Applications for diagnostic electronics

Machine tools

During the machining of metal blocks, high process forces are generated. At the same time, the machines have to achieve high machining speeds and a constantly high production quality. Incipient damage has a direct impact on the condition of machine parts, tools and product quality.

The vibration sensors of types VSA or VSM in combination with the VSE diagnostic electronics can detect such damage at an early stage and communicate it within the shortest periods of time.

Dynamic monitoring of different conditions enables reliable condition monitoring of processes and machines. Increased unbalance, tool wear, the bearings of the main spindle and sudden impacts due to a crash can be precisely monitored, preventing costly consequential damage. Achieving a fast response time of 1 ms, the VSE diagnostic electronics will reliably protect your machine. Through flexible integration with common fieldbus interfaces, seamless interaction between the diagnostic electronics and the machine controller is ensured. The diagnostic electronics is designed for comprehensive condition monitoring, process monitoring and reliable protection of machine tools.

Decanter centrifuges

Decanters are centrifuges that are specially designed for the sedimentation and separation of solid particles or suspended solids from liquids. Decanters can be found in many industries, including wastewater treatment, the food and beverage, chemical and pharmaceutical industries and also in heavy industry (oil and gas, mining and minerals).

Decanters are subject to many different vibration frequencies (unbalance, bearing frequencies, gear frequencies, liquid vibrations, process-related vibrations and machine resonances), which are detected by vibration sensors on the machine, and analysed, separated and dynamically monitored by the high-resolution VSE diagnostic electronics based on the relevant process states.

Screw and reciprocating compressors

Screw and reciprocating compressors are mechanical devices that are used to compress gas or vapour based on the volumetric principle in order to increase the pressure. They are indispensable in multiple branches of industry and are used for targeted supply of compressed air, refrigerant compression, gas transport (e.g. ammonia) and many other production processes. Typically, these types of compressors have variable parameters (speed, flow rate, nominal pressure, intake volume, medium temperature, output) and complex kinematic arrangements (electric motor, multiple gear stages, screws/pistons, outlet valves) and are firmly embedded in complex systems. These operating conditions of reciprocating and screw-type compressors are a major challenge for reliable condition monitoring.

The VSE diagnostic electronics can dynamically monitor increased unbalance, damage to gear teeth, bearing damage or increased friction of metallic components. Thanks to the analogue inputs of the VSE, existing pressure or flow signals can be used as auxiliary variables to support the monitoring task. Using current transducers (ZJF056), the motor current can be used as a trigger condition for a load change. Using a standardised 4-20 mA output signal, these current transducers can be connected to the analogue inputs of the VSE to enable load-dependent vibration monitoring. The diagnostic electronics can be used for measuring and evaluating vibrations according to DIN ISO 20816-3/-7, ISO 7919-3 and VDI standard 3836.

Gearboxes

Gearboxes are indispensable in our industry and integral components of nearly all systems. Gearboxes are mechanical or electromechanical components that use a kinematic arrangement to transfer and increase or reduce the speed and torque of motors or drive trains.

The kinematic interaction, the mechanical forces, the different shafts and bearing seats can make vibration analysis a challenging task. Our VSE diagnostic electronics can dynamically monitor the different transmission ratios. In addition, individual components can easily and reliably be monitored using narrowband analysis methods.

Storage and retrieval systems

Automated storage and retrieval systems (ASRS) are rail-guided transport vehicles for transporting items in high-bay warehouses and for bridging vertical distances.

The lifting drives, guides and deflection rollers of the supporting structures are exposed to high dynamic loads, and thus to potential damage. Unplanned downtime can have a significant impact on the flow of goods and lead to high follow-up costs due to disruptions.

The ability to perform dynamic monitoring with auxiliary variables such as speed or optical trigger signals is an essential feature of a reliable ASRS condition monitoring solution, making the VSE diagnostic electronics the perfect tool for the job.

Cross belt sorters

Cross belt sorters deliver high performance in modern logistics and distribution centres, sorting thousands of parcels efficiently with speed and accuracy.

Any unexpected failure during peak seasons (such as Christmas or marketing weeks) can result in long delivery times and disruptions of the entire supply chain, ultimately leading to considerable financial losses.

The VSE diagnostic electronics can trigger an emergency switch-off within fractions of a second before sudden collateral damage to the transported goods or trolleys can occur.

Vibratory conveyors

Vibratory conveyors or screeners are used for sorting and classifying solid materials (rock, minerals, waste, etc.).

The machines are set into circular motion by vibrating equipment, gears and drive units, which subjects them to enormous forces. Condition monitoring is crucial to ensure a reliable process and avoid unplanned downtimes due to overload. High material stress or broken spring elements would have a direct effect on the machine structure, cause natural resonances and lead to costly consequential damage.

Dynamic monitoring of different process conditions and special operating frequencies in combination with a robust network connection to the machine controller make the VSE diagnostic electronics the ultimate choice in such applications.

Filling systems and bottling lines

The food and beverage industry is an integral part of our society, as are essential production facilities such as filling systems.

They basically consist of a drive motor, one or multiple worm gears, a star wheel and different drive shafts with multiple bearing seats.

A frequency-specific real-time analysis inside our diagnostic electronics enables targeted monitoring of this critical machine. Process noises caused by colliding cans or bottles have no effect on the measuring task, nor do the dynamic speeds of the different drive shafts.

Industrial mixers

Industrial mixers are versatile devices that can be used in many industrial sectors, for example for mixing of liquids or chopping of solid materials. They are typically used in the food and beverage industry, in battery production, in wastewater treatment and in other chemical and pharmaceutical areas.

The heterogeneous materials can result in different load distributions, which can quickly develop into an unbalance of the mixing element. The high load caused by the mixing process can also directly affect the rolling element bearings and drive gears and damage the machine in the long term. In the food industry in particular, worn mixing elements or leaking shaft seals can lead to foreign bodies in the product. Thus, condition monitoring is not only essential to assess the health status of machines, but also to guarantee the quality of the product.

Shredding and milling machines

Shredding and milling machines are used to break existing products or raw materials into smaller pieces. These machines are often bottlenecks in the wood processing, recycling and plastics industries, but also in the automotive industry and in foundries.

There are many different types, such as hammer mills, shredders or crushers, which are characteristically subjected to very high forces and loads. The structural components of the machines, including roller bearings, shafts and reduction gears, are constantly affected by these forces.

Here, the VSE diagnostic electronics assumes essential functions in suppressing the high vibrations caused by the process. Especially narrowband monitoring and triggered measurements offer a distinct advantage in these applications.

Pump monitoring

Unplanned downtime due to misalignment, cavitation, bearing damage or increased friction can be reliably detected by our vibration systems. Whether the pump is used in hazardous areas (VSP01A) in the chemical industry or as a submersible pump (VSP004) in the mining industry – we have the right solution for every application.