Revolutionizing Manufacturing with Wireless Vibration Monitoring: A Case Study
In today’s competitive industrial landscape, sustainability is a top concern for manufacturers. To maintain a competitive edge while minimizing environmental impact, organizations are exploring innovative ways to optimize their processes. One such innovation involves the implementation of effective maintenance measures through condition monitoring.
In this post, we will dive into a case study where NI CompactDAQ and NI LabVIEW were employed to create a wireless vibration monitoring system for a precision grinding machine in the print media industry.
The Challenge: Monitoring in Harsh Industrial Environments
Imagine the challenge: facilitating machine condition monitoring in dynamic and hazardous industrial environments. Heidelberger Druckmaschinen AG, a leader in engineering print media, needed a solution for monitoring their precision grinding machines which play a vital role in printing. These machines are known for their micron-level precision, requiring advanced vibration and condition monitoring systems.
The problem was multifaceted. The internal machining environment was harsh, featuring hazardous airborne particulate, corrosive coolant, and electrical noise. Furthermore, the grinding machine’s electronic controller provided limited data for monitoring, with constrained process variables, acquisition rates, and real-time data transfer options. Traditional cable routing for communication was impractical due to the machine’s dynamic nature.
The Innovative Solution: Wireless Vibration Sensing Units
In response to these formidable challenges, a team of experts embarked on a journey to create two industrial wireless vibration sensing units, each carefully composed of essential components:
Firstly, there was the inclusion of the NI cDAQ-9191 wireless communication chassis, a pivotal element in ensuring seamless wireless data transfer within the system.
The second key component was the NI-9234 signal acquisition module, meticulously selected for its high-speed data measurement capabilities and modular design, which allowed it to effortlessly integrate into the cDAQ-9191 chassis.
Finally, to complete the triumvirate of essential components, a triaxial Integrated Electronic Piezoelectric (IEPE) accelerometer was incorporated, ensuring the accurate measurement of vibrations critical for monitoring the machine’s condition.
However, what truly set this solution apart was the meticulous design considerations that went into its construction:
Custom magnetic-mounted enclosures were engineered to house the accelerometers. These enclosures not only shielded the accelerometers but also provided them with a robust layer of protection certified at IP66. This meant that the accelerometers were impervious to the infiltration of fine dust and the onslaught of high-pressure water jets, ensuring their durability and reliability in the harsh industrial environment.
The cable conduits, another vital element of the system, were equipped with internal electrostatic dissipation foam. This ingenious feature served to dampen the effects of both electrical and vibration noise, safeguarding the accuracy of the data collected.
The NI-9234 module, with its high-speed data measurement capability and modular design, was seamlessly integrated into the cDAQ-9191 chassis, ensuring a harmonious and efficient operation of the system.
Furthermore, the compact design of the NI hardware played a pivotal role in facilitating system placement within the machine. This design characteristic not only added a layer of flexibility to the system but also ensured that the installation was noninvasive, allowing for quick and efficient deployment.
Both of these ingeniously designed systems were equipped for wireless connectivity, connecting effortlessly to a single notebook computer. This connection facilitated configuration and data acquisition through a WiFi network, streamlining the entire process.
To ensure that the acquired data was not only captured efficiently but also analyzed and stored effectively, a LabVIEW interface was meticulously developed. This interface provided a sophisticated, customized, and user-friendly solution, making data management an accessible and manageable aspect of the system.
Sustainable Manufacturing Through Flexibility
The success of this project showcased the power of NI CompactDAQ hardware and NI LabVIEW software in breaking technological barriers for manufacturing condition monitoring. It highlighted the importance of adaptability in today’s manufacturing processes and environments.
As manufacturers worldwide strive for sustainable existence, they require a diverse range of adaptable tools for unique processes and subsequent environments. The combination of NI hardware and software empowers manufacturers to incorporate flexibility into their systems, resulting in dynamically capable setups and ultimately enabling more sustainable manufacturing practices.
This case study is a testament to the transformative potential of technology in industrial settings. It demonstrates how wireless vibration monitoring, powered by NI CompactDAQ and LabVIEW, can not only optimize machine condition monitoring in challenging environments but also contribute to the broader goal of sustainable manufacturing. As the manufacturing sector evolves, embracing innovative solutions like these will be pivotal in achieving both competitiveness and environmental responsibility.
The case study discussed in this post was originally authored by Jeff Morgan from the Trinity College Dublin.
