Additional applications of machine condition analysis

Machine condition analysis usually emphasises maintenance work, especially some form of predictive maintenance programme. That is, the detection, analysis and correction of machine problems. However, predictive maintenance is not the only application of machine condition analysis.

As will be detailed below, there are additional applications that are perfectly suited for the use of the machine condition analysis techniques. Let's see:

• Inspection of incoming materials

  Many companies perform vibration and balancing checks on purchased parts. Inspection of items such as gearboxes, prime movers and components, pulleys, blower rotors, flywheels and couplings ensures that they conform to specified quality standards.

  One company recently reported setting up a testing facility to verify the quality of new replacement bearings. Another company checks new and reconditioned spindles before installing them in precision machine tools.

  These companies know that detecting defective components before installation is easier and less costly than locating the problem after installation and commissioning. In addition, equipment manufacturers have found that using quality, defect-free components results in a longer, trouble-free life for their own products.

  The analysis of machine conditions can meet these needs. In fact, many of the tools for predictive maintenance are used in incoming materials inspection programmes.

• Rules for the acceptance of machinery

  Many private industry sectors, government agencies and regulatory bodies have established acceptance levels for newly installed machines. By including maximum acceptance levels for vibration and noise in equipment specifications, the customer can be assured that a new unit will be properly aligned, balanced and in good operating condition.

  Acceptance standards for machine vibration can be expressed in the same terms used for the detection, analysis and correction of vibration in a machine. predictive maintenance programme. Therefore, the principles, procedures and nomenclature you will find in this manual are applicable to the acceptance standards for machine vibration.

• Quality control

  Many manufacturers use machine condition analysis techniques in various ways in order to reduce waste and ensure the quality of their products. For example, one major engine manufacturer had a high percentage of engine block rejects.

  The problem was attributed to poor cylinder bore finish, so a machine condition analysis system (of the same type used for predictive maintenance) was installed on the 16-spindle drilling machine. When the vibration reached a preset level, the monitor stopped the drilling machine and identified the fault which was corrected immediately. This technique improved the quality of the bore finish of the cylinders, greatly reducing the reject rate.

  Detecting, identifying and correcting excessive machine tool vibration improves product quality and extends tool life. On-site balancing of grinding wheels saves time and ensures consistent productivity and product quality.

  Of course, machine condition analysis procedures apply directly to the products being manufactured as well as to the machinery performing the work. Vibration checks of fully or partially assembled units result in improved product quality.

  The dynamic balancing of the relative components is an important element in the correction phase of a complete predictive maintenance programmeHowever, the same procedures and tools can be used in the production of new machines. Many manufacturers include dynamic balancing in their production plans.

• Engineering

  The measurement and vibration analysis play an important role in the development and testing of new or prototype machines. Measurements provide the overall performance and performance data, while analysis techniques reveal problems that may have arisen as a result of incorrect installation and adjustment or indexed design and construction.

  In many cases, government regulations specify noise standards for newly manufactured machines. The vibration analysis provides the information needed to define the modifications necessary to meet these standards.

• Service in the field

  Despite numerous technical tests and inspections and quality control, there are problems that arise during the normal operation of the machinery on site. Even if the machine is well balanced when it leaves the factory, there is no assurance that it will remain well balanced during transport and installation on site. For this reason, many manufacturers include adjustment balancing as a normal part of the installation and assembly procedures. Adjustment balancing, through the use of various predictive maintenance techniques and tools, ensures the smooth operation of the machine and its perfect condition.

  During normal on-site operation, unforeseen problems such as foundation settlement problems or assembly defects often occur. The machine condition analysis not only locates the cause of such problems on site, but also clearly indicates the corrective procedure to be followed.

  Sometimes the drive system for a new installation is supplied by one contractor while the driven machine is supplied by another. And it is not uncommon for the final installation to be carried out by a third party. While each contractor delivers his products and services "in full compliance", there is no guarantee that the whole package will work perfectly. A thorough vibration analysis of the installation is often the only way to clearly define the source of a problem and to indicate on the spot the necessary corrective measures.

Summary of additional applications of machine condition analysis

Regardless of how they are applied, whether as predictive maintenance, quality control, field service, or other, it is a fact that machine condition analysis techniques work. To make them work, you need the right equipment for vibration measurement, analysis and dynamic balancing. Your company has already invested money in these devices. Equally and perhaps even more important is the operator, an operator who is properly trained to use these devices with care and efficiency.

Instruments provide the necessary information about the vibration of a machine, but it is you who has to study, evaluate and interpret the data. It is you who has to locate the problem and prescribe corrective measures. This requires two important skills, the first, which you undoubtedly already possess, being a basic knowledge of machine operation, common machine problems and how to repair them.

The second skill is the ability to recognise and accurately determine mechanical difficulties in the early stages of their development. Vibration measurement and analysis is the key to this last skill.

If you are interested in learning more about the additional applications of machine condition analysis, we invite you to find out which are the most important ones. practical methods for vibration analysis of rotating equipmentor also a example of application of vibration analysis on pumps and fans.

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