Ludlum Presentation

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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