Condition monitoring
on gear units by means
of SIPLUS CMS®
Service International
© Siemens AG 2010. All Rights Reserved.
Diagnosis and service from one source
As the largest manufacturer of
i d
industrial
i l gear units
i we are
leading in many industries
worldwide and have gained
experience and the widest
application-related know-how
for decades.
Our service always keeps an eye
on the application and provides
full and comprehensive support.
© Siemens AG 2010. All Rights Reserved.
Industry Sector
Availability and productivity
We do not only keep the highest
possible
ibl availability
il bili off your
drives in focus but also the
productivity of your entire plant.
The scope of maintenance
management covers inspection
and
d maintenance,
i t
th
the manufacture and stockpiling of spare
parts, repair and field service.
© Siemens AG 2010. All Rights Reserved.
Industry Sector
Condition Monitoring: Monitoring with all senses
For complex plants it is important
t properly
to
l evaluate
l t and
d iinterpret
t
t
superposing signals of different
origin. We see, hear, and sense
if something
g is wrong
g and act
immediately. Therefore, to us
Condition Monitoring means
above all to have a good sense
for your plant.
plant
© Siemens AG 2010. All Rights Reserved.
Industry Sector
Condition Monitoring and its disciplines
We ensure that your plant
operates well, using every
possible method:
 Telediagnosis
 Alignment checks
 Simulations
 Mobile vibration analyses
y
 Acceptance tests
 Measurements of load and
torque
 Inspections
 Endoscopies
 Thermographies
g p
© Siemens AG 2010. All Rights Reserved.
Industry Sector
Our services at a glance
 Worldwide machine
di
diagnosis
i b
by means off mobile
bil
diagnostic technology
(fixed/variable speed)
G
GearControl
C t l and
d SIPLUS CMS
measurement systems
 Identification and indication
off early
l d
damage
 Monitoring of power
parameters and torques
 Intelligent monitoring systems
with interface to automation
systems ex works
© Siemens AG 2010. All Rights Reserved.
Industry Sector
Optimum service life
Cost-intensive machines running
under
d ffullll lload
d can b
be perfectly
f l
monitored by our Condition
Monitoring System and the
trouble free operation of complex
trouble-free
plants can be optimally ensured.
© Siemens AG 2010. All Rights Reserved.
Industry Sector
Acting before the worst case arises
After a longer period of undisturbed operation, significant
irregularities can be detected and remedied in good time by means
of documented trending before major damage to the gear unit,
cost-intensive consequential damage, or total loss can occur.
© Siemens AG 2010. All Rights Reserved.
Industry Sector
Avoiding unpredictable costs
While the initial defect itself
might
i h b
be manageable
bl and
d easily
il
correctable, later repair actions
can multiply the costs several
times.
times
© Siemens AG 2010. All Rights Reserved.
Industry Sector
Your benefits at a glance
 Availability of the plant
 Support in the case of damage
 Process optimization
 Increase in performance
 Diagnosis and service
from one source
 Fast support by specialists
 Cost minimization
 Certification byy Allianz and
Germanischer Lloyd
© Siemens AG 2010. All Rights Reserved.
Industry Sector
Diagnosis signals
Example:
V i l mill
Vertical
ill
KMPP gear unit
 Vibration
 Speed
 Torque
 Oil temperature
p
 Bearing temperatures
 Production data (mass flow
flow,
product, operating hours)
a [m/s2]
 Oil condition
Frequency [Hz]
© Siemens AG 2010. All Rights Reserved.
Industry Sector
SIPLUS CMS 4000 Online System
SIPLUS CMS 4000
I
Interface
f
Nodes
N d (IFN) are
installed at the gear unit and
completely wired to sensors.
© Siemens AG 2010. All Rights Reserved.
Industry Sector
Integrated sensors ex works:
Acceleration, speed, pressure
© Siemens AG 2010. All Rights Reserved.
Industry Sector
Integrated sensors ex works:
Torque, temperature, displacement
© Siemens AG 2010. All Rights Reserved.
Industry Sector
Mobile measurements
Ready-for-use diagnostic routes
prepared
db
by gear unit
it specialists.
i li t
Switch box combines benefits of
fixed sensors and mobile data
collector.
© Siemens AG 2010. All Rights Reserved.
Industry Sector
Example: Detection of a tooth defect
in a gear unit for vertical mills
250
300
(530,94) MesSt1H2
3,0
(318,57) MesSt2
2H2
3,5
(265,47) MesSt1
1H1
4,0
raw mill\A-7 input shaft bearing 151,1203\1002 SV3,0kHz0,25Hz20s 26.06.2007 13:48:12
(159,28) MesSt2
2H1
v op [mm/s]
2,5
2,0
1,5
1,0
0,5
150
200
350
400
450
500
550
600
650
700
750
800
850
900
950
1000 1050
f [Hz]
v [mm/s] raw mill\KMPS 656 \A-7 input shaft bearing 151,1203\1002 SV3,0kHz0,25Hz20s\noise_375
1,6
1,4
Gear unit repaired
Trend of a sideband
amplitude
1,2
1,0
0,8
0,6
Alarm
0,4
0,2
0,0
07.02.0728.03.0716.05.0704.07.0722.08.0710.10.0728.11.0716.01.0805.03.0823.04.0811.06.0830.07.08
Date
© Siemens AG 2010. All Rights Reserved.
Industry Sector
Permissible torqu
ue
Long-term
Long
term measuring results, vertical mill drive
Min. / Max. / Mean values show dynamics and peak loads at a glance.
© Siemens AG 2010. All Rights Reserved.
Industry Sector
Event monitoring, vertical mill drive
M_max
M_perm
The permissible value is exceeded by factor 2.4.
© Siemens AG 2010. All Rights Reserved.
Industry Sector
Rovsing OPENpredictor Software
TM
Early fault detection, AutoDiagnosis and prediction
© Siemens AG 2010. All Rights Reserved.
Industry Sector
Remote Services using
Siemens common Remote Service Platform (cRSP)
© Siemens AG 2010. All Rights Reserved.
Industry Sector
Endoscopy/Videoscopy
Pitting on tooth flanks, videoscopy at site
© Siemens AG 2010. All Rights Reserved.
Industry Sector
Laser-optical
Laser optical alignment
Good alignment reduces vibration and extends service life
© Siemens AG 2010. All Rights Reserved.
Industry Sector
Analysis and evaluation service
Measurements taken by
service
i and
d sales
l engineers
i
are analyzed by diagnostic
specialists.
© Siemens AG 2010. All Rights Reserved.
Industry Sector
Condition monitoring in the
Siemens automation environment
We offer you remote diagnosis
and
d service,
i
so that
h you as the
h
plant operator do not have to
allocate specialized staff. The
data of the CMS is transmitted to
Siemens via safe data channels
and automatically supplied for
qualified diagnosis.
Our assembly service includes
stockpiling of spare parts and the
sending of experienced master
fitters.
© Siemens AG 2010. All Rights Reserved.
Industry Sector
Condition monitoring in the
Siemens automation environment
The new measuring systems
b
based
d on SIPLUS CMS® components fit right in with the Siemens
automation environment.
Sensor signals and on-/off-states
of the machine control that have
already
l d b
been ttransmitted
itt d via
i
Profibus can be easily integrated
into the diagnosis. In this way,
the quality of the condition
diagnoses is significantly
improved.
© Siemens AG 2010. All Rights Reserved.
Industry Sector
Instruction and training
Knowledge of technical processes is the foundation for
continuously running production plants. We impart the knowledge
to your employees and so help them to self-help:
 Know-how transfer by our FLENDER Academy seminar series
 Higher qualification of your staff
 The “train
train-the-trainer
the trainer” concept makes students become teachers
teachers.
© Siemens AG 2010. All Rights Reserved.
Industry Sector
Thank you for your attention!
© Siemens AG 2010. All Rights Reserved.