~ Wireless monitoring system reduces downtime with early fault detection ~
Improper lubrication is a common cause of bearing failure, accounting for up to 50 percent of machine breakdowns. As manufacturers navigate mounting pressure to reduce costs while ensuring optimal performance, early intervention becomes increasingly critical. Here’s how WEG’s partner AZserv, a leader in enhancing reliability and maximising plant uptime, has effectively deployed the WEGscan® wireless monitoring system to identify dry bearing defects in a raw mill elevator drive and critical fan unit.
WEGscan uses state-of-the-art algorithms designed for predictive maintenance of industrial equipment. The sensor monitors the performance of an asset and shares this data with operators via the Motion Fleet Management platform — WEG’s cloud-based software for condition monitoring. Now in its second generation, WEGscan ensures operational excellence through real-time vibration and temperature monitoring, significantly reducing the risk of unplanned downtime and increasing system availability in a cost-effective manner.
Optimised for motors, the system suits any rotating machinery. Users can input or select relevant bearing numbers from MFM’s library to configure machines easily. The system presents clear data on a user-friendly dashboard for non-technical users, while offering advanced analytical tools for detailed vibration analysis.
With a wideband frequency range up to 13.5 kHz, WEGscan measures vibrations in three axis simultaneously, enabling early identification of bearing faults to prevent catastrophic failures. Reliable signal strength and data collected in five-minute intervals provides effective fault alarm indications, with daily notifications alerting users of undesirable equipment conditions.
Identifying a dry bearing defect in a raw mill elevator drive
In a recent deployment in a raw mill elevator drive within the cement industry, the WEGscan system quickly demonstrated its effectiveness by detecting an alarm state at the non-drive end (NDE) of a motor shortly after installation.
The raw mill elevator operates as a bucket elevator system that elevates raw product to the top of the mill house. If the raw mill elevator drive fails, production halts, leading to significant downtime and economic losses due to halted operations and potential material buildup. This disruption can also affect downstream processes, resulting in inefficiencies and potential quality control issues.
Three days after installation, a WEGscan alert promptly entered the event log and a detailed analysis revealed a concerning trend. Over a six-hour period, the root mean square (RMS) acceleration trend — a statistical value that measures the average vibration level of a machine or component — showed a significant increase. This triggered the alert between 18:00 and 24:00 and the system immediately sent a notification directly to an AZserv field engineer via the WEG notify app.
“Upon receiving the alert, our engineer conducted a thorough analysis, beginning with the velocity spectra to ascertain the motor’s rotational frequency, which the team recorded at 23.03 Hertz (Hz) and 1381 revolutions per minute (RPM),” explained Jens Thinnesen, technical director at AZServ. “By measuring how fast the motor was spinning, this helped us understand the motor’s operating speed.
“The acceleration spectra used band-pass filters set between 500 Hz and 6500 Hz to envelope the data, revealing the fundamental frequencies of the NDE motor bearing (FAG 6317). These special filters allowed us to focus on important vibration data, which showed us the key frequencies of the motor’s bearing. Recognising the urgency, we requested lubrication for the motor’s bearings.”
Since greasing, the acceleration trend returned to baseline levels, demonstrating the effectiveness of the WEGscan system. Prior to this deployment, portable vibration equipment monitored the machine monthly, which would have missed the six-hour spike in vibration. The WEGscan unit identified the issue in real-time, enabling timely intervention and preventing potential long-term damage.
Correcting high vibration levels in a critical fan unit
In a second application, AZserv deployed the WEGscan system to monitor a critical fan unit that had been facing high vibration levels. Shortly after installation, the RMS acceleration showed increases across all three axes, with the horizontal axis reflecting the most significant change, likely due to the belt-driven configuration of the fan.
“Notably, the trends across all axes rapidly dropped before the vibration patterns began to repeat,” continued Thinnesen. “When we looked at the data at the highest point of the trend, we noticed unusual noise in the system between 4 kHz and 7 kHz, with an amplitude of 0.3G-s. The peak-peak waveform parameter, the difference between the highest and the lowest values in a waveform, measured at 15G-s — a sign that the bearing was running dry.”
After applying grease, the noise and vibration levels both went down. However, a day or two later, the vibration levels started to rise again, showing that the bearing wasn’t getting enough lubrication. After adjusting the greasing regime and applying the correct quantity, vibration levels stabilised, demonstrating the system’s capability to inform maintenance decisions effectively.
AZserv’s deployment of WEGscan in these two applications highlights the system’s ability to provide real-time monitoring and critical alerts, improving operational reliability across a range of applications. By enabling timely interventions, WEGscan proves invaluable in preventing equipment failure and optimising maintenance strategies, underscoring WEG and AZserv’s commitment to maximising plant uptime and reducing costs.
WEGscan features Bluetooth 4 sensors that communicate with IP66-rated gateways, each supporting up to 40 sensors within a 100-meter wireless range. For more information, visit WEG’s website today.
