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Christoph Behler, Senior Business Development Manager, Mitsubishi Electric Europe, FA-EBG
Smart Condition Monitoring (Preventive Maintenance) with FAG SmartCheck support that and
delivers data from the application to the entire levels!
Cost End User
Costs lower during the whole Life Cycle (LCC) with SCM
Visible Costs Visible Costs
Acquisition
Installation and start-up
Invisible Costs
Invisible costs Lowing with SCM
Cost of employee qualification measures
Easy machine diagnosis through intuitive operation and
easy retrieval of measured data
Shutdown (production lost) cost
Significantly higher level of plant availability and
Factor 5 to 10 avoidance of unexpected shutdowns with high
consequential costs
Energy costs
Energy efficient operation through correlation of machine
and process parameters
Maintenance and reconditioning costs
Optimized maintenance and reconditioning intervals
in terms of information through access to history data
SCM support cost down!
Cost down for unexpected shutdown
Reliable real time machine and process online monitoring with
status alarm
Plannable service, because of long pre-warning period
Presure
Flow
Demand
Lubricant condition
Temperature
Vibration
Diagnosis by a Doctor
and Technical Machine Monitoring
it's comparable
change in
condition
Vibration
machine condition
time
Minutes
Days
weeks
Month
lead time or pre-
warning period
COPYRIGHT 2015 MITSUBISHI ELECTRIC CORPORATION. ALL RIGHTS RESERVED. 13
How does SmartCheck work?
Status Indication
Normal status Detect danger, Pre-Alarm Detect danger , Main-Alarm
(Green LED) (Change from green to (Change from yellow to red LED)
yellow LED)
Change of
status
Vibrations
Machin status
Sounds
Temperature
Machine stopp
Days
Week
Month
Pre-warning time
COPYRIGHT 2015 MITSUBISHI ELECTRIC CORPORATION. ALL RIGHTS RESERVED. 14
Machine Diagnosis Trends
Typical application: Motor & pump arrangement
FFT-Analysis
"Fast Fourier Transformation"
bearing defect
cavitation
misalignment Hz
g
unbalance
time
Seismic
Mass
A
Piezo
Crystall
Common information
Specification SmartCheck
ECP FA-EBG - C. Behler COPYRIGHT 2010 MITSUBISHI ELECTRIC EUROPE B.V. ALL RIGHTS RESERVED. 21
FAG SmartCheck meets Mitsubishi
SMLP
CONFIDENTIAL 05/ 2012 Christoph Behler / FA-EBG AMD COPYRIGHT 2010 MITSUBISHI ELECTRIC EUROPE B.V. ALL RIGHTS RESERVED. 25
Eplan drawings for the cabinet
Easy and fast connectivity
ERP
Level
Our partner:
AUTINITY Systems
Ethernet
Cloud/
Internet
Internet
MES
Level SCADA
z.B. MAPS
Gateway
Ethernet
Level DB
Modbus
TCP
****
Profibus
Profinet Analog/
Agent CANopen
CC-Link Digital
DeviceNet
SmartController EtherCAT
In/Out
SLMP
SLMP
TCP/IP
Field
Level
SmartCheck
125
COPYRIGHT 2015 MITSUBISHI ELECTRIC CORPORATION. ALL RIGHTS RESERVED. 27
SCM - Fast start up
Cost efficient retrofit - Fast installation and one Ethernet cable
Scalable budget - Start with applications sorted by priority
Intelligent sensor - Reduced number of sensors
Easy adaption of field signals like speed, flow, etc
Pre-defined Function Blocks for the controllers und SC setups
Various Applications:
Electrical motors
Gear boxes
Ventilators
Fluid pumps
Compressors
Vacuum pumps
Vibrating screens
Schaeffler, FAG Industrial Services (D) , Advanced Condition Monitoring For Overall Equipment Efficiency
COPYRIGHT 2015 MITSUBISHI ELECTRIC CORPORATION. ALL RIGHTS RESERVED. 29
Mounting types
Various Possibilities
TCP/IP
TCP/IP
Smart Condition
Monitoring Kit-1
Optional for no. 2 to no.5
(Housing and one FAG
SmartCheck) - Smart Condition Monitoring Kit - Extension 10 m m (#272511) or
#283165 with GT2103 - Smart Condition Monitoring Kit - Extension 20m (#272512)
CONFIDENTIAL COPYRIGHT 2010 MITSUBISHI ELECTRIC EUROPE B.V. ALL RIGHTS RESERVED. 33
Smart Condition Monitoring Kit-1
Pre-configured Solution in Detail
Smart Condition Monitoring Kit-1 for new or existing machines
Settings
The communication between the SmartCheck sensors, PLC
and GOT is via Ethernet
using the MC Protocol, TCP port 1280. The following IP
addresses are defined:
PLC (factory default): 192.168.3.39
GOT (factory default): 192.168.3.18
Smartcheck sensors: 192.168.3.100 to 192.168.3.104
CONFIDENTIAL COPYRIGHT 2010 MITSUBISHI ELECTRIC EUROPE B.V. ALL RIGHTS RESERVED. 34
SCM Kit-1 Quickstart Communication Guide
Option:
192.168.3.101
192.168.3.100
192.168.3.39
192.168.3.18
192.168.3.xx
SCM delivers
Delivers Online-Information about the Status and Conditions
and stores the data historical in the SmartCheck and the
internal intelligence reduces the number of sensors.
37
Reference
Waste Water Plant, Germany
Application:
Tree Archimedes-Screw pumps with
gear box, redundant, FAG
SmartCheck, System Q, analog
Values, Telemetric access and
access point for SCADA
Break down of the gear box in frame
of 1-3 years
Detected failure:
4 Month after installation gear wheel
defect detected
Costs
Overhaul of gear box: 1.000Euro
New gear box: 5.500Euro
Difference to save: 4.500Euro
SCM solution cost:
HW: 4.700Euro
Installation: 1.000Euro
Installation
By Mitsubishi Automation partner
References
Incinration Plant, Germany
Examples of Condition Monitoring
Company
Iserlohn city office
district power station
Country
DE
Application
Waste incineration, Energie
transport
Products
Modular PLCs, Inverter and FAG
SmartCheck
Detail
Four Motors 250KW with FAG
SmartCheck
References (Offer)
Water infrastructure, Brazil
Architecture of Project Water, Brazil
up to 50 pump stations with 3-8 pumps, each pump with 4 SmartCheck
Vizualisation Mobile Vizualisation Router
EXTEND 7000 SQL-Data base
for remote
optional (new or existing)
acces
to smartRTU-L
Enterprise
Level
Analouge value
(if needed)
Device
Level
LAN (Ethernet)
References
Sugar Factory, Germany and Sweden
Application:
Four gear boxs at a sugar beet
washing machine, 4x FAG
SmartCheck, SmartController,
Information to 3rd party PLC
Buffer time during stop is 10
minutes
Costs
1 hour stop : 60.000Euro
(Campaign modus)
1 hour stop: 1.000Euro
(24/7 modus)
SCM solution cost:
HW: 5.000Euro
Installation: 3.000Euro
Installation
By FAG system integrator
supported by Mitsubishi
Automation partner
References
Universal Studios, Florida, Orlando, USA
Application:
Passenger elevator in a theme
park.
High temperature and lot of people.
Two station with SmartController
and total 18 SmartCheck sensors
to control the two idler pulleys and
the rope.
Min. 2.5 hours stop to evacuate
the people during failure
Costs
Image damage and money back:
??? Euro
SCM solution cost:
HW: 13.500Euro
Install: 5000Euro
Installation
By FAG system integrator
supported by Mitsubishi
Automation partner
Historical question after using SCM:
Have you ever seen this in your application?
Innovation
Solution
Competence