To measure reference values for condition-based maintenance on a die casting machine, Stefan Pinkert from Schwabenhydraulik is using The Parker Service Master CONNECT from SensoControl by Parker's High Pressure Connectors Europe Division for the first time.
Does the new device convince the measurement technology expert in practice?
One way to prevent damage to machines is to take regular measurements, the results of which are compared with reference values. From the deviation of the measurement data, it is possible to infer the wear on the machine and make a forecast about the remaining service life of certain components. Ideally, these reference values are measured before wear has occurred, i.e. on the new machine. For this reason, Pinkert, managing director at maintenance provider Schwabenhydraulik, travels to the metal foundry Druko Metallguss in October 2020. The foundry had purchased a new die casting machine six months earlier. Pinkert's goal on this day is to measure comparative values for later adjustment. In particular, he is concerned with valve technology.
He explains, "We can take the same measurement again in a year, for example. From the difference in response, we can see what the machine condition is and whether a failure is possibly imminent." Such comparative values also help in the event of an unplanned shutdown, as they can provide clues as to which fault has occurred. Two employees of Parker accompany the managing director to the appointment: Rolf Streicher, application engineer and Jörg Simon, project manager for diagnostic measurement technology.
In their luggage, the three have a brand-new diagnostic measurement system that was launched in April 2020: the Parker Service Master CONNECT. "We already had the previous model and were also very satisfied with it," reports Pinkert. "However, we had the problem that there were certain limitations, for example in the recording capacity and the recording duration."
The service provider was in close contact with Parker and learned about the new version of the device early on. Pinkert is now using the model for the first time during the measurement in October.
How does the measurement work?
Measurements that serve maintenance purposes are one of the cases in which the managing director or his colleagues are called to the site. Another is troubleshooting. In the maintenance strategy that Druko Metallguss and Schwabenhydraulik follow in this case, they connect numerous sensors to the diagnostic system. Points are checked where experience shows that failures can occur.
"With the help of Parker's device, you can easily derive ten different measured values," Pinkert notes. "In large machines, you have up to four proportional valves on the press-fit part, so you often have to connect up to 16 different measuring points." This requires a lot of preparation, he continues, "You connect different measuring points for an hour and a half. The measurement itself is then finished after about ten machine cycles." So in failure prevention, the preparation time turns out to be quite long and the measurement time rather short.
Things are usually somewhat different when damage is detected. In this case, the failure pattern already provides initial indications of the cause. In this case, it is often sufficient to connect four to six sensors and take a measurement. Alternatively, the service employee can run the machine for six or seven cycles and compare the measurement results with the known values of previous measurements. Depending on how a machine or plant operates, longer measurements also make sense, for example overnight.
Measuring devices in maintenance
Pinkert lists what is important for a measuring device in such applications: "For me, it is important to have a recording rate of one millisecond and to be able to measure very many different measuring points. I then have to be able to store the whole thing in the device accordingly, and with a reasonable recording time, not just 60 seconds." With the new device, he can now display the complete machine cycle, even if it takes three or four minutes. "Now it is possible for us not only to measure the actual process of casting but also to repeatedly record the complete cycle," Pinkert emphasizes.
"For me, it is important to have a recording rate of one millisecond and to be able to measure very many different measuring points. I then have to be able to store the whole thing in the device accordingly, and with a reasonable recording time, not just 60 seconds."
Stefan Pinkert, managing director at maintenance provider Schwabenhydraulik
In fact, the device can record and process up to 100 channels simultaneously, confirms Simon. "We not only measured pressures on the machine today, but also temperatures, currents, voltages and so on," he relates. The device can also read out third-party sensors and machine data, he adds. "In that respect, this is a nice little electronic all-rounder."
Differences from the previous version
Parker has changed several aspects of the measuring device compared to the previous version. One of the new features is the modularity of the hardware and software: the older device had a single input module that was installed in the device at the factory and also calibrated. Today, a user can use different measurement modules, two at a time, as needed. It's also possible to buy individual modules and replace them yourself on site. "The measuring devices recognize the input modules independently. The user is free to decide what he needs, depending on the application," explains Simon. At the moment, there are three standard measurement modules:
- The analog input module for connecting Parker sensors and analog sensors from other manufacturers.
- The ISO variant of the analog module: It is galvanically isolated from the rest of the measuring device.
- The CAN module for measuring, monitoring and analyzing Can systems or connecting Can sensors from different manufacturers.
In addition, individual measuring module variants are possible.
Operation has also been revised in the development of the new generation of devices: With a color seven-inch touch display, it now resembles that of a smartphone or tablet. Users can create so-called measurement templates for recurring measurements. Parker has also improved protection against moisture and dust, as Streicher explains:
"We have increased the protection class from IP64 to IP65." Simon adds, "In general, this device can withstand very strong shocks and vibrations. For safe operating comfort, we have added additional tactile buttons on the right, on the side." There is also a fold-out stand and carrying handles to simplify handling. In practice, the clear display of the measurement data pays off above all, explains Pinkert: "The graphic display has improved extremely. You can now simply zoom with two fingers, just like on a cell phone. Operation is now much more intuitive." In addition, he can now evaluate a great deal on the device itself, instead of having to transfer the data to a PC in advance. "So that you can see something in the target/actual comparison, it is important that the recording rate is in the millisecond range, because a nicely smoothed curve is of no use to anyone," he points out.
Additional equipment for measurements
The measurement system is available from the manufacturer either individually or as a pre-assembled kit, including a basic set of accessories. Pinkert chose this kit for the previous version and had good experiences. His conclusion: "You can already get very far with it." Parker offers various products for a wide range of applications, for example cables in different lengths, hoses, mechanical components and various sensors, as well as an outdoor case with trolley function. "One measures volumetric flow, the other might need speed or just pressure, maybe chemical compatibility, because of the aggressiveness of the media. We are very, very broadly positioned there," enumerates Simon.
Intuitive operation counts
"It is of course extremely pleasant to have a measuring device where you can evaluate voltages and pressures very easily combined with each other. That is relatively rare on the market," concludes Pinkert. This is exactly the case with the proportional valve, for example: "There is the setpoint value, the actual value; then you have an enable signal, and in addition, you may still need to measure the 24-volt supply voltage, but at the same time you also want to see how the pressures develop accordingly."
“It is of course extremely pleasant to have a measuring device with which you can evaluate voltages and pressures combined with one another very easily. This is relatively rare on the market.”
Stefan Pinkert, managing director at maintenance provider Schwabenhydraulik
However, another point is important to the managing director: that the device can also be operated by someone who does not have it in their hands every day. "Then, when the fault occurs, he takes the device, connects it - and has no problem with the operation. The original measurement files can be sent worldwide and interpreted by a specialist using standardized software." Simon adds, "The device has sensor recognition. This means that if you connect a Parker sensor, it immediately displays the current measured value without any additional parameterization effort."
This article was first published in the January 2021 issue of Fluid.de
Find out more on the SensoControl website.
This post was contributed by Jörg Simon, project manager SensoControl, Parker Hannifin High Pressure Connectors Europe
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