Cost savings from the CMS Vibration Monitoring and Predictive Maintenance Presented by: Tim Parmer Manufacturing in America 02/22-23/2017

Transcription

1 Cost savings from the CMS Vibration Monitoring and Predictive Maintenance Presented by: Tim Parmer Manufacturing in America 02/22-23/27

2 Condition Monitoring with SIPLUS CMS For early detection of mechanical damage Unrestricted / Siemens AG 23. All Rights Reserved. siemens.com/siplus-cms

3 SIPLUS CMS How Can Mechanical Components be Monitored? Machine state Vibrations Noise Heat Smoke Breakdown Minutes Days Weeks Months Vibration Monitoring with SIPLUS CMS the most reliable method for the early detection of mechanical damage Unrestricted Siemens 27 All rights reserved. Time to react

4 Condition Monitoring with SIPLUS CMS For early detection of mechanical damage for the purpose of intelligent maintenance and avoiding unscheduled outages. SIPLUS CMS SIPLUS CMS What can be monitored? Monitoring Unrestricted Siemens 27 All rights reserved.

5 SIPLUS CMS The mechanics under control Data ERP Production Enterprise resource planning Product lifecycle management Transparency of mechanical components over all levels MES Management Plant wide condition monitoring of mechanical components across all levels SCADA TIA Portal Operations Integrated predictive maintenance Decision-making aids for maintenance Controller HMI IPC Control personnel, operators, management Connection to cloud solutions Field I/O System Drive System CMS Unrestricted Siemens 27 All rights reserved.

6 SIPLUS CMS in all branches applicable, e. g., for Fans + pumps Mixers + centrifuges Wind engines, press lines, Unrestricted Siemens 27 All rights reserved.

7 a [m/s 2 ] Condition parameter S Measurement of data and Trend analysis of significant condition symptoms Monitoring: Absolut value: Trend of S: S S = ds dt Prognosis Breakdown (failure) a(t) Spectral Analysis warning condition S III Extrapolated trend significant condition change Status display S II Alarm Warning S I normal condition lead time Ok Frequency [Hz] Run-inphase operation with normal wear increased wear Service life Unrestricted Siemens 27 All rights reserved.

8 The necessity of spectral information v [mm/s] Effective vibration - RMS date a [m/s²] 0.30 Inner ring rollover frequency from the envelope frequency range date Unrestricted Siemens 27 All rights reserved.

9 SIPLUS CMS Product portfolio SIPLUS CMS12 SIPLUS CMS20 SIPLUS CMS40 Integrated in TIA Portal Vibration Monitoring with S7-12 Engineering in TIA Portal Expert diagnosis possible Easy to integrate Modular Simple applications Complex tasks Stand-alone operation Expert diagnosis possible Easy to integrate Projectable Sophisticated applications Superior tasks Stand-alone operation Expert diagnosis possible Easy to integrate Basic analysis methods Standard analysis methods Basic analysis methods Standard analysis methods Programming of own analysis models Unrestricted Siemens 27 All rights reserved.

10 Significance of the analysis SIPLUS CMS The analysis methods of condition monitoring Frequency-selective analysis Expert analysis Freely configurable analysis with diagnostics software CMS X-tools, e.g. orbit, histogram, vector/waterfall diagram Parameter-based analysis What damage is imminent? Every type of damage has its own frequency spectrum Is damage imminent? Trend history of characteristic values Unrestricted Siemens 27 All rights reserved.

11 Condition Monitoring with SIPLUS CMS What sort of damage can be detected? An extracted Pumps / fans Gears units Drives Blade passing frequency Resonance Misalignment Field faults Rotor bar breakage Unbalance Meshing faults Bearing damage Mechanical damages Electronic errors Resonance Bearing damage Misalignment Unbalance Meshing faults Blade passing frequency Stator field faults Rotor bar breakage Unrestricted Siemens 27 All rights reserved.

12 SIPLUS CMS The three Condition Monitoring Systems Quick video /watch?v=qjqc816vl-o CMS12 Integrated and flexibly expandable Monitoring with SIMATIC for 1-7 drive trains per station Analysis software on board CMS20 Modular and autonomous SIMATIC-independent monitoring for 1-4 drive trains per station Analysis software on board CMS40 Powerful and freely configurable Autonomous monitoring of the drive trains of complete plants Monitoring of slide bearings CMS X-Tools as analysis software Unrestricted Siemens 27 All rights reserved.

13 SIPLUS CMS12 integrated and flexibly expandable SIMATIC based condition monitoring solution SM1281 condition monitoring module for SIMATIC S7-12 Easy integration of + permanent condition monitoring of mechanical components into SIMATIC S7-12 with complete application example to the testing Ensuring plant availability: Continuous condition monitoring of motors, generators, pumps, fans, centrifuges, + No additional analytical software required: analysis algorithms on board Up to 4 IEPE vibration-acceleration sensors per SM 1281 max. 7 SM 1281 per CPU Extraction and storage of raw data for further diagnostics Unrestricted Siemens 27 All rights reserved.

14 SIPLUS CMS12 Highlights Condition monitoring solution with SIMATIC S7-12 Feature / Function SIMATIC S7-12 based condition monitoring via TIA Portal from V13 SP1: SM 1281 Continuous condition monitoring of motors, generators, pumps, fans, via up to 28 IEPE vibration sensors per S7-12 Analysis algorithms in the SM 1281 condition monitoring module Visualization via web browser Long-term storage of raw data/ trend (8 MB) in the SM 1281 Benefits Easy integration of condition monitoring of mechanical components in SIMATIC S7-12 Early detection of mechanical damage Scheduled maintenance instead of spontaneous repair No additional software required for diagnostics and visualization Simple data archiving Further analysis via raw data Unrestricted Siemens 27 All rights reserved.

15 SIPLUS CMS20 The autonomous solution CMS20 with expansion modules Self-sufficient solution for condition monitoring: 2, 9 or 16 IEPE chanels depending on state of plant + No additional analytical software required: analysis algorithms on board + Ensuring plant availability: Continuous condition monitoring of motores, generatores, pumps, fans, centrifuges, + Basic module VIB-MUX Temperature modules Basic Unit with: 2 AI, 3 DO, 3 DI (rpm, Inhibit, Trigger) Modular expandable: Temperature modules, VIB-MUX Extraction and storage of raw data for further diagnostics + + Unrestricted Siemens 27 All rights reserved.

16 SIPLUS CMS40 The powerful solution Freely configurable condition monitoring Ensuring plant availability : Continuous condition monitoring of complete plants incl. gear, bearing + Preperation of own analysis + models, know-how protection, multi-user-ability Analysis software + CMS X-Tools for the detailed analysis, archiving, visualizing e.g. as histogram orbit, vectorand waterfall diagram Up to 180 IEPE-vibrationacceleration- or analog sensores, time synchron registration Process data (SIMATIC, SIMOTION, ) via software nodes possible to integrate + + Unrestricted Siemens 27 All rights reserved.

17 SIPLUS CMS Advantages at a glance Early detection of mechanical damage Condition Monitoring Systems Part of digitalization Record and analyze mechanical variables Connection to cloud solution Decision-making aids for service Higher productivity Higher productivity: continuous condition monitoring Predictable maintenance and repair Easy diagnosis Cost reduction Longer lifecycle time Effective spare parts maintenance Investment protection Easier error research System benefits Simple system configuration Open standards Easy expandability Unrestricted Siemens 27 All rights reserved.

18 SIPLUS CMS12 Sample system setup CMS X-Tools for further leading analysis SCADA zb. Via WinC, PCS7 MindSphere Siemens Cloud for Industry Monitoring mechanical components with SIMATIC S7-12 SIMATIC IPC Remote access Condition Monitoring with TIA Portal PROFINET/ Ethernet SIMATIC S7-12 withsm 1281 Up to 28 IEPE-vibration-sensors modular attachable via max. 7 SM 1281 Support by cloud based solution Optional: Expert analysis e. g. via CMS X-Tools Drivetrain: drive gear bearing pump Unrestricted Siemens 27 All rights reserved.

19 Questions? Presenter Name : Tim Parmer CMS Product Manager 53 Triangle Parkway Norcross, GA 392 Phone: (678) Tim.Parmer@siemens.com For more information see: siemens.com/siplus-cms Unrestricted Siemens 27 All rights reserved.

20 MindSphere the cloud-based, open IoT operating system Your way to digital services Unrestricted Siemens AG 27 siemens.com/mindsphere

21 MindSphere The cloud-based, open IoT operating system from Siemens MindApps Industrial App Store Apps from Siemens, partners or develop own apps Gain asset transparency & analytical insights MindSphere MindSphere Open interface for development of customer specific apps Various cloud infrastructures: SAP, AtoS, Microsoft Azure offered as public, private or on-premise (planned) MindConnect Open standards for connectivity, e.g., OPC UA Plug and play connection of Siemens and 3 rd party products Secure and encrypted data communication Unrestricted Siemens 27 All rights reserved.

22 Data-driven services based on MindSphere enable new business MindSphere The cloud-based, open IoT operating system Insight Virtual World Real World MindSphere Gain immediate insights on whole fleet as well as individual assets using own, Siemens or partner apps Data Action Configure data collection as well as connectivity quickly and easily Transform insights into actionable results to increase uptime and efficiency Unrestricted Siemens 27 All rights reserved.

23 MindSphere and MindApps to increase business value for equipment suppliers and operators Business Value Equipment supplier Increase service efficiency / lower warranty expenses Visualize and manage fleets worldwide Automate failure and event alarming Offer additional services and new business models Provide availability guarantees Enhance products via feedback loop to R&D Use operational data to verify and optimize simulation & engineering Equipment operator Increase uptime / asset availability Predict failures to run in-time maintenance and reduce / prevent unplanned downtime of machines Optimize assets Identify optimal configuration for your equipment to reduce energy consumption, peak loads, etc. Increase maintenance efficiency Prolong maintenance cycles over product lifetime Unrestricted Siemens 27 All rights reserved.

24 MindSphere: Multiple OEMs and end-customers are already subscribing Prediction of crane failures thereby avoiding unplanned downtime Offer additional services to their end-customers Out-of-the box digital service offering for end-customers Insights about usage of machines Very low-cost solution for monitoring small motors (previously not economically feasible) Prediction of motor failures thereby avoiding unplanned downtime Unrestricted Siemens 27 All rights reserved.

25 MindSphere enables a quick, easy and secure start into data-driven services STEP 1 Connect Get MindSphere user-account, receive and integrate your MindConnect element into your machine/equipment STEP 2 Configure Configure data acquisition, connectivity and Visual Analyzer via MindSphere STEP 3 Run the Service Monitor e.g. health status of all assets and drill into details using MindApp Fleet Manager Asset Configuration on MindSphere - experience how easy it. Click here Unrestricted Siemens 27 All rights reserved.

26 Questions? Presenter Name Ed Sugay Cell: Siemens Industry, Inc. Digital Factory DF PL DS 48 North Point Parkway Alpharetta, GA 322 Deutschland Unrestricted Siemens 27 All rights reserved.