Even if your company has a multitude of data about your assets, with service orders, spreadsheets, papers and a structured maintenance routine, unfortunately we know that managers can be surprised by a lack of knowledge in this field.
For several generations, the maintenance sector has only been remembered in emergency situations, besides being referred to as a source of excessive expenditures. Bearing that in mind, the TRACTIAN sensor and platform were created to streamline the maintenance manager’s life, being the best tool to combine productivity and monitoring in only one place.
We manage to monitor more than 30 categories of machines, such as:
Basically, the platform can monitor each and every rotary asset that works with any type of behavior considered critical, or that has a vibration profile statistically defined.
In this article, we bring the main machines monitored by the TRACTIAN Smart Trac sensor, their functionalities and some case studies. Enjoy!
When we talk about maintenance, we talk about maintaining a rhythm. The manager’s job is not catching up with what already happened, but keeping activities up and running every single day.
We find many solutions in the market that promise the future industry, but when it comes to execution, it normally takes ages to be implemented and often times they don’t think about the reality of the shop floor.
TRACTIAN is a system of online monitoring and condition analysis, carefully designed for the routine of maintenance teams. We deliver a solution to the sector with a focus on intelligence (condition monitoring + predictive analysis).
Unlike most traditional alternatives, our solution is focused on the day-to-day needs of maintenance. Let’s remember the industry’s information is on the machines, and the decision-makers are people who are involved in the maintenance routine.
TRACTIAN’s solution provides state-of-the-art online monitoring for the assets as well as predictive maintenance. With our tools, you can have access to all equipment’s analytics and spectrum. You can also instantly view the reliability and availability of the assets in a very simple interface.
Through automatic insights and alerts sent via the TRACTIAN App or a browser available on smartphones, tablets or your computer, it’s possible to request service orders to the right people and monitor all machines from one place only, with automatic warnings when something goes wrong.
Now we have chosen, among more than 30 machines we monitor, the four most common:
With the sensor implanted on the compressor, it’s possible to detect the wear and overload on the axis. It can be divided into different models, such as:
Failures of imbalance, misalignment and resonance, for instance, can be identified with the TRACTIAN sensor. Basically, the electric motor converts electric energy into mechanics. Among all types of electric motors, the two most common are:
TRACTIAN’s sensor makes the detection of belt misalignment and bearing defects possible. Fans can be classified as:
These are utilized to transfer water or other liquid products. They have the option to be powered by gasoline, diesel or electrically and there are also models with impulsion by a water wheel.
The motor pumps or electric pumps are monitored through TRACTIAN’s sensor, which detects signals of excessive temperature or imbalance. They are hydraulic pumps with strong motors, and have functions of specific energy increase, depending on the industrial segment. The main types are:
Corteva Agriscience – a multinational seed, crop protection, and digital agriculture company – has a plant that operates 24 hours a day, 7 days a week. Downtime for maintenance or cleaning, even if infrequent, had a big impact when it happened.
Fernando Vicente, the plant’s maintenance leader, contacted TRACTIAN thanks to a colleague’s recommendation. He prioritized the most important equipment for the production line and installed 10 sensors – in a short time, several alerts were identified by the platform.
Among the most critical assets were two pumps with very high failure rates and oscillating vibration patterns, and an exhaust tag: B270, whose worst issue was unbalance.
Even with planned shutdowns on the way, a week before the maintenance, the vibration of one of the pieces of equipment rose unexpectedly and the TRACTIAN sensor detected the anomaly.
“We did the vibration analysis sample a week before the insight was issued, and if we waited a month, maybe, we wouldn’t notice it. You notice noise in the area but without the data, you have no way to confirm it.”
Fernando also added that, in addition to vibrations, the sensor also detected unbalance and misalignment.
“The sensor has been useful for decision making, to know whether we stop before or not, to see how far back the equipment can operate.”
This insight shows that the sensors identified an unbalance in the 1st harmonic (H1), where the set limit was exceeded. After the alert, a preventive was done and the RMS Speed levels went back below the ISO Critical Zone limit.
Thanks to the insight, serious damage and losses were anticipated and Corteva was able to avoid a breakdown that could have cost anywhere from US$4,000 to US$13,000.
Another company, AmstedMaxion, reference in the manufacturing and supply of industrial and railway castings, had contact with the sensor after the maintenance team struggled with a lack of information to understand and predict the equipment’s repairs.
“This data that is sent by the sensor to the platform help us understand what is related to vibration and allow us to act preventively. And it ends up being very productive.” Maintenance supervisor of the company.
Assets utilized in the company such as the sand mixer F1135 and the mechanic pickling machine F5226 need constant balancing. With the use of the platform, it was possible to identify in an easy way the abnormalities, in order to prevent a severe breakdown that could lead to a halt in production.
After the preventive maintenance in the mixer, the company had a reduction of approximately 40% in the equipment’s vibration, preventing the asset’s early wear and tear and future downtime deriving from unplanned maintenance.
By implementing TRACTIAN’s online monitoring sensor and platform, you spare your assets from future unexpected failures and turn your company’s maintenance routine more efficient and assertive.
Thinking of any machine in your plant that must be safe and that cannot break down? Speak to one of our specialists to schedule a demonstration.
About the author:
Industrial Designer by UNESP (State University of São Paulo). He specializes in product design with an emphasis on digital manufacturing, innovation and communication. Contributing to the creation and relevant content for industry. Head of Marketing at TRACTIAN.
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