机器状态监测
概述
机器状态监测是监测振动和温度等参数的过程，以识别表明性能下降或即将发生故障的变化。它是预测性维护解决方案的必要组成部分，允许在发生故障之前安排维护，或采取其他措施来防止机器损坏和生产损失。除了改进维护计划之外，状态监测还提供了价值。例如，提高对机器操作的可见性可以指出产品缺陷的根本原因，并可以支持能源消耗的优化。
适用行业
- 设备与机械
适用功能
- 离散制造
- 维护
市场规模
2017 年机器状态监测市场价值 22.1 亿美元，预计到 2024 年将达到 35 亿美元，预测期内的复合年增长率为 6.7%。
到 2023 年，机器状态监测设备市场将突破 32 亿美元。
资料来源： P&S Intelligence
商业观点
机器状态监测的优势是什么？
- 提高机器可用性和可靠性
- 提高运营效率
- 改进风险管理（减少停机时间）
- 降低维护成本（更好的规划）
- 减少备件库存
- 提高安全性
- 提高了对机器状况的了解（可能的机器安全短期过载）
- 延长机器的使用寿命
- 改善客户关系（减少计划/计划外停机时间）
- 消除长期故障（根本原因分析和重新设计）
- 减少因维护或重新组装不当导致的大修后故障
部署挑战
在决定使用机器状态监控和故障诊断时必须权衡哪些缺点？
- 监控设备成本（通常很大）
- 运营成本（运行程序）
- 需要熟练的人员
- 需要强有力的管理承诺
- 通常需要大量的运行时间来收集机器历史和趋势
- 与增加的利润相比，降低的成本通常更难作为收益出售给管理层。
案例研究.
Case Study
Wireless Vibratory Data Acquisition System for Maintenance
In the framework of its predictive maintenance offering, ONEPROD part of the ACOEM group provides monitoring solutions that allow to avoid unexpected breakdowns in industrial production tools. Traditionally ONEPROD was using wired data acquisition systems. However they were costly and hard to install in harsh environments or explosive zones, like in the oil & gas and mining industry. To cover the distance to connect and power the monitoring equipment considerable lengths of cable are required especially in industrial spaces with difficult access. Developing a wireless data acquisition system became a key success factor in the ONEPROD strategy in order to avoid any cabling issue and to improve the safety of the staff in charge of portable measures.
Case Study
Smart SCADA-based Deployable Communications & Information System
Following the Fukushima incident in Japan, EDF-Energy NGL undertook a rigorous assessment into the resilience of its fleet of UK nuclear power stations against the highly unlikely occurrence of an extreme weather or other natural event. Through this process, they identified a requirement for the provision of mobile emergency response systems which will be deployed on the occurrence of such an event.
