SIPLUS CMS - Condition Monitoring Systems for early ...

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SIPLUS CMSCondition Monitoring Systems for early

detection of mechanical damages


7

Content

Condition Monitoring Overview & Possibilities

1 4

Analysis methods2 7

Solution with SIPLUS CMS1200SM1281 Overview

3 12

Application booklet4 16

Page 2 12.2019

Contact point5 64


SIPLUS CMS

The machine under control

There is no machine without vibrations.

But when do vibrations cause damages?

And what kind of damages?

And will the machine suddenly break down?

SIPLUS CMS

The answer to preventive maintenance

in industry

Page 3 12.2019


SIPLUS CMS

Possibilities of Condition Monitoring

Reaction time until breakdown

Minutes Days Weeks Months

Watch

Smoke

Feel

Heat

Hear

Noise

SIPLUS CMS

Early detection

Page 4 12.2019

https://www.google.de/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjm0JaRwcrYAhVN_aQKHcqXCRYQjRwIBw&url=http://freevector.co/vector-icons/weather/thermometer-with-high-temperature.html&psig=AOvVaw02isTLcpHFlTghewtwYtzQ&ust=1515574482463430


SIPLUS CMS - Real example

Bearing failure gear box

Drawing Resulting damage at the inner ring

08.07.03 02.09.03 28.10.03 23.12.03 17.02.04 13.04.04 08.06.04 03.08.04 28.09.04 23.11.04 18.01.05 15.03.05 10.05.05date

0,2

0,4

0,6

0,8

1,0

1,2

1,4

1,6

1,8

2,0

a [m/s²]

Warning

08.07.12 02.09.12 28.10.12 23.12.12 17.02.13 13.04.13 08.06.13 03.08.13 28.09.13 23.11.13 18.01.14 15.03.14 10.05.14

Trend

Picture

Page 5 12.2019


Mechanical damages Electrical faults

Drive

Condition Monitoring with SIPLUS CMS

What sort of damage can be detected? An extract

Resonance

Resonance

Blade passing frequency

ImbalanceMeshing fault

Alignment fault

Bearing danage

Field faultBroken rotorbar

Imbalance

Bearing damage Meshing fault

Alignment fault Blade passing frequency

Pump / Fan Gear box

Condition Monitoring with SIPLUS CMS – more than just Motor Condition Monitoring

Field fault stator

Broken rotorbar

Page 6 12.2019


7

Content


1 4

Analysis methods2 7


3 12


Page 7 12.2019

Contact point5 64


SIPLUS CMS - Analysis methods

Frequency-selective analysis (1)

Monitoring for

machine vibration

• Cyclic monitoring

• Peaks

• Trend

Frequency-

selective analysis

Monitoring for roller

bearing damage

Examples of detectable

mechanical damage

Resonance

Unbalance

Alignment

fault

Coupling fault

Detectable mechanical damage

Outer race

defect

Inner race

defect

Rolling

element

damage

Cage damage

Signal How it works

Advantages:

▪ Quick and easy to implement

▪ Type of damage identifiable → less troubleshooting

▪ Electrical faults detectable

Page 8 12.2019



Frequency-selective analysis (2)

Monitoring for

machine vibration

• Cyclic monitoring

• Peaks

• Trend

• …

Frequency-

selective analysis

Examples of detectable

electrical faults

Broken rotorbar

Field fault stator

Signal How it works

Electrical faults are also visible

in the frequency spectrum

Advantages:

▪ Quick and easy to implement

▪ Type of damage identifiable

→ less troubleshooting

Page 9 12.2019


Raw data

Signal How it works

Advantage:

Raw data used for analysis models

exactly tuned to the gear unit

Monitoring for

gear unit wear

Detectable mechanical

damage

Meshing faults


Expert analysis

Event-driven recording

A message signal “meshing

fault detected”

Recording + saving sensor

channel raw data

1. Exporting of the raw data:

• Via FTP manual

• Via FTP event-driven

2. Online raw data streaming

to CMS X-Tools

Expert analysis

• OFFLINE analysis of exported raw data

• ONLINE raw data streaming to CMS X-Tools

• Engineering + project of meshing faults

via SIMATIC S7-1200 CPU + SM 1281 Web Interface

• Engineering expert analysis via analysis software,

such e.g. CMS X-Tools

Page 10 12.2019


SIPLUS CMS

The analysis methods of condition monitoring

Expert analysis

• Freely configurable analysis with

diagnostics software CMS X-tools, e.g.

orbit, histogram, vector/waterfall diagramFrequency-selective

analysis

• What damage is imminent?

• Every type of damage has its own

frequency spectrum

Sig

nif

ican

ce

of

the

an

aly

sis

Parameter-based analysis

• Is damage imminent?

• Trend history of characteristic values

Page 11 12.2019


7

Content


1 4

Analysis methods2 7


3 12


Page 12 12.2019

Contact point5 64


SM 1281 Condition Monitoring Model

SIPLUS CMS1200: Condition Monitoring with SIMATIC S7-1200

SM1281 - Overview

Features

• Characteristic-based diagnostics

• Frequency-selective diagnostics

• Export of raw data

• SIMATIC and web-based

Connections

• Up to 4 vibration sensors (IEPE-sensors)

• 1 optional speed input (Bero)

• Ethernet (2 ports)

• Power supply 24VDC

Expansion option

Up to 7 modules can be connected;

depending on the S7-1200 CPU used

Operating principle

• Calculations are performed

continuously

• The 4 IEPE channels and

the speed sensor are read in and

processed simultaneously

Diagnosis

• Characteristic values

via SIMATIC S7-1200 and TIA Portal

• Frequency selective

via integrated Web Server

Advantages and Costumer benefits

No additional software for diagnosis and

visualizing needed

Page 13

IEPE-sensors

BERO

12.2019


Hardware requirements

SIPLUS CMS1200: Condition Monitoring with SIMATIC S7-1200

SM1281 – What is required?

Software requirements Optional software

Important:

SM 1281 is supported as of

FW version V4.1 for S7-1200 CPU

• TIA Portal is required to configure the

module

• The lowest license, SIMATIC

STEP 7 Basic, is sufficient for

S7-1200

*) Not available for S7-1200

S7-1200 CPU Max. connectable SM1281

CPU 1211C None

CPU 1212C 2

CPU1214C / 1214FC 7

CPU 1215C / 1215FC 7

CPU 1217C 7

SIMATIC STEP 7

Programming languages

KOP, FUP, SCL, AWL*, S7-GRAPH*

STEP 7 Safety option package

WinAC (incl. Failsafe**)

S7-300/400 (incl. Failsafe**)

S7-1500

S7-1200

Pro

fessio

nal

Basic

• If panels are used, optional use of the

corresponding WinCC version is

possible

→ Browser functionality for panels is

NOT supported by SM1281

SIMATIC WinCC

Machine-level operating and monitoring

SCADA applikations

SCADA

PC (single user)

Comfort Panels + x77

(without Micro), Mobile

Basic Panels

Pro

fessio

nal

Ad

van

ced

Co

mfo

rt

Basic

Page 14 12.2019


SIPLUS CMS1200: Analysis methods

SM1281 – Overview

Monitoring of machine vibration

based on characteristic values

• Simple representation, e.g. via traffic

light

• Trend analysis

Engineering in TIA Portal +

analysis via integrated software

Parameter-based analysis

Frequency-selective diagnostics of

machine vibration and bearing

• Spectrum view

via browser

• Integrated

message system

Engineering in TIA Portal / SM 1281

web-interface +

analysis via integrated software

Frequency-selective analysis

e.g. CMS X-Tools

Freely configurable analysis models,

e.g. for

• Detail analysis

• Gearbox diagnostics

• …

Engineering via separated analysis-

software e. g. CMS X-Tools

Expert analysis

Raw data analysis: on- or offlineMonitoring online in SM1281

Online Datastreaming /

Raw Data Export

Page 15 12.2019


7

Content


1 4

Analysis methods2 7


3 12


Page 16 12.2019

Contact point5 64


SIPLUS CMS1200 Application Booklet

12.2019Page 17

Fan2

Extruder3

Pump4

compressor5

Drive (Triaxial)6

Agitator7

Winders8

Filling line9

Tooling machine10

Support11

Sensorposition and detecable errors1


SIPLUS CMS Concept – Fan

Application example

12.2019Page 18

Threaded bolt with flat and smooth support

Upper frequency limit at 10 - 20 kHz

Intermediate adapter for non-level and / or painted surfaces


Fixing by gluing


Attachment with permanent magnets

Upper frequency limit depending on the adhesive force

(approx. 5 - 15 kHz)

Mounting types Picture


SM 1281

Terminal box (near the engine)

CPU 1214C

12.2019Page 19


Application example


12.2019Page 20

Application example Fan with CMS1200 SM 1281

Sensorposition and detecable errors

Electrical Field

Bearing resonance

Assembly


12.2019Page 21



Imbalance Alignment

Electrical FieldBearing

resonance

Assembly


12.2019Page 22



Imbalance Alignment Bearing

FrequenciesResonance


12.2019Page 23



Imbalance

BearingResonance

Frequencies


Assembly

12.2019Page 24




12.2019Page 25



Imbalance Alignment Electrical FieldBearing

ResonanceFrequenciesAssembly



12.2019Page 26


Extruder3

Pump4

compressor5

Drive (Triaxial)6

Agitator7

Winders8

Filling line9

Tooling machine10

Support11

Fan2



Overview

• Fans are often directly connected

to the drive shaft

• Vibrations are transmitted directly

from motor to fan and vice versa

• Monitoring of engine, transmission,

belt and fan

• Harmful or explosive gases are no

longer extracted

• Cooling of the machine is no longer

guaranteed

• Temperature distribution is no

longer optimal

• With general vibration speed vRMS

is monitored for imbalances,

bearing damage and blade passing

frequencies

• Monitoring according to DIN

10816-3 to ensure vibration

analysis

• Condition monitoring of the plant

• Predictability of plant downtime for

maintenance work

• Eliminate troubleshooting by error

identification

• Provision of replacement

components “just in time”

• Lower service and maintenance

costs

• Cost savings

• Higher plant availability

Application /

Customer Requirement

Customer benefitIn case of failure

+Solution

12.2019Page 27



Technical Topology

IEPE Sensor cable

Ethernet

Other

SM 1281

HMI TP1200

PM 1207 CSM 1277 CPU 1214C SM 1281

SINAMICS G120 SINAMICSG120

CPU 1512SP

PC-Station / programming device

Carbinet

Max. 100m

Page 28

Max. 30m sensor cable from

SM1281 to sensor5m from motor to motor

Terminal box (located at the motor)

12.2019



Bill Of Material

Pos. Description MLFB Quantity

1 VIB sensor S01 Vibration transducer, frequency range 0.5Hz 6AT8002-4AB00 8

2 Cable-MIL-1000, connection cable to connect VIB sensors, length 10,0m 6AT8002-4AC10 8

3 SIPLUS CMS1200 SM 1281 Condition Monitoring 6AT8007-1AA10-0AA0 2

4 SIPLUS CMS1200 SM 1281 Shielding bracket set 6AT8007-1AA20-0AA0 2

5 Profile rail 35mm, length: 483 mm, for 19" cabinets 6ES5710-8MA11 1

6 CPU 1214C (14 DE 24V DC; 10 DO 24V DC ; 2 AI), PS 24V DC 6ES7214-1AG40-0XB0 1

7 Power supply PM1207, AC 120/230 V, output: 24V DC 6EP1332-1SH71 1

8 Memory Card, 4 Mbyte 6ES7954-8LC02-0AA0 1

9 Compact 4 Port Ethernet Switch Module CSM 1277 6GK7277-1AA10-0AA0 1

10 TP Cord RJ45/RJ45, CAT 6A, TP cable 4x2, assembled with 2 RJ45 connectors, length 0.3m

6XV1870-3QE30

3

Page 29 12.2019



12.2019Page 30


Fan2

Pump4

compressor5

Drive (Triaxial)6

Agitator7

Winders8

Filling line9

Tooling machine10

Support11

Extruder3


SIPLUS CMS Concept – Extruder

Overview

• Extruders need a longer time to

restart after failure -> material must

first be brought back to

temperature

• After cooling, the solidified material

must be removed

• The following system parts must

wait for the extruder to restart



bearing damage and

misalignments



analysis

• Bearing state using envelope

analysis to identify conspicuous

frequencies

Application /



+Solution

12.2019Page 31



maintenance work


identification




costs

• Cost savings


• Vibrations are transmitted directly

from the motor and vice versa

• Monitoring of engine and

transmission

• Motor speed varies depending on

the output



Technical Topology

IEPE Sensor cabel

Ethernt

Bero Signal

Other

CPU 1214C SM 1281

Klemmkasten

PM 1207 CSM 1277

Simatic Touch

Panel

Programming device

MindConnect

IoT2040

MindSphereOptional:

Signal light for

Alarm and

Warnings

Page 32

Pulse

generator

Engine Gear

Extruder

12.2019



Bill Of Material

Page 33











10 TP Cord RJ45/RJ45, CAT 6A, TP cable 4x2, assembled with 2 RJ45 connectors, length 0.3m 6XV1870-3QE30 2

12.2019



12.2019Page 34


Fan2

Extruder3

compressor5

Drive (Triaxial)6

Agitator7

Winders8

Filling line9

Tooling machine10

Support11

Pump4


SIPLUS CMS Concept – Pump

Overview

• Several bearings on one pump

• Flow Monitoring

• Differential pressure monitoring

• Defined flow direction

• Danger of cavitation at reversed

direction of flow

• Cooling of the machine may not be

guaranteed

• Temperature distribution is no

longer optimal

• Exchange is often very expensive

12.2019Page 35



maintenance work


identification




costs

• Cost savings



is monitored for imbalances and

bearing damage



analysis

Application /



+Solution



Technical Topology

IEPE Sensor Cabel

Ethernt

Other

Main PC-StationCPU 1214C SM 1281 CSM 1277

Programming device

SIMATIC Touch Panel

Speed Sensor

(Bero)

Terminal box

SM 1231

Flow MeterPressure 2Pressure 1

Motor current L1 – L3

Page 36

PM 1207

12.2019



Bill Of Material

Page 37












11 SM1231 Analog module 8 AE; 13 Bit +/-10V, +/-5V, +/-2.5V, or 0-20mA /4-20mA, 6ES7231-4HF32-0XB0 1

12.2019



12.2019Page 38


Fan2

Extruder3

Pump4

Drive (Triaxial)6

Agitator7

Winders8

Filling line9

Tooling machine10

Support11

compressor5


SIPLUS CMS Concept – Compressor

Overview

• Compressors have plain bearings

in some cases

• Lubrication is monitored by oil

pressure

• Monitoring engine mounts

• Monitoring of compressor

pressure stages

• Process air is no longer available

• Failure may affect entire

production lines



bearing damage and

misalignments

• Error analysis to limit the time of

services



analysis

12.2019Page 39



maintenance work


identification




costs

• Cost savings


Application /



+Solution


Page 40


Technical Topology

SM 1231 SM 1281 S7-1214CCSM-1277PM-1207

IoT 2040

MindSphere – Fleet Manager (App)

• Overview of all compressors

• Location of all compressors

• Customer Management (with Subtenants)

• Visualization of all data

• Data export (CSV & JSON)

• Rules and Messagehandling

• E-Mail Notification

• Data upload & Data download

(Handbooks / Reports)

KP300 Basic Mono

Cabinet

Bearing NDE (radial)Bearing DE (radial)

pressure stage 1pressure stage 2

Sleeve Bearing

Oil Level

Motor

Bero

Compressor12.2019



Bill Of Material

Page 41












12 SM1231 Analog module 8 AE; 13 Bit +/-10V, +/-5V, +/-2.5V, or 0-20mA /4-20mA, 6ES7231-4HF32-0XB0 1

13 MindConnect IoT2040 9AC2112-0AA00-1YA2 1

14 SIMATIC HMI KP300 Basic mono PN, Basic Panel 6AV6647-0AH11-3AX0 1

15 Siemens - Sitrans P200 – pressure sensor (stage 1) 0-10 bar 7MF1565-3CA00-2AA1 1

16 Siemens - Sitrans P200 – pressure sensor (stage 2) 0-40 bar 7MF1565-3CE00-2AA1 1

17 Siemens - Sitrans P200 – pressure sensor (sleeve bearinge) 0-10bar 7MF1565-3CA00-2AA1 1

18 Honsberg – oil level meter (oil level) LCC1-AA126-65-NIYS-1 1

12.2019



12.2019Page 42


Fan2

Extruder3

Pump4

compressor5

Agitator7

Winders8

Filling line9

Tooling machine10

Support11

Drive (Triaxial)6


SIPLUS CMS Concept – Motor (Triaxial)

Overview

• Triaxial monitoring influences from

the process on the motor

• Monitoring of engine, transmission,

belt and fan

• From failure of individual drives to

complete system downtime (for

system-critical motors)

12.2019Page 43



maintenance work


identification




costs

• Cost savings




bearing damage



analysis

Application /



+Solution



Technical Topology for 2 Motors (up to 7 SM1281 for 7 Motors)

IEPE Sensor cabel

Ethernt / Profinet

Others

CPU 1214C SM 1281 CSM 1277

Speed Sensor (Bero)

Terminal box

Bearing NDE (radial)

Bearing DE (vertical)

Bearing DE (radial)

Bearing DE (horizontal)

PM 1207 SM 1281

Bearing NDE (radial)Bearing DE (radial)

Page 44

Bearing DE (vertical)

Bearing DE (horizontal)

Speed Sensor (Bero)

Main PC-Station

Programming device

SIMATIC Touch Panel

12.2019



Bill Of Material for two Motors

Page 45












12.2019



12.2019Page 46


Fan2

Extruder3

Pump4

compressor5

Drive (Triaxial)6

Winders8

Filling line9

Tooling machine10

Support11

Agitator7


SIPLUS CMS Concept – Agitator

Overview

• Motor monitoring

• Impact on the engine (long shaft)

• Replacement of the engine may be

very expensive due to the

placement of motor

• Stirring process as an important

process step affects other trades in

case of failure

• Product quality may suffer or entire

batches become unusable

12.2019Page 47



maintenance work


identification




costs

• Cost savings




bearing damage



analysis

Application /



+Solution


Page 48


Technical Topology

S7-1214C SM 1281 CSM-1277

Terminal Box

PM-1207

Max. 100m

Max. 30m sensor cable from

SM1281 to sensor

IEPE Sensor cabel

Ethernt / Profinet

Other

Gear unit (OUT)

Bearing Radial

Gear unit (IN)

Bearing Radial

Motor NDE

Bearing Radial

Motor DE

Bearing Radial

Sinamics G120

Main PC-Station

Programming device

12.2019



Bill Of Material

Page 49












12.2019



12.2019Page 50


Fan2

Extruder3

Pump4

compressor5

Drive (Triaxial)6

Agitator7

Filling line9

Tooling machine10

Support11

Winders8


SIPLUS CMS Concept – Winders

Overview

• Variable speed of the motor

• Motors are subject to an increased

radial load due to the weight of the

rollers

• Complete standstill of the

production if winder motor fails

12.2019Page 51



maintenance work


identification




costs

• Cost savings



is monitored for imbalance and

bearing damage



analysis

Application /



+Solution



Technical Topology for the winder

Gear

unit

SM4

Reel 2

Gear Unit

SM3

Real 2

Motor

SM1

Reel 1

Gear Unit

SM2

Reel 1

Motor

CPU 1214C

Reel

1

Motor Coupling

Terminal box on turnet armTerminal box

Hülsen-

spanner AS

Hülsen-

spanner BS

Gear

unit

Coupling

Hülsen-

spanner AS

Hülsen-

spanner BS

Automation-

networkMaintenance

network

ClientAccess

Point

Client

Motor

= bearings

Access

Point

Page 52

Reel

2

12.2019



Bill Of Material









8 IE FC RJ45 PLUG 180 2X2 6GK1901-1BB10-2AA0 14

9 SCALANCE W721-1 RJ45 (ROW) 6GK5721-1FC00-0AA0 2

10 SCALANCE W761-1 RJ45 (ROW) 6GK5761-1FC00-0AA0 1

11 Antenne ANT795-4MA 6GK5795-4MA00-0AA3 3

12 IE FC TP Standard Cable GP 2 x 2 (Type A), per meter 6XV1840-2AH10 1x 20 meter

13 InLine® WLAN cable, R-SMA-connector on R-SMA Coupling, 3m, bulk 40863 3

Page 53 12.2019



12.2019Page 54


Fan2

Extruder3

Pump4

compressor5

Drive (Triaxial)6

Agitator7

Winders8

Tooling machine10

Support11

Filling line9


SIPLUS CMS Concept – Filling line

Overview

• Often different speeds within the

system

• Complete standstill of the

production if motor fails

• Batches can be corupted

12.2019Page 55



maintenance work


identification




costs

• Cost savings




bearing damage



analysis

Application /



+Solution


CPU 1214C SM 1281

Terminal box

PM 1207 CSM 1277

SIMATIC HMI

Prgoramming device

SM 1281 SM 1281SIMATIC S7-1500

IEPE Sensor cabel

Ethernet


Technical Topology

Page 56

286 1/min

1400 1/min

25 1/min

Conveyor

Filling line

11 1/min

12.2019



Bill Of Material

Page 57












12.2019



12.2019Page 58


Fan2

Extruder3

Pump4

compressor5

Drive (Triaxial)6

Agitator7

Winders8

Filling line9

Support11

Tooling machine10


SIPLUS CMS Concept – Tooling Machine

Overview

• Produktionsmaschinen in

verketteten betrieben

• Oft hohe Motorumdrehungen

• Production machines operating in

interlinked processes

• Often high engine revolutionsHigh

motor-rotations

12.2019Page 59



maintenance work


identification




costs

• Cost savings




bearing damage



analysis

Application /



+Solution


IEPE Sensor cabel

Ethernt

Other

NCU & SINAMICS S120

CPU 1214C SM 1281 CSM 1277

Terminal box

PM 1207

SINUMERUIK Operate

(internal S7-300er

controler)

Programming device

SM 1281 CM 1242

Profibus-DP


Technical Topology

Page 60

Main motor

Gear unit

Main tooling bearings

12.2019



Bill Of Material

Page 61












12.2019


Siplus CMS: APC Cologne – competent knowledge & Support

...from the sensor to the cloud...

• Based on the SIPLUS CMS Portfolio

• Concept creation (from sensor to cloud)

• System integration (e.g. SIMATIC or Mindsphere)

• feasibility studies

• project management

• System Consulting

• Component Consulting

• Consulting on sensor technology & assembly

• Customer advice on site

• Customer acquisition (if required)

• Promotion of products and services

Technical Consulting & Promotion

• Commissioning on site

• Customized solutions

• Customer-specific instructions

• Workshops

• Remote support

Commissioning and training

Engineering and project support

• Design and definition of the necessary hardware and software components

• offers for services (Commissioning, workshops, etc.)

• On-site sales support for customers

• Technical contact for sales and customers

Sales support & offer preparation

CMS

Pre- sales

support

12.2019Page 62


12.2019

Siplus CMS1200 Concept

Additional information

Page 63

Additional information

Applicationexample:

Monitoring of vibration variables of a machine by a Condition Monitoring System SIPLUS CMS1200 SM 1281

https://support.industry.siemens.com/cs/ww/de/view/109480750

FAQ:

Which sensors can be used for SIPLUS CMS1200 SM 1281 and SIPLUS CMS2000 and how are they connected electrically and

mechanically?





For further information and support, please contact:

Mr. Le Nguyen Hoang Nam

Sales specialist

Digital Industries – Factory Automation

Siemens Vietnam

Mobile: (+84) 0917 017 744

Email: [email protected]

www.siemens.com.vn

www.facebook.com/Siemens.Vietnam

Thank you for your attention!

12.2019Page 64

Subject to changes and errors. The information given in this document only contains general descriptions and/or performance features which may

not always specifically reflect those described, or which may undergo modification in the course of further development of the products. The requested

performance features are binding only when they are expressly agreed upon in the concluded contract.

All product designations, product names, etc. may contain trademarks or other rights of Siemens AG, its affiliated companies or third parties.

Their unauthorized use may infringe the rights of the respective owner.

mailto:[email protected]

http://www.siemens.com.vn/

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