September 2002Maintenance, Test & Measurement, Calibration
Today we hear a lot about preventive maintenance and reliability in the process industry. In a finely tuned process a stoppage can cost enormous sums in terms of reduced production and much energy is expended in avoiding such an occurrence.
Analysing and understanding problems and their sources can make for more effective preventive maintenance. When a problem or deviation arises in a process it is often encoders that are checked first. Each check costs more than the component itself and studies have shown that encoders are among the most reliable components.
Today's modern systems provide many opportunities for the use of more intelligent components where diagnostic functions can give the user information on what is wrong or, even more important, what is right. A diagnostic function in an encoder does not just save money for the user when it foresees a problem. Information that tells the user there is nothing wrong can be even more valuable.
Leine & Linde's ADS system is designed to detect internal problems in rotating incremental encoders at an early stage. The system is based on fast logic together with a microprocessor that continuously supervises the encoder's functions and is consequently able to detect a problem in its early stages. With this warning, in most cases the encoder can continue to work, and replacement can be done at a planned maintenance stop.
The paper industry has shown great interest in Leine & Linde’s robust encoders with ADS.
The principal control system is informed of a detected problem in an encoder via a signal over the encoder's alarm output. This alarm signal is relayed to the operator who, with the help of a PC and the diagnostic system's analysis software, can communicate with the encoder and find out the reason for the alarm. The operator is informed of the frequency, internal temperature and operating time at the time the problem occurred. External problems can also be detected. The internal signals in the encoder are compared to the signal generated in the cable. In this fashion it is possible, for instance, to detect an overloaded output signal from the encoder. The analysis software can also provide information on total operating time and maximum and minimum operating temperatures.
The ADS system is an effective means of real preventive maintenance. Meaningful savings are realised when unscheduled stoppages are avoided by making use of such a system. There is also a significant savings in routine testing - as the system will indicate the operational status of the encoder during troubleshooting sessions, requiring less effort on the part of the technician/operator.
For more information contact Wim Annandale, ATI Systems, 016 986 2267.
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