case study: tubular strander
Let’s take a tubular stranding machine for instance. This machine consists of nine super large size bearings with an inner diameter of 1000 mm. Each of it costs over 25,000 EUR and takes 100 - 200 days to deliver.
Theoretically speaking, these bearings have a lifetime of about 84,000 hr. However, from the maintenance information from customers, we found that the lifetime of the bearings have extreme differences depending on the working environment. The shortest lifespan recorded before the bearing came to failure was just around 2 - 3 years.
After collecting feedback from the customers over the past few years, we found out that the lifetime of the bearings was much shorter than ought to be expected, mostly due to the deterioration of the operation conditions.
- Unbalance of the rotor causes vibration during operation.
- Lubricant causes a huge temperature difference between two sides of the bearing.
- Tilt of the basement creates extra torque on the rotor.
With Predictive maintenance, product managers are able to monitor the health and estimate the lifetime left of a bearing. As the bearing accelerates in deterioration, the product manager can purchase the key components and arrange annual maintenance in advance. Thus decreasing the possibility of unexpected failure of the machines.
In order to solve the problems of unexpected failure, Pioneer Machinery in cooperation with the top leader bearing manufacturer SKF, introduces a solution based on the analysis of the vibration acceleration at each bearing seat and the performance of an harmonic analysis based on this data. After analyzing data such as dynamic loading, torque on the bearing, deformation and so on, the system is capable of detecting the abnormality and informing ahead of the problem.