MAAGTM online condition monitoring system

Save money by investing in condition based preventive maintenanceFLSmidth MAAG Gear has worked with leading suppliers to develop a system for vibration data acquisition, gear unit diagnosis and remote data transmission.

The system was developed for Condition Based Preventive Maintenance (CBM) which allows you to detect faults at a very early stage and predict/plan future interventions.

You gain the following benefits Protectionofmachinery Continuouson-linecondition

monitoring Analysisofconditionmonitoring

results Continuousstoringofdata Alertindication Assistanceindecidingonnecessary

maintenance activities and their order of priority

Assistanceinperformingplannedmaintenance activities

Our offerings Supplyofreadytousesystems Installationandcommissioning Onlinevibrationmonitoring(surveil-

lance) Reportingcustomersupport

(standard twice a year or per custom-er requirements)

Traininghardwareandsoftware

Two versions of online vibration monitoring availableBasic systemIncludesavarietyofvibrationsensorsconnected at defined points and the system is integrated to also show temperatures from installed temperature sensors.

Advanced systemAdditionally includes strain gauges mounted on the input shaft for torque measurements. This direct measurement allows early gearbox failure detection, has a high sensitivity regarding irregular or unstable

process operations and detects overload. As an additional benefit a relationship between the torque output and the production parameters can be built and maintained, allowing for smoother production and longer life.

Analysing data Time analysis Accelerationsignals:rms,peak-to-

peak, crest, kurtosis Torque signal: min. torque, max.

torque, mean torque, rainflow classification

Frequency analysis Acceleration signals: gear frequencies

and harmonics, sideband and fault frequencies

Torque signal: mill table and roller frequencies, gear frequencies, torsional frequencies

Envelope analysis Timerange:RMS,peak-to-peak,crest frequency range, bearing and gear

frequencies, fault frequencies

Still unplugged? Good vibrations are the key to good production

Remote system accessRemotesystemaccesscanalsobebeneficial within a group of companies/plants.Ifoneproductionfacilityisfacing problems, colleges from a different site can look at the data and share expertise. As online monitoring is a joint effort/relationship, certain requirements need to be fulfilled:

Access to be given to operational data in accordance with relevance to the installed monitoring system; for example motor power, mill vibrations, hydraulic pressure, grinding bed depth, mill differential pressure, mill air flow rate, water injection rate, feed rate, mill outlet temperature, separator speed.

Connections, interfaces, electricity etc. to be provided to guarantee remote access to reading the data of the vibration equipment.

Uninterrupted access of the monitoringsystemtotheSMTPserver to be ensured to guarantee continuous flow of data.

FLSmidth MAAG Gear to be informed if a shutdown takes place

Incaseoffailureofasensorormonitoring equipment access to be given to remedying the problem.

FLSmidth MAAG Gear AG Lagerhausstrasse 11 P.O. Box8401 Winterthur SwitzerlandTel +41 52 260 35 00Fax +41 52 260 35 35Service@FLSmidthMaagGear.com www.FLSmidthMaagGear.com

Sensor positioning for MAAG WPU

Sensor positioningAs most of the sensors are positioned inside the gear, the gear unit needs to be stopped before the sensors can be installed.A selection of sensors is used to acquire the best range of signal inputs.

Sensor positioning for MAAG WPV

Sensor positioning for MAAG CPU

System setup for remote access