic unit option /DUB, Diagnostic Unit Brake
Brake monitoring
Features:
- Ideal sensor to monitor the wear and proper functioning of the brake
- The voltage-dependent signal can be evaluated by an SEW-EURODRIVE frequency inverter or a higher-level controller
- Two sensors can reliably monitor both the correct functioning of the brake and the wear of the lining
Benefits:
- Brake lining wear can be detected in good time
- Reliable brake function monitoring
- The condition signal of the microswitch can be implemented as a normally closed (monitoring wear) or normally open (monitoring proper functioning) contact
- Direct evaluation via an SEW-EURODRIVE frequency inverter with corresponding error protocol
- Can be used in damp conditions up to IP65
- Self-cleaning contacts inside the sensor
- Maintenance intervals can be planned individually according to wear
Oil check – lubricant analysis
All gear units need oil. The gearing wouldn’t last long without suitable lubricants. By protecting gear units against wear, lubricants also help prevent driven machinery from breaking down.
Oil also has a remarkable "memory" – during its service life and ongoing aging process, it takes on board a whole host of information about the gear unit’s inner workings and condition.
Using lubricants as a source of information
Each and every gear unit component that the oil comes into contact with during operation gradually passes on tiny wear particles as a result of mechanical and thermal stresses. The lubricant is therefore an important source of information about its own condition and also about the state of the gear unit and its components.
This information can be accessed at any time by performing an oil check. Trends revealed by regular checks enable very precise conclusions to be drawn about oil aging and component wear.
That’s why we work closely with OELCHECK GmbH, an independent laboratory for lubricant analyses. If you so wish, SEW-EURODRIVE will take care of the entire lubricant analysis process – including any subsequent measures that may be required – thus leaving you to devote yourself to your key strengths as a plant operator.
This eliminates time-consuming and costly production downtimes and enables scheduling of condition-based maintenance operations. If the assessment of the oil’s condition is positive, it is possible to extend the oil change intervals.
How an oil analysis works
- Oil analysis ordered
- Oil analysis set supplied
- Oil sample taken
- Oil samples returned
- Oil analyzed
- Analysis report sent
Your advantages
- You minimize production downtimes by identifying wear at an early stage
- Analyzing the oil’s condition enables longer intervals between oil changes
- You avoid damage caused by impurities in the lubricant (e.g. due to water or dust)
- You can schedule condition-based oil change and maintenance operations
- You benefit from clear and comprehensible diagnostics, including specific recommendations for action
- You can combine oil analyses with further services from our modular system
Every analysis report contains an overall evaluation. In addition to written findings based on the latest laboratory values, this also includes a recommendation as to whether the oil needs to be changed or can continue to be used.
Wear (gear unit)
The following wear metals are analyzed:
- Iron [mg/kg]
- Chromium [mg/kg]
- Tin [mg/kg]
- Aluminum [mg/kg]
- Nickel [mg/kg]
- Copper [mg/kg]
- Lead [mg/kg]
- Manganese [mg/kg]
- Molybdenum [mg/kg]
- and the PQ (particle quantifier) index
Impurities (foreign matter)
The following substances may contaminate the gear oil over time and are therefore analyzed:
- Silicon [mg/kg]
- Potassium [mg/kg]
- Sodium [mg/kg]
- Water [%]
Oil condition
As it ages, the oil’s physical and chemical properties change, too. The following are analyzed:
- Viscosity at 40° [mm2/s]
- Viscosity at 100° [mm2/s]
- Viscosity index
- Oxidation [A/cm]
Additives (oil components)
The proportion of the various oil additives may also change (fall) over time. The following are analyzed:
- Calcium [mg/kg]
- Magnesium [mg/kg]
- Zinc [mg/kg]
- Phosphorus [mg/kg]
- Barium [mg/kg]
- Boron [mg/kg]
Additional tests
If one of the wear/impurity values exceeds 1 mg/kg, additional analyses are performed as follows:
- Neutralization number [mgKOH/g]
- Infrared spectrum
Contact
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