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Matthew KaminskiSupervisors: Tom Thayer & Brian Gilchrist
August 11, 2010
Introduction
Machine Background
Vibration Analysis & Reliability Centered Maintenace (RCM)
Plan Do Check Act (PDCA)
Evaluating My Experience
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Graduated in 2008 from Bethel Park High School
Entering junior year at the University of Pittsburgh
Studying Mechanical Engineering
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Worked with the maintenance group with a team responsible for performing a RCA (Root Cause Analysis) and a FMEA (Failure Mode and Effects Analysis) for the Pangborn blast machine
Identify machine failure modes and potential causes
Goal is to eliminate these problems and increase machine reliability
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SIDE VIEW ENTRANCE VIEW
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OPERATOR STAND EXIT VIEW
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Wear detection is an important problem associated with high speed rotating machinery
A damage not detected in time can result in severe damage to machinery, injuries and financial losses
The abrasive shot wears the vanes, impeller and impeller case
Creates an uneven distribution of mass on the blast head poor blast pattern or unbalance
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New Impeller
New Vane
New Impeller Case
Damaged Impeller Case
Damaged Impeller
Damaged Vane
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New Straight
Vane
DamagedStraight Vane
Damaged Curved Vane
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New Impellers
Damaged Impellers
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A predictive maintenance technique that uses instruments to monitor and analyze machine vibrations to determine if the machine is working properly
Operation of a machine can cause it to vibrate. Transducers and diagnostic electronic equipment can translate these vibrations into a frequency spectrum graph
A vibration analysis allows one to analyze the graphs to monitor and trend the overall condition of the machine over time.
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Transducer Output
Signal Conditioning
Data Filtering
Fast Fourier
Transform (FFT)
Extraction of frequency
information and storing
Fault Diagnosis
Continuous Monitoring
Vibration Analysis
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Develop a procedure to ensure that the company’s assets will continue to run in their desired manner
RCM is a process used to determine the maintenance requirements of any physical asset in its operating context
Maintenance is typically categorized into three separate categories: reactive, preventative, and predictive maintenance
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Plan
Identify the Problem
Understand how the Pangborn machine operates
Speak with maintenace workers about current maintenace procedures and problems
Familiarize myself with vibration analysis
Set my objectives
Order and install the necessary equipment
Perform the analysis and interpret the results
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Determined the mounting technique, location, and position of accelerometers, diagnostic electronic, and power source
Mounted accelerometers in horizontal position of the spindle on each of the three top blast heads using a mounting pad and adhesive
Diagnostic electronics and power source were placed in protective housing
Electricians helped to draw necessary power to wire up the accelerometers, diagnostic module, power source, and interface my computer with the equipment
Learned how to operate the software and determine necessary parameters to analyze the vibration signals
Calculated speed (RPM) of spindle shaft using strobescope
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Head #1 Close Up of Head #1
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Head #2 Head #3
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Acquired baseline values
These are readings that correspond with equipment operating correctly without any faults
Had to make sure all equipment was up to par before gathering data
All subsequent readings were compared to the baseline values in order to diagnose the problems on the machine
Used to set warning and alarm levels
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Achieve better baseline values Have all new equipment/parts installed prior to
gathering baseline values
Account for variable speed of motors with a switching output
Connect diagnostic electronics to PLC to provide more advanced warnings & alarms for operators
Train employees to interpret the data and anticipate faults before they occur
Employ SDCA: Suggest standardizing PdM procedures for critical machinery at the plant
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Safety is #1!
Must keep in mind the person who must fix the equipment when designing something
Good communication is essential between different members of the team (planners, maintenance crew, operators, engineers)
Learn about all the new technology in school; in reality, most is very old and primitive
At school, the only one holding you back is yourself, at work it can be anyone
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Questions?
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