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Machine condition evaluation

The principle of Condition Monitoring (CM) or Condition Based Maintenance (CBM) of machinery is straightforward:

• The goal is to identify changes in the condition of a machine that will indicate some potential failure.
• Physical characteristics are identified that collectively indicate the current condition of the machine.
• Each of these characteristics is measured, analysed, and recorded so that trends can be recognized.

Rockwell Automation condition-monitoring technologies and services are widely available to assist in proactively identifying minute changes in machine condition - some-times weeks or months before any problems become visibly apparent. Predictive and proactive maintenance methods, such as using information gathered from vibration, temperature and oil analysis, can help companies identify potential machinery problems that ultimately could result in downtime if not corrected.

Capturing, analysing and effectively using machine condition information provides a strategic and competitive advantage, allowing companies to maximize their return on investments (ROI). To successfully compete and ultimately win the game, companies need to reassess their maintenance philosophy and restructure processes to capitalize on the opportunity that lies in front of them.

Condition Monitoring Tools

• Vibration Analysis - the analysis of the unique patterns of vibration created by specific components of an electro mechanical system.
• Temperature Analysis - identifying an abnormal rise in the temperature of machinery that could result from problems such as bearing wear, lack of lubrication, poor electrical connections, etc.
• Oil Analysis - analysing the physical and chemical properties of lubrication to identify contamination, wear particles, as well as changes in viscosity and other chemical properties.
• Motor Current Signature Analysis - analysing the unique signature patterns in the motor supply current created by fluctuations in load, high resistance joints in rotor bars and end rings or uneven air gap between the rotor and stator.
• Operating State Dynamic Analysis - the correlation of machinery operating parameters such as load, pressure, speed, etc to the dynamic characteristics of the machinery such as vibration and motor current signature.
• Ultrasonic Leak Detection - the use of ultrasonic measurements to identify changes in sound patterns caused by high-pressure gas/steam leaks, bearing wear or other deterioration.
• Balancing - the use of vibration measurements to reduce the mechanical imbalance of a rotating piece of equipment.
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