A mill consists of a continuously circulating drum that crushes large medium into smaller particles for further processing. Given the harsh environment of a mill and the high production quantities that are required, the use of vibration monitoring systems is becoming a preferred method for predictive maintenance.
The monitoring and evaluation of the vibration is done in the Octavis VSE100 diagnostic unit, through Fast Fourier Transformation (FFT) of the signal received from the accelerometer, VSA001. The VSA001 is the transducer that converts energy from the mechanical vibration to an electrical signal and it can be connected to a maximum of four VSA001 accelerometers and two digital or analogue inputs for speed reference or process feedback (shaft float, temperature, pressure, flow).
The VSE100 has two digital outputs of which one can be configured for an analogue out. This will use the vibration value of the highest input transducer and display the value at 4-20 mA. There is an additional 8 x I/O that can be configured in the software for certain events and used for local indication e.g. panel lights, or connecting to PLC I/O cards.
Another option is to use the TCP/IP port on the VSE100. This is used to program the VSE100 and retrieve data via an OPC server to a scada system.
The local installation consists of two VSE100s and six VSA001s, a speed sensor will be added in the near future. The first VSE100 has three VSA001s installed on the motor non-drive end, motor drive end and gearbox input drive end. The second VSE100 has three VSA001s installed on the gearbox output drive, pinion drive and pinion non-drive ends. The motor has journal bearings and runs at 740 rpm; the gearbox has two x 23148 CC/W33/C3 bearings on the input shaft and a 27 tooth gear. On the output shaft there are two x 23064 CC/W33/C3 bearings and a 160 tooth gear. There is no bearing detail on the pinion shaft bearings and one of the accelerometers has not yet been connected.
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