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Reduce maintenance costs with

Smart Condition Monitoring (SCM)

Christoph Behler, Senior Business Development Manager, Mitsubishi Electric Europe, FA-EBG

COPYRIGHT 2015 MITSUBISHI ELECTRIC CORPORATION. ALL RIGHTS RESERVED. 1


Overview

Smart Condition Monitoring (SCM) Solution


Reduce maintenance costs
Technical Items in Detail
Plug & Play with SCM Kits
Project examples

COPYRIGHT 2015 MITSUBISHI ELECTRIC CORPORATION. ALL RIGHTS RESERVED. 2


Some device examples for Maintenance
Electric Motors & Geared Motors
I guess
Vacuum and Fluid Pumps
Ventilators and Fans
everyone
Gearboxes knows these
Compressors
devices in
Separators and Decanters
daily
Spindles and Machine Tools work!
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What all these devices
have in common?
.

Roller bearings!

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Do you know the status of the bearing
in that devices ???

Have you ever seen this in your application?


Can you guarantee herewith proper working ? No!
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Why does typical maintenance problems at applications
with bearings happen????
Lack of lubricants
Unbalance
Misalignment of shafts
Wrong reconditioning timing
Low bearing quality
ServiceWe have always done it!
What results from this?
Unexpected shutdown and production downtime!!!
High costs for downtime and stock for spare parts
Bad quality and rejects
To avoid this, Mitsubishi Electric developed
Smart Condition Monitoring (SCM)
COPYRIGHT 2015 MITSUBISHI ELECTRIC CORPORATION. ALL RIGHTS RESERVED. 6
SCM background

Mitsubishi Electric work together with Schaeffler FAG,


one of the leading companies in bearings, since
year 2010 to built a solution in Condition Monitoring
FAG SmartCheck Sensor with intelligence and
Ethernet conn. based on online vibration measurement
Build together common solution Smart Condition
Monitoring (SCM) from Shop floor to top floor via
SLMP protocol with SmartCheck, MELSEC controller,
GOT and MAPS
Built up pilot references with SCM in different
industries
Easy to use pre-configured solution Smart Condition
Monitoring Kit (SCM Kit) available in stock
But as well open and scalable SCM for plant solution

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Value of the SCM solution
Support for IoT - Industry 4.0 - OEE

High machine and plant availability

Scalable system growth with the


demand and easy to operate

Informational through access to


history data for trends

Reduce life cycle cost to a minimum


and full support service

Smart Condition Monitoring (Preventive Maintenance) with FAG SmartCheck support that and
delivers data from the application to the entire levels!
Cost End User

Costs lower during the whole Life Cycle (LCC) with SCM
Visible Costs Visible Costs
Acquisition
Installation and start-up
Invisible Costs
Invisible costs Lowing with SCM
Cost of employee qualification measures
Easy machine diagnosis through intuitive operation and
easy retrieval of measured data
Shutdown (production lost) cost
Significantly higher level of plant availability and
Factor 5 to 10 avoidance of unexpected shutdowns with high
consequential costs
Energy costs
Energy efficient operation through correlation of machine
and process parameters
Maintenance and reconditioning costs
Optimized maintenance and reconditioning intervals
in terms of information through access to history data
SCM support cost down!
Cost down for unexpected shutdown
Reliable real time machine and process online monitoring with
status alarm
Plannable service, because of long pre-warning period

Cost down of employee qualification


Simple Alarm indication via intuitive LEDs
Pre configured and Automatic alarm level setting

Maintenance and reconditioning costs down


Easy to install and start up in new or existing applications (retrofit)
Proposal for maintenance operation via SmartController and GOT
(bearing damage, lack of lubricant, unbalance or other failure)
Exact reconditioning when it is needed
Reduce number of spare parts (motors, gears, etc) in stock
Web based online diagnostic as well via remote access
Historical data storing shows trend
Prove of quality after the maintenance
Connection through SmartController to the SCADA
and MES / ERP level
Machine Monitoring

A few measureable parameter at machines:


Power / Torque

Presure

Flow

Demand

Lubricant condition

Temperature

Vibration
Diagnosis by a Doctor
and Technical Machine Monitoring

it's comparable

Vibration measurement for each application by innovative sensor technology


Early detection of a damage saves!
Typical Damage Progress of a Roller Bearing detected by SmartCheck
Spectrographically analysis

change in
condition
Vibration
machine condition

Noises Status indication


SmartCheck
and add. text with
Heat
proposal on GOT
or MAPS SCADA
Smoke

time
Minutes
Days
weeks
Month
lead time or pre-
warning period
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How does SmartCheck work?
Status Indication
Normal status Detect danger, Pre-Alarm Detect danger , Main-Alarm
(Green LED) (Change from green to (Change from yellow to red LED)
yellow LED)
Change of
status
Vibrations
Machin status

Sounds

Temperature

Machine stopp

Days
Week
Month
Pre-warning time
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Machine Diagnosis Trends
Typical application: Motor & pump arrangement

FFT-Analysis
"Fast Fourier Transformation"

bearing defect
cavitation
misalignment Hz
g
unbalance

Complex Time Signal


from Vibration
t Spectra

Time wave form Trend Data

time

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How to measure Vibrations?

Seismic
Mass
A

Piezo
Crystall

The FAG SmartCheck is


an integrated solution:
Sensor and CM system in
one device!
Spezification SmartCheck

Common information
Specification SmartCheck

Typical speed band: 50 15.000 rpm


Appication area: -20 C -- +70 C (-4 - +158 F) , IP67
Others: 24VDC, Ethernet TCP/IP, Web-Server, SLMP Protocol
Functions FAG SmartCheck

Smart check supports two substantial functions at


the test specimen

Vibration sensor functions


Evaluation over Fourier analysis
Implementation of know-how in Smart checks for direct status
information without specialized knowledge
Integration of load, achievement, frequency and amplitude and
the temperature

Temperature measurement at the test specimen


Admission of the current temperature at the test specimen
Also for temperatures more highly than 70 C
Vibration Monitoring
Delivers good information about the machine condition
Recognize failure and damages in an early stage
Specially fit for recognizing:
- Bearing damages
- Imbalance, misalignment, wracking
- Gear damages (gear wheel)
- lack of lubricant *; cavitation at pumps*; phase
failure (~3Ph), resonance frequency detection*
and as well good for: b
a

Quality control for machine builder during delivery


e.g. Bearing damage at start-up by transport can be detected,
because it was measured before delivery!
* Additional analyses needed
Openess
Visualization and Analyse

The data can be monitored and analysed


The following is possible:
Visualization with MAPS SCADA, FAG SmartVisu
or other SCADA Products
Software Tools via MES-IT or OPC
ERP/MES connection via MES-IT or OPC
Analyse, Alarm and Reporting
Different end user devices

ECP FA-EBG - C. Behler COPYRIGHT 2010 MITSUBISHI ELECTRIC EUROPE B.V. ALL RIGHTS RESERVED. 21
FAG SmartCheck meets Mitsubishi

SMLP

MC 3E-Frame (or SMLP)


FB for the SmartController *
Assumption of the
variables from existing
project

* Standardisation with MELSEC Q- or L-series


FAG SmartCheck
Software

FAG SmartUtility FAG SmartWeb


PC Software for Administration Web basied Software in the system for easy startup and
of various FAG SmartCheck and configurationof FAG SmartCheck
of Diagnostic

CONFIDENTIAL 05/ 2012 Christoph Behler / FA-EBG AMD COPYRIGHT 2010 MITSUBISHI ELECTRIC EUROPE B.V. ALL RIGHTS RESERVED. 25
Eplan drawings for the cabinet
Easy and fast connectivity

ERP
Level
Our partner:
AUTINITY Systems
Ethernet
Cloud/
Internet
Internet
MES
Level SCADA
z.B. MAPS
Gateway

Ethernet

Controller PLC (e.g. SIEMENS, Schneider, Rockwell, Beckhoff, )

Level DB
Modbus
TCP
****
Profibus
Profinet Analog/
Agent CANopen
CC-Link Digital
DeviceNet
SmartController EtherCAT
In/Out
SLMP
SLMP
TCP/IP

Field
Level

SmartCheck
125
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SCM - Fast start up
Cost efficient retrofit - Fast installation and one Ethernet cable
Scalable budget - Start with applications sorted by priority
Intelligent sensor - Reduced number of sensors
Easy adaption of field signals like speed, flow, etc
Pre-defined Function Blocks for the controllers und SC setups

Various Applications:
Electrical motors
Gear boxes
Ventilators
Fluid pumps
Compressors
Vacuum pumps
Vibrating screens

COPYRIGHT 2015 MITSUBISHI ELECTRIC CORPORATION. ALL RIGHTS RESERVED. 28


SC Mounting Examples
OEE

Schaeffler, FAG Industrial Services (D) , Advanced Condition Monitoring For Overall Equipment Efficiency
COPYRIGHT 2015 MITSUBISHI ELECTRIC CORPORATION. ALL RIGHTS RESERVED. 29
Mounting types
Various Possibilities

Screw on M6 on plane surface

Screw on SPM adapter (M6 inside/SPM M8 outside)

Magnetic mounting for non-permanent installations

Adhesive fortification of a mounting plate with M6 hole

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Mitsubishis pre-defined step into
Condition Monitoring with SCM
MAPS visualisation
OEE
and / or expert service

TCP/IP

Smart Condition Optional for no. 2 to no.5


Monitoring Kit-1 - Smart Condition Monitoring Kit - Extension 10 m m (#272511) or
(Housing and one FAG - Smart Condition Monitoring Kit - Extension 20m (#272512)
SmartCheck)
#283165 with GT2103
#279498 with GS2107
#290578 COMPACT

No. 1 No. 2 No. 3 No.4 No.5


Smart Condition Monitoring Kit-1
with up to 5x FAG SmartCheck via optional ME-RTU
MAPS visualisation
OEE
and / or expert service

TCP/IP

Smart Condition
Monitoring Kit-1
Optional for no. 2 to no.5
(Housing and one FAG
SmartCheck) - Smart Condition Monitoring Kit - Extension 10 m m (#272511) or

#283165 with GT2103 - Smart Condition Monitoring Kit - Extension 20m (#272512)

#279498 with GS2107


#290578 COMPACT

No. 1 No. 2 No. 3 No.4 No.5


Smart Condition Monitoring Kit-1
Pre-configured Solution in Detail
Smart Condition Monitoring Kit-1 for new or existing machines

CONFIDENTIAL COPYRIGHT 2010 MITSUBISHI ELECTRIC EUROPE B.V. ALL RIGHTS RESERVED. 33
Smart Condition Monitoring Kit-1
Pre-configured Solution in Detail
Smart Condition Monitoring Kit-1 for new or existing machines
Settings
The communication between the SmartCheck sensors, PLC
and GOT is via Ethernet
using the MC Protocol, TCP port 1280. The following IP
addresses are defined:
PLC (factory default): 192.168.3.39
GOT (factory default): 192.168.3.18
Smartcheck sensors: 192.168.3.100 to 192.168.3.104

Following device areas are reserved in the PLC

CONFIDENTIAL COPYRIGHT 2010 MITSUBISHI ELECTRIC EUROPE B.V. ALL RIGHTS RESERVED. 34
SCM Kit-1 Quickstart Communication Guide

Option:

192.168.3.101

192.168.3.100

192.168.3.39

192.168.3.18

192.168.3.xx
SCM delivers
Delivers Online-Information about the Status and Conditions
and stores the data historical in the SmartCheck and the
internal intelligence reduces the number of sensors.

Information from SmartCheck will be delivered over


Ethernet TCP/IP with SLMP Protocol to the Controller and
then analyzed and send to the next level systems (DB,
SCADA or Terminal GOT).

Information's include the following


1. Status (OK, Pre-Alarm, Main-Alarm and Ethernet-
Communication error)
2. Diagnostic (Bearing failure, Leak of Lubricants, Un-
balance or not defined error (deeper analysis necessary via
SmartWeb or SmartUtility Software).

Possible failure and damages are detected at an early stage


and the service is so predicable. Up to 4 month in advance!
Reference Examples with SCM

Waste Water Plant Rotenburg, Germany


Incineration Plant - Heat Pumps, Germany
Project Drink Water, Brazil
Sugar Factory, Germany
Passenger Elevator, Florida, USA

37
Reference
Waste Water Plant, Germany
Application:
Tree Archimedes-Screw pumps with
gear box, redundant, FAG
SmartCheck, System Q, analog
Values, Telemetric access and
access point for SCADA
Break down of the gear box in frame
of 1-3 years
Detected failure:
4 Month after installation gear wheel
defect detected
Costs
Overhaul of gear box: 1.000Euro
New gear box: 5.500Euro
Difference to save: 4.500Euro
SCM solution cost:
HW: 4.700Euro
Installation: 1.000Euro
Installation
By Mitsubishi Automation partner
References
Incinration Plant, Germany
Examples of Condition Monitoring

Company
Iserlohn city office
district power station
Country
DE

Application
Waste incineration, Energie
transport

Products
Modular PLCs, Inverter and FAG
SmartCheck

Detail
Four Motors 250KW with FAG
SmartCheck
References (Offer)
Water infrastructure, Brazil
Architecture of Project Water, Brazil
up to 50 pump stations with 3-8 pumps, each pump with 4 SmartCheck
Vizualisation Mobile Vizualisation Router
EXTEND 7000 SQL-Data base
for remote
optional (new or existing)
acces
to smartRTU-L

Enterprise
Level

PUMP STATION #1 PUMP STATION #n


Local Local
Vizusalisation FAG SmartConroller smartRTU Visualisation FAG SmartConroller smartRTU
GOT optional GOT optional
if IT-Network if IT-Network
is defect or is defect or
not reliable not reliable
e.g. E.Mail, SMS,, e.g. E.Mail, SMSA,
Data access Data access
Controller
Level LAN (Ethernet) LAN (Ethernet)

Pump #1 Pump #n Pump #1 Pump #n

Analouge value
(if needed)

Device
Level

LAN (Ethernet)
References
Sugar Factory, Germany and Sweden

Application:
Four gear boxs at a sugar beet
washing machine, 4x FAG
SmartCheck, SmartController,
Information to 3rd party PLC
Buffer time during stop is 10
minutes
Costs
1 hour stop : 60.000Euro
(Campaign modus)
1 hour stop: 1.000Euro
(24/7 modus)
SCM solution cost:
HW: 5.000Euro
Installation: 3.000Euro
Installation
By FAG system integrator
supported by Mitsubishi
Automation partner
References
Universal Studios, Florida, Orlando, USA
Application:
Passenger elevator in a theme
park.
High temperature and lot of people.
Two station with SmartController
and total 18 SmartCheck sensors
to control the two idler pulleys and
the rope.
Min. 2.5 hours stop to evacuate
the people during failure
Costs
Image damage and money back:
??? Euro
SCM solution cost:
HW: 13.500Euro
Install: 5000Euro
Installation
By FAG system integrator
supported by Mitsubishi
Automation partner
Historical question after using SCM:
Have you ever seen this in your application?

Can you guarantee now proper working ? Yes!


SCM Solution

Innovation

Solution

Competence

reduce costs in maintenance!

COPYRIGHT 2015 MITSUBISHI ELECTRIC CORPORATION. ALL RIGHTS RESERVED. 44


Thank you for your time!

More information: christoph.behler@meg.mee.com