Sensor-based Condition Monitoring and Predictive Maintenance-An Integrated Intelligent Management Support System

Abstract

To maintain a competitive edge, it becomes increasingly important for companies to manage their maintenance dollars effectively. This study reveals that a surprisingly large part of capital investment is associated with equipment maintenance in real business environments. Moreover, equipment availability also affects productivity, profitability and the ability to response to market demand. Therefore, maintenance management is becoming an important business area in many industrial settings. Sensory data utilization and interpretation is vital in the decision‐making process for maintenance management. The paper proposes that indicative information and early warning about the health of the constituent components of a system are gathered through appropriate sensor measurement and monitoring. This strategy does not specify the use of fixed intervals for maintenance but dynamically adapt the maintenance intervals to the system's actual need for service. This strategy is called condition‐based predictive maintenance, in contrast to scheduled maintenance with fixed intervals. Technologies including sensor measurement, data processing, knowledge‐based intelligent systems and software implementation are integrated in this research to provide solid support for maintenance management. The purpose of this study is to investigate this new paradigm, its implications in business settings, and its implementation as a software system. Preventing catastrophic failures and damage to equipment is a major objective in this research. Adding value, reducing maintenance costs, and increasing the company's competitiveness are other driving factors for establishing a computerized management support system.

Uso do sensor inteligente na manutenção preditiva do motor de uma extrusora

“…Sinais ou características operacionais, como vibrações, temperaturas, taxa de desgaste, degradação e contaminação do fluido transportador, geralmente exibem anormalidades antes que ocorra uma falha e, se monitorados continuamente, podem ser usados com muita eficácia na previsão desta falha [7]. Uma indicação ou aviso antecipado de uma falha iminente pode ajudar no gerenciamento da manutenção e na tomada de medidas corretivas eficazes em caso de falha.…”

“…Uma indicação ou aviso antecipado de uma falha iminente pode ajudar no gerenciamento da manutenção e na tomada de medidas corretivas eficazes em caso de falha. Na Figura 1 pode-se observar de forma gráfica e visual como o controle de parâmetros permite uma atuação eficaz da manutenção preditiva [7]. Sendo µ (t) o parâmetro que está sendo avaliado, M o parâmetro de ocasião de falha e Mc o parâmetro crítico, entende-se que o sistema pode entrar em falha quando µ (t) > Mc.…”

“…Ela destina-se a reduzir a probabilidade de falha ou degradação do funcionamento de um item [1]. Dentre as técnicas usadas preventivamente para manutenção, a preditiva garante uma identificação precoce do estado dos equipamentos, permitindo que a manutenção do equipamento se realize quando houver a real necessidade, reduzindo custos de paradas programadas e descarte de peças ainda em boas condições [7].…”

Condition‐Based Maintenance

“…The IMSS framework, which includes several individual expert systems, and numerical processing programs, was developed. In 1996, Zhu [25] presented an integrated intelligent management support system with sensor-based condition monitoring for a mining truck. In this system, sensor measurement, data processing, knowledge-based intelligent systems and software implementation are integrated to provide a solid support for maintenance management.…”

Uncertainty Problem in Decision Support System for Means of Transport Maintenance Processes Performance Development / Problem Niepewności W Systemie Wsparcia Decyzyjnego Procesów Utrzymania W Stanie Zdatności Środków Transportu

“…The continuation of maintenance decisions support for equipment operating under condition-based maintenance strategy is given e.g. in [20,69,74] and in [40], where authors analysed Intelligent Maintenance Systems based on CBM implementation.…”