The client factory didn't have a maintenance plan in place for the rotating machinery. Therefore there was a necessity to assess the current state of the Yankee Motors condition and to put in place a maintenance plan. The company personell was trained by ISE in order to get the sufficient understanding of Yankee Motor vibrations, its impacts on operation and to be able to set alarm values as well as KPI's.

In the second step ISE permanently installed the MonoDAQ Condition Based Monitoring solution (with 3dB bandwidth at 10Khz), composed of 2 channel data acquisition system, 2 vibration and temperature sensors and DEWESoft data acquisition software, to contiuously monitor machine vibrations and temperatures. On top of that vibration and temperature tresholds where set by ISE and the company.

Axial and radial sensors were positioned in the bearing’s load zone to minimise vibration signal attenuation.

Monitoring vibrations on bearing is important because:
1.) critical bearing failure stops machine operation and permanent monitoring provides early detection of bearing problems and allows corrective action to be scheduled.

2.) bearings carry the machine’s load. Because of that many typical machine problems such as misalignment, imbalance and looseness can be detected by monitoring vibration at the bearing.

For bearing condition assessment enveloped detection, of the raw FFT signal, is used. Envelope detection is a ready to use feature available in DEWESoft software package which comes along with MonoDAQ CBM solution.

Since the system installation, already 5 critical machine failures have been detected. Client assessed that loss of revenue, due to a sudden stop/downtime caused by bearing fault failure, exceeds 15k EUR not taking into account damage on other machine parts that normally occur when bearings fail. Based on that they assessed the annual savings rate to be around 150k EUR.