Machine Monitoring Can be achieved by means of conventional manual monitoring based on experience and this process carries forward certain mistakes which can be controlled by means of proper visual aids by incorporating sensors and gauges.
Pressure: By incorporating gauges, transmitters & switches to the machine design parameters to control flow of hydraulic oil / system pressure generated on forward stroke or at the time of load application.
Temperature: Sensors / gauge incorporated can help to control oil temperature to be with in the limits, for instance if bearing temperature exceeds it’s recommended limit then the lubricating film fails and the damage can be severe to the extent of rotor damage and so on.
Flow: Sensors, Indicators & Switches gives an satisfactory operating condition to the operator preventing serious damage to tools in use. For instance if for any reason cooling water is not flowing through the coolant line this leads to the damage of the cutting tool & job in a machining process. Use of flow sensors / switches assures the job & the tools life along with criticality of failure analysis.
Displacement: Linear traverse of a process bed, cylinder, etc which are to be precisely controlled cannot be achieved by means of conventional methods and this can be replaced by means of LVDT & potentiometers which avoids human eye to hand errors.
Timers: Programmable Digital timers with display are recommended for sequential & cyclic operations and are best time managers compared to stop clocks and analog timers.
Load Sensors: Weight and load control is to be precisely controlled to prevent loss of money in terms of wastage of finished product( in case of FFS machines) by excess filling or spillage or damage to the job in case of compression or tension operations performed on the job.
Rotation Control: Rotation of the feed drive control is very much essential than latter process and the basic in cycle variation in excess or lower rotation leads to erroneous result of the manufacture process in progression. This can be better controlled with the help of absolute shaft encoder whose output signal is a analog signal which can be given as source to the controller or any other feed back device.
Automation: Data acquired by all these above referred sensors are given as a input signal to a data logger which has a direct printer port for quality control purpose along with PC connectivity interface so that the data acquired by this data logger can be retrieved from its memory and can be monitored on statistical view formats for quality & crisis analysis. Control action can be achived by providing relays to individual sensor inputs for feedback & corrective action.
For acheving on line correction module of PLC programmed with HMI will be a best solution.
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