Infinite Uptime’s collaboration with TVS Motors has resulted in a reliable predictive maintenance practice

tvs-motors-infinite-uptime-collaboration

Digitize Any Equipment Within 1 Minute! 

Yes, with Infinite Uptime’s Industrial Data Enabler (IDE), it is possible. We are an industrial Edge solution provider for mechanical predictive maintenance in the engineering and process industries. Infinite Uptime specializes in high-frequency data analytics, such as Triaxial Vibration, Acoustic analyses, Spectral analyses, and configurable Edge diagnostics. Infinite Uptime ranks in the top ten world’s IoT Solution providers.

We have collaboration and partnership with many prestigious and pioneering companies across the world. Our customer base is spread across all sectors including Automotive, Steel, Cement, FMCG, Power, Chemical, Oil and Gas, Glass, Plastic, Rubber, Pharma, and Construction.

IDE vEdge is a lightweight, compact smart edge device that can be installed on a motor, pump, gearbox, fan, etc. In other words, we can say it can be mounted on any rotating equipment. 

It empowers the maintenance team to monitor the machine uptime, reduce unplanned downtime, and combat impending equipment damage in advance.

Our esteemed customer, TVS Motors, one of the leading two-wheeler manufacturers with technical support of 800 engineers, has an investment of 1100 crores in India. With an annual capacity of 4 million two-wheelers, the company has six plants in India. The plant in Hosur, Tamil Nadu, which is a major contributor to the overall profit of the organization by producing fuel tanks and mudguards for the automotive industry, was having problems in stamping press.

A stamping press is used to manufacture fuel tanks by stamping a hot metal sheet. The 120 HP Seyi Amino induction motor running with a speed of 1450 RPM is used to drive the press. The press is used for stamping of approximately 4000 tanks per day. Failure of this motor not only affects production but also disrupts further processes. It is extremely important to monitor the performance of this motor to achieve the daily production target.

To find the root cause of the underperformance of the motor, the IDE was installed on the drive and non-drive end of the motor to monitor triaxial vibrations, temperature, and complimentary acoustic signals in real-time. The thresholds were set with a mutual discussion with the Maintenance Head, the recommendation standards, and the ISO benchmarks. The IDE was configured with the software to visualize the trend on the mobile app as well as the dashboard. 

Generally, motors fail due to mechanical issues and bearing wear. By using FFT spectrum analysis, one can diagnose the root cause of the abnormality in any equipment. When a bearing fault starts developing, the clearance starts increasing within the bearings, ultimately resulting in motor failure. Overload in a motor can cause problems in the windings, and the rotor bar can crack ultimately resulting in the failure of the motor.

After getting specific alerts, the maintenance team analysed the FFT spectrum of the vibrations on the dashboard, which can be generated on-demand.  TVS Motor’s team studied the FFT spectrum at this point. The spectrum showed prominent peaks at higher frequencies. The TVS Motors team identified the lubrication fault because of the 5th harmonic which was dominant in the spectrum.

The indications empowered the maintenance team to carry out remedial measures and increased the availability and reliability of the equipment.  The maintenance team could equip themselves with correct spares and could service the equipment as and when required. The use of IDE ensured consistent motor-operations, safe operation of the die, prevented Seyi Amino motor failure and confirmed achievement of production target. (~ 4000 fuel tanks per day). The use of IDE conserved the production downtime of approximately 25 hours.  TVS motor is using approximately 60 IDE devices for 1.5 years on various machines in various plants. 

Various faults at various locations that are detected are

    • Damage of the die on the stamping press saved production loss of 4000 Fuel tanks and die damage.
    • Incorrect belt tension saved repairs of USD 5000 and predicted spindle and motor failure 
    • Plummer block failure saved production downtime of 8 hours.
    • Failure of Nadi blower-motor saved repairing expenses of entire Plastic Line Top-coat exhaust line ~USD 40,000 
    • Poor lubrication of the motor saved production downtime of 100 hours and prevented the rejection of approximately 1440 components.
    • Predicted the inappropriate usage of lubricant to lubricate the motor, saved asset repairs, and rebuild worth USD 6000 and enhanced motor life by 50% and conserved the production downtime of approximately 100 man-hours.
    • Damage to internal motor windings ensured the production of approximately 100 vehicles.
  • Unbalance of the exhaust fan saved asset repair and rebuild worth USD 45,000 and increased MTBF in the Paint Shop.

Let’s take a look at an example of the fault of looseness. With the help of equipment history and the FFT graph, one can know the fault in the equipment. In the following graph, vibration limits are beyond the normal limit range, they are in warning range. FFT spectrum shows that there is a dominating 1X frequency, which is a symptom of looseness. 

Vibration Analysis   Vibration Analysis

Figure 1: Trend history and respective FFT spectrum when the fault occurs

The maintenance team took corrective action and resolved this problem. The following FFT graph and Trend history are taken after the correction of the fault.

Vibration Monitoring  vibration monitoring

Figure 2:  Trend history and respective FFT spectrum after correction of the fault

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