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
Thingworx Helps EET Monitor Real-Time Energy Savings
Embedded Energy Technology (EET) wanted to build a dashboard for their customers to visualize the data analytics for the stream systems. They wanted the readings collected from the sensors to provide a complete picture of what is happening inside the component, and are displayed in a Web Portal that analyzes and presents the data in a concise format. The dashboard interface will also let customers set up email and text message alerts to be triggered when temperatures of the sensors customer select fall outside of the range they set. Summary reports are emailed monthly that highlight total energy savings, component health and month-over-month / year-over-year comparisons.

Case Study
American Eagle Achieves LEED with GE LED Lighting Fixtures
American Eagle Outfitters (AEO) was in the process of building a new distribution center. The AEO facility management team decided to look at alternate options for lighting layout that could provide energy and maintenance savings. AEO would need a full-time maintenance employee just to replace burned-out fluorescent tubes.

Case Study
Improving Instrument Recovery Time and Reducing Downtime
While in the midst of developing SYMPHONY®, a fully automated slide staining system for standard Hematoxylin and Eosin (H&E) staining, Ventana realized that they required a remote service solution to ensure that customers received an exceptional level of service. However, with a tight timeline to develop and launch this new product, there was some reluctance to integrate additional software. “There was some internal reluctance toward implementing the remote service technology with our SYMPHONY instrument given the short timeframe,” explains Greg Dameron, Director of Development at Ventana. “In fact, the executive team informed me that if the software would delay the SYMPHONY launch by even one day, then we would not implement it at all.” The company began evaluating commercial remote service offerings, seeking a solution that would provide value to customers without disrupting system stability. “Our products are based on stability, so we needed the remote service technology to be stable as well,” says Dameron. Ventana sought to reduce instrument downtime to fewer than 24 hours by remotely monitoring all field instrumentation on a 24/7 basis. This would enable the abilities to remotely diagnose and repair issues, provide “over-the-shoulder” troubleshooting and training for users, and track inventory to automatically replenish reagents in real time. “We felt strongly that delivering remote service would help us achieve a response time that we could not otherwise meet,” says Dave Flaten, Vice President and General Manager of the Primary Staining business unit at Ventana. “We believed that it would become an integral part of the product line.”