ULTRASOUND IS MORE THAN A LEAK DETECTOR By Deborah Hays Dmax Ltd.
Dmax Ltd. We machine and assemble the Duramax Diesel Engine for General Motors Heavy Duty Trucks.
Machining Side of the Plant Cylinder Block Cylinder Head Crank Shaft FLIR Systems 97.0 F 80 68.7
Assembly Side of the Plant Short Block Head Sub-Assembly Main Test Dress
Dmax Predictive Maintenance Team 1 Mechanical Service Tech (Me) 16 years maintenance 6 years predictive 1 Electrical Service Tech 15 years maintenance 1 year predictive
Infrared-Flir P65 Predictive Tools Vibration Analysis-Emerson/CSI 2130 Motor Circuit Analysis-All Test Pro On and Off line testers Ultrasonic-UE Systems Ultraprobe 10,000
ULTRASOUND & BALLSCREWS WITH THE UE 10,000 PROBE
Block Line Transfer Machines CB-10 ST12 X-axis BALLSCREW FLIR Systems Sp1 88.1 F 88 86 84 82 80 78.3 CB-20 ST15 X-axis BALLSCREW FLIR Systems Sp1 89.7 F 85 80 77.8
Problem 90.3 F 90 Ballscrews Failing Yearly Sp3 Sp1 Sp2 85 80 78.8 Gearboxes Failing 6 months FLIR Systems Quality Issues Machine not holding tolerances
COSTS CB-10 ST12 Ballscrew-$13,598.00 Gearbox-$5,000.00 Quality- Priceless CB-20 ST15 Ballscrew-$17,682.93 Gearbox-$7,000.00 Quality- Priceless Too Expensive
SOLUTION Use Ultrasound to Trend Ballscrews
CB-10 & CB-20 BALL SCREW TRENDS CB-10 ST12L BALL SCREW TREND 10-22-10 CB-20 ST15 BALLSCREW TREND CHART 7-29-09 DB'S 80 70 60 40 30 20 41 42 38 37 39 41 43 45 40 37 51 48 45 68 69 67 64 64 2/23/2008 6/23/2008 10/30/2008 2/4/2009 9/3/2009-1 9/3/2009-2 9/11/2009 6/9/2010 DB'S 80 70 60 40 30 20 74 45 75 69 30 68 10/8/2008 10/28/2008 1/13/2009 1/14/2009 1/15/2009 7/29/2009 10 10/22/2010 10 0 W-AXIS POSITION Z-AXIS 0 X-AXIS BALLSCREW
CB-10 & CB-20 BALL SCREW TRENDS AFTER REPAIRS CB-10 ST12L BALL SCREW TRENDS 4/6/11 After Ball Screw Replacement CB-20 ST15 BALLSCREW TREND CHART 1-5-11 DB'S 80 70 60 40 30 20 10 0 51 48 45 41 42 3837 39 41 434543 40 41 37 W-AXIS AXIS 686967 64 64 Z-AXIS 4846 2/23/2008 6/23/2008 10/30/2008 2/4/2009 9/3/2009-1 9/3/2009-2 9/11/2009 6/9/2010 10/22/2010 10/25/2010 4/6/2011 DB'S 80 70 60 40 30 20 10 0 74 45 75 69 68 30 X-AXIS BALLSCREW 35 56 47 10/8/2008 10/28/2008 1/13/2009 1/14/2009 1/15/2009 7/29/2009 8/5/2009 6/1/2010 1/5/2011
ULTRASOUND & GEARBOXES
WHY ULTRASOUND? WHY NOT VIBRATION ANALYSIS? ULTRASOUND IS MORE THAN A LEAK FINDER 10 COMPONENTS ON VIBRATION ROUTES VS. 2 TECHS = 1 CHECK P/YEAR ULTRA + VIBE = 3 CHECKS P/YEAR VIBRATION FOLLOW-UP IS A MUST
GEARBOX ULTRASONIC TRENDS CB-120 SPINDLE GEARBOX ULTRASONIC TREND 12-10-08 90 80 DB'S 70 60 40 30 20 CB-120 13L CB-120 10R CB-120 10L CB-120 3R CB-120 3L WARNING LIMIT FAULT LIMIT 10 0 Jun-07 Dec-07 Jun-08 Dec-08 DATE
VIBRATION DATA
CB-120 ULTRASONIC CURRENT TREND CB-120 SPINDLE GEARBOX ULTRASONIC TREND 2-14-11 90 80 DB'S 70 60 40 30 20 CB-120 3R CB-120 3L CB-120 10L CB-120 10R CB-120 13L CB-120 13R WARNING LIMIT FAULT LIMIT 10 0 Oct-07 Jun-08 Oct-08 Apr-09 Nov-09 Feb-10 Nov-10 Feb-11 DATE
ULTRASOUND & TRANSFERS
TRANSFER BEARING TRENDS CB-120 TRANSFER BEARINGS CB-130 TRANSFER BEARINGS DB'S 56 54 52 48 55 52 51 53 51 48 52 53 CB-120 BEARING TRANSFER DB READINGS DB'S 60 58 56 54 52 57 55 55 51 56 53 58 CB-130 BEARING TRANSFER DB READING 46 48 44 STATION #1 STATION #2 STATION #4 STATION #6 STATION #8 STATION #9 STATION #11 STATION #12 STATION #14 STATIONS 46 STATION #1 STATION #3 STATION #4 STATION #6 STATION #7 STATION #10 STATIONS STATION #11 STATION #13 CB-140'S TRANSFER PILLOW BLOCK BEARINGS 9-23-08 80 70 70 65 60 60 61 DB'S 40 30 40 39 37 47 CB-140 TRANSFER PILLOW BLOCK BEARINGS FRT CB-140 TRANSFER PILLOW BLOCK BEARINGS REAR 20 10 0 STATION #2 STATION #5-#6 STATION #9 STATION #12 STATIONS
TRANSFER GEARBOX TRENDS CB-120, CB-130, CB-90 & CB-20 TRANSFER ADVANCE & RETURN GEARBOX CB-120, CB-130, CB-20, & CB-90 TRANSFER LOWER & RAISE HYDRAULIC CYLINDER 100 100 DB'S 90 80 70 60 40 30 20 10 45 24 82 CB-120 TRANSFER ADVANCE AND RETURN GEARBOX DB READING 7-29-08 CB-130 TRANSFER ADVANCE AND RETURN GEARBOX DB READING 7-18-08 CB-20 TRANSFER ADVANCE AND RETURN GEARBOX DB READING 8-1-08 CB-90 TRANSFER ADVANCE AND RETURN GEARBOX DB READING 9-24-08 DB'S 90 80 70 60 40 30 20 10 80 83 55 47 CB-120 TRANSFER RAISE AND LOWER HYDRAULIC CYLINDER DB READING CB-130 TRANSFER RAISE AND LOWER HYDRAULIC CYLINDER DB READING CB-20 TRANSFER RAISE AND LOWER HYDRAULIC CYLINDER DB READING CB-90 TRANSFER RAISE AND LOWER HYDRAULIC CYLINDER DB READING 0 CB-120 CB-130 CB-20 CB-90 BLOCK OPERATION 0 CB-120 CB-130 CB-20 CB-90 BLOCK OPERATION 100 90 80 CB-120 TRANSFER ADVANCE & RETURN GEARBOX 7/18/08-7/29/08 90 80 70 60 CB-140 TRANSFER DRIVES 9-23-08 72 DB'S 70 60 40 30 CB-120 TRANSFER ADVANCE AND RETURN GEARBOX DB READING 7-18-08 CB-120 TRANSFER ADVANCE AND RETURN GEARBOX DB READING 7-29-08 DB'S 40 30 20 45 CB-140 TRANSFER LOWER & RAISE MTR/GEARBOX 9-23-08 CB-140 TRANSFER ADV & RETURN MTR/GEARBOX 9-23-08 20 10 0 1 7/18/08 7/29/08 10 0 CB-140 TRANSFER LOWER & RAISE MTR/GEARBOX 9-23-08 MOTOR/GEARBOX CB-140 TRANSFER ADV & RETURN MTR/GEARBOX 9-23-08
TRANSFER GEARBOX FOLLOW- UP CB-140 TRANSFER DRIVES FOLLOW-UP 10-30-08 80 70 72 DB'S 60 40 30 20 45 47 60 CB-140 TRANSFER LOWER & RAISE MTR/GEARBOX 9-23-08 CB-140 TRANSFER LOWER & RAISE MTR/GEARBOX 10-30-08 CB-140 TRANSFER ADV & RETURN MTR/GEARBOX 9-23-08 CB-140 TRANSFER ADV & RETURN MTR/GEARBOX 10-30-08 10 0 Raise & Low Adv & Ret TRANSFER GEARBOX
Ultrasonic Benefits Non-intrusive PM Most Ballscrew Servo Drives are accessible while machine is running, if not check can be completed within 5 min. 0 like components make trending a snap. When problems are found follow-up work is done on 3 rd shift with no production downtime! With 10 hundred spindles, gearboxes, pumps, and motors Ultrasound is a must.
RESULTS TOTAL PDM COST SAVINGS 2005-2007 TOTAL PDM COST SAVINGS 2008 $30,000,000.00 $30,000,000.00 $25,536,000 $25,000,000.00 $25,000,000.00 $20,151,000 COST SAVINGS $20,000,000.00 $15,000,000.00 $10,000,000.00 $5,000,000.00 $- $15,800,000 $6,000,000 $3,700,000 $36,000 Technology ULTRASONIC COST SAVINGS MCA COST SAVINGS IR COST SAVINGS VIBRATION COST SAVINGS TOTAL COST SAVINGS YTD COST SAVINGS $20,000,000.00 $15,000,000.00 $13,400,000 $10,000,000.00 $5,900,000 $5,000,000.00 $336,000 $515,000 $- Technology ULTRASONIC COST SAVINGS MCA COST SAVINGS IR COST SAVINGS VIBRATION COST SAVINGS TOTAL COST SAVINGS YTD TOTAL PDM COST SAVINGS 2009 TOTAL PDM COST SAVINGS 2010 $30,000,000.00 10,000,000 $9,196,000 $25,000,000.00 9,000,000 8,000,000 COST SAVINGS $20,000,000.00 $17,000,000 $15,000,000.00 $10,620,000 $10,000,000.00 $5,000,000.00 $5,000,000 $180,000 $1,200,000 $- Technology ULTRASONIC COST SAVINGS MCA COST SAVINGS IR COST SAVINGS VIBRATION COST SAVINGS TOTAL COST SAVINGS YTD COST SAVINGS 7,000,000 6,000,000 5,000,000 4,000,000 3,000,000 2,000,000 1,000,000 0 $4,200,000 $3,600,000 $1,200,000 $196,000 Technology ULTRASONIC COST SAVINGS MCA COST SAVINGS IR COST SAVINGS VIBRATION COST SAVINGS TOTAL COST SAVINGS YTD
Summary Non-intrusive PM s are the key to keeping production running without excessive downtime and still maintaining the machinery s integrity. Trending is the key ingredient to using ultrasound effectively. Trending specific components enables maintenance to replace only those components nearing failure. By finding failures before they are critical, companies not only save money by not having collateral damage, the job is planned so downtime is a minimal. Parts are ordered well in advance and no special shipping charges apply. Parts are ordered when they are needed. Inventory is kept to a minimum.
Lessons Learned 0 Ballscrews is a lot of trending! Have an open mind! We aren t always going to be right! Try all your PDM tools on all components See what fits best! PDM technologies work best when they are used together to identify problems and their solutions!
Achievements 2009 Published in May 2009 Issue of Hydraulics & Pneumatics Magazine: Reducing Hydraulic System Temperatures Published in Inframation 2009 proceedings: IR Trending and 1HP Motors 2009 S ULTRASONIC PROGRAM OF YEAR BY UPTIME MAGAZINE Published in Solutions 2.0 2009 proceedings: Ultrasonic Inspections on Ball Screws, Gearboxes, and Transfers 2010 MCA Plant-wide Published in Solutions 2.0 2010 proceedings: How Dmax Ltd. became an awarding Predictive Maintenance Organization 2011 Steve James Keynote Speech Solutions 2.0 2011: From Surviving to Thriving How Dmax survived the economic downturn to thrive today. Published in Solutions 2.0 2011 proceedings: PDM and Production Partnership, Dmax teamwork at it s best.
THANKS DMAX, Ltd. Maintenance & Production DMAX, Ltd. Leadership for allowing us to think outside of the box Dwight Richardson, Larry Stevens, & BJ Thornbury (Past and Present Predictive Techs)
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