Vibrations might be inherent for industrial machinery, but in an automotive production plant, this could mean faulty products coming down the assembly line, leading to costly rework translating into downtime and delays in delivery. Whether you’re an automotive OEM or a Tier 1/Tier 2 Supplier, machine health is a huge deal.
Imagine the advantage of discovering a deteriorating process quality before real problems occur. Maintenance engineers, whose essential job is to prevent any disruption in the manufacturing process, could better plan the replacement timeline and make the necessary workarounds until new equipment is installed.
To stay ahead of machine vibration and other issues, automotive factory engineers have turned to an early-warning system developed by Parker: SensoNODE™ Gold Sensors and Voice of the Machine™ software. This uninterrupted, real-time condition monitoring technology can be implemented throughout automotive production facilities to automate measurement taking and alert of trending situations. An additional advantage is the elimination of the tedious manual review of each device, freeing up the engineering team to attend to other tasks.
Parker’s robust automotive production machine monitoring system provides data that extends well beyond vibration. SensoNODE Gold Sensors monitor and transmit pressure changes, temperature, humidity, flow, current, displacement and analog signals—all to any internet-connected device via the cloud or localized edge applications. This Internet of Things (IoT) enabled solution allows plant managers to easily monitor process parameters that reveal changes in machine health as they develop, giving them the time and information needed to prevent failures.
Parker’s Voice of the Machine condition monitoring software provides machine alerts, status, and analytics in real-time on your desktop. The software can publish data to the cloud or most edge devices. The interface is simple to connect to the sensors, and measurements are displayed in a highly readable style. Users can customize dashboards and alarms. In only one click, data is sent via a .csv file to be shared from the cloud or via FTP on the edge.
Pressure, level, temperature and other condition monitoring sensors can (and should) be implemented throughout automotive production facilities to automate measurement taking. They do so safely as well as providing early warnings of deteriorating process quality. Wherever a vital production process is taking place, SensoNODE Gold Sensors can ensure machines are operating at an optimum level.
Monitoring fluid quality or ISO count can alert to declining oil quality before it reaches an unacceptable condition
Tracking hydraulic fluid temperatures can prevent overheating conditions by allowing maintenance engineers to identify and troubleshoot changes earlier
Monitoring hydraulic pressures alert to worrisome changes known to precede faulty manufacturing operations
Monitoring humidity in pneumatic lines prevents rusting, clogging and damage to equipment, as well as product defects
Tracking pneumatic system pressures help keep power tools operating at peak efficiency by indicating pressure drops
Observing motor temperatures to indicate the need to troubleshoot mechanical components of conveyance systems
Gauging filter performance and air quality
Indicating the presence of clogs sooner by monitoring differential pressures of multi-stage filtration processes
Monitoring air temperature and humidity within paint booths alert to preserve finish quality and keep drying times consistent
Injection molding temperatures and fluid level
Adhesion system temperatures and pressures
Plating operation parameters and chemistries
Die casting gas detection
Heat treating temperatures and chemistries
Vacuum and cooling system efficiency
Vibration in production assets such as robots is usually the result of worn gears or loose joints. A little lubrication or a mechanical tweak here and there can be a temporary fix, but they only delay the inevitable—a complete replacement of the affected machinery. Regular inspection of these huge machines requires a labor-intensive, time-consuming process to discover and address any issues before they become a real threat to production.
Recently, one manufacturer of trucks and SUVs that relies on robotics throughout the plant, looked to eliminate the inefficiencies related to the manual inspection. They called on Parker for a solution.
SensoNODE Vibration Sensors were placed on the joints of both new and older robots, recording vibration signatures in real-time. Measurements were compared on good and bad robots, establishing a threshold of when to service or replace a robot. Employing the Voice of the Machine software provided technicians with alerts of when thresholds were exceeded.
SensoNODE Sensors and Voice of the Machine Software provide this manufacturer with the ability to monitor asset conditions and view real-time data to diagnose issues before spiraling into a production catastrophe.
This is just one of many successful automotive industry installations Parker has performed. Maybe it’s time for your plant to get on board with this innovative technology.
For additional information on Parker’s IoT-based condition monitoring solution, read the Automotive Industry case study.
Contributed by Westin Siemsglusz, IoT market sales manager, Parker Hannifin