Przemysław Moczko

Proactive Condition Monitoring of Low-Speed Machines

This chapter represents the principle of proactive approach in condition monitoring (CM) with a focus on low-speed machines. Comparison is made to the standard recommendations for CM, and the weak points of this approach when dealing low-speed machines are highlighted. The theory of a new concept for proactive CM is given.

Structural Modifications of Excavator’s Bucket Wheel by the Use of Numerical Methods

In this paper the character of loads exerted on bucket wheel was evaluated. The places of maximal stresses were determined by using finite element analysis. After this operation, a new wheel hub design was initiated. The first phase was related to development of new conceptions of the hub. The proposed conceptions were rated with respect to mass and total length of welds. This procedure led to selection of the most suitable design, which was optimized in order to minimize stress. The work at this stage consisted of continuous modification of the geometrical form, meshing of finite element model and structural analysis thereby providing information about stresses and deformations. The workmanship of the structural component and welded joints were defined according to DIN 22261 2:2006 standard.

Maintenance Management and Applied Strategies

This chapter describes the basics of maintenance management systems and key factors for successful organization and performance. It also points out the main characteristics of major maintenance strategies with their advantages and disadvantages.

Introduction—Review of Today’s Industry and Role of Condition Monitoring

Brief review of the condition, the new developments and trends in industry and related researches is given. Difference of today’s maintenance process and system with the adequate systems only a decade ago is given appointing to the fast-growing demands and responsibilities. The main reasons for the development of separate condition monitoring systems for low-speed machinery are given. A short intro of the contents of next chapters is also given.

Analysis of the Fatigue Fractures in the Eccentric Press Shaft

The paper presents selected aspects of stress analysis of eccentric press. This approach is based on the assumption that fractures can be present in the analyzed constructions. Calculations define the current state of the component with respect to fracture mechanics. Reported research work was performed using analytical, numerical and experimental methods in order to evaluate durability of the considered structural element.

Case Studies of Proactive Condition Monitoring Applications

This chapter presents practical case studies of applying the new proactive approach for condition monitoring of a cement rotary kiln as a typical example of low-speed machines. All required steps are given for the preparatory phase and the ongoing cycle of activities together with recommended proactive and corrective measures. Few real cases recorded in industry are given pointing to the proactive side of such condition monitoring system.

FEM in Proactive Condition Monitoring

This chapter presents application of FEM as a supporting tool for condition monitoring of existing equipments (technical assessment of condition, determination of best monitoring parameters, setting limits for early corrective actions).

Condition Monitoring Techniques for Low-Speed Machines

Review of condition monitoring techniques for low-speed machines is given describing their possible usage. Good practices for monitoring and technical assessment of new and already in use equipment for most frequently used low-speed machines in heavy-duty industry are given. How to obtain information for proactive actions from the listed techniques is explained. Special focus is paid on vibrodiagnostics as condition monitoring tool.

Field and Numerical Testing of the BWE SchRs4600.50 Dynamic Behavior

Surface mining machines are the largest mechanical engineering structures. Bucket wheel excavators operating in lignite mines are continually exposed to dynamic loads. Moreover, nearly all structures are over 10 years old. The methods used in design and construction did not cover the dynamic behavior of machines, which resulted in problems in their operation and decreased durability. The tendency to optimize and increase the operational time of machines is currently also visible in the field of surface mining. As a result the machines which have been operating for many years are subject to investigation. The SchRs (Schaufelradbagger auf Raupenschwenkbar) 4600.50 excavator, which is over 120 m long, 64 m high and weighs approximately 5,000 tons (excluding the dumping bridge), was investigated with regard to vibrations. Operational modal analysis was performed with 15 measurement points in different directions. This approach allowed to determine the variability of the dynamic characteristics of the machine in terms of operational conditions. Simultaneously a numerical model was prepared. Eventually, it was possible to compare and correlate both the numerical and experimental models and to establish the differences based on the operational load acting on the structure.