Forming machine bearings condition monitoring

Increasing productivity causes permanent pressure on maintenance to ensure continuous production. Failure of forming machine bearings can cause a very long and expensive shutdowns with enormous loss of money. Bearing condition monitoring is time consuming and conventional methods fail very often.

WE SPECIALIZE IN FORMING MACHINES' LOW-SPEED BEARINGS
100

revolutions under
rpms

6

months
in advance failure prediction

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4DOT SERVICE BENEFITS

OEE monitoring

downtime eliminated

malfunction localization

maintenance management

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Technology 4dot

4dot system continuously monitors bearings’ vibrations on the main parts of your machine. Measured data is being sent in real time to 4dot cloud where processed by our algorithms and interpreted. Based on the analysed data, you can easily determinate machine condition or predict the machine failure.

CONTINUOUS

MONITORING

CONDITION OF THE

BEARINGS

VALIDATION OF DATA BY

EXPERTS

ALWAYS

UP TO DATE

SHARED

USER-FRIENDLY

DATA

INTERFACE

MONITORING

ONLINE

SIMPLE

IMPLEMENTATION

HARDWARE

POWERFUL

HIGH

SECURITY

OF YOUR DATA

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FORMING MACHINE DIAGNOSTICS
LOW ENERGY OF VIBRATIONS
TEMPERATURE MONITORING
Condition monitoring of low speed bearing requires special sensors and data processing algorithms developed for forming machine as the energy of vibrations is low making them hard to detect.
Impacts of the forming tool during the forming process disable conventional methods of condition monitoring as they shadow relevant signals. 4dot can filter those impacts and localize malfunction of the part.
Temperature of the bearing increases only in the final stage before its failure. That is why temperature monitoring is not effective tool for predictive analysis.
IMPACTS
COMPARISON WITH CONVENTIONAL METHODS

50

60

70

80

90

100

beginning of the damage,
detection of the pitting

4dot vs. temperature monitoring

0

50

100

150

200

0

5

10

15

20

time [hours]

temperature [°C]

4dot algorithm output [m.s-2]

BEARING LUBRICATION MONITORING
When bearing oil is being monitored, presence of small metal chips is monitored indicating bearing damage. With this method, only severely damaged bearing can be detected. Moreover, when machine has central lubricating system damaged bearing can’t be localized.
Due to cyclical stress subsurface fatigue occurs. Material cracks expand up to the surface causing metal chip to peel off. Vibration monitoring with 4dot detects first stages of the subsurface fatigue development sooner than metal chips peel off.
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SIGNAL PROCESSING FROM THE FORMING MACHINES

signal from the sensor

processing the signal with 4dot algorithms

data interpretation

bearing

impacts

noise

+

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MACHINE CONDITION MONITORING

For perfect overview of the machine condition, acceptable vibration limits are set. When the limits are exceeded, data is verified by the 4dot application engineers. You always know whether machine needs to be serviced or not.

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Implementation of 4dot technology

Machine condition monitoring When the system is fully operational, condition limits are being monitored automatically. When good condition limits are exceeded, data is verified by 4dot engineers. You can monitor your machine condition with our online application and thorough pdf reports.

extended machine lifetime

1-3 months

System learning It takes 1 to 3 months to set the limits for machine condition monitoring.

1-2 work shifts

4dot unit instalation Instalation of the unit takes one or two work shifts depending on the machine parameters.

Machine without 4dot High level of production uncertainty. Risk of unplanned downtime.

unmonitored machine

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4dot Mechatronic Systems s.r.o., Purkyňova 649/127, Medlánky, 612 00 Brno, IČO: 036 24 633, C 85955 vedená u Krajského soudu v Brně

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