Preventative measures are always preferable to dealing with costly fixes. Plants and factories with high-end machinery need assurance that their machines will run with ease. This means continual production lines with no lag in output and no dangers to workers.
This smooth operation isn’t always a guarantee. There is always the chance that machines, with all their belts and rotating parts, can develop faults. Electrical issues can also put productivity and safety in jeopardy. So, it is important to make sure that all machinery receives regular checks to locate potential faults.
Thermal imaging can help to locate problems, although thermal cameras have their limitations. The ongoing developments in high-tech sensors and wireless devices will continue to improve their potential.
Thermal Imaging The Best Solution For Preventative Maintenance
- Why is preventative or predictive maintenance so important?
- How does thermal imaging work in this situation?
- Why are semi-fixed thermal sensors so helpful in improving results?
- Why should companies look into wireless tech in these systems?
Why is on-going maintenance so important?
- Repair Costs
- Production Down Time
- Worker Safety
Once technicians locate these overheated areas or faulty elements, they should be repaired or replaced. The sooner this happens, the better the impact on production within the plant. The more minimal the impact and damage, the lower the overall cost. It is much easier to lubricate those bearings when starting to overheat than to replace machines when broken. There is also the issue of the overall longevity and durability of the equipment. No plant owner wants to jeopardize that. Rotating equipment is both specialized and costly. This means a strong need to avoid replacing systems until absolutely necessary. Finally, there is a worker safety element. The more unpredictable and combustible a machine, the higher the risk to users.
How do thermal imaging cameras help in this situation?
The only way to truly understand the problem with overheating equipment is to see it with our own eye. Obviously, this is only really possible with the right visual equipment. Thermal imagers have the potential to help with predictive maintenance in many areas. These include the following:
- overloaded electrical systems
- blocked fluid systems
- poor insulation in low slope roofs
- faults in a range of mechanical systems
Technicians find it hard to detect problems in rotating equipment without the use of these thermal cameras. It is all about finding abnormal heat signatures that signal a malfunction in one of the components. Sometimes this comes from the friction generated between bearings and couplings, which in turn leads to heat. At other times there can be electrical failures. This friction on the mechanisms is the sign of a machine no longer performing at best because of a fault. Undetected faults can later develop into much larger problems. These problems may be more difficult to fix and potentially dangerous for any workers and technicians involved.
Source: Ferret.com.au
How do these thermal systems work?
Thermal cameras see the world differently. They turn heat signatures into visual images, creating a scene we can better understand. The finished image highlighted areas of a piece of machinery in different colors. These tones represent the heat produced at the time of the capture. Some tones are likely too cold with blue and other dark tones. These areas aren’t overheating, or are perhaps dormant. Others will be warm and red due to more intense activity. Then there are bright white areas that indicate more extreme heat. This is where problems are most clear. These anomalies literally shine like a beacon alerting users to problems. This is where faults and malfunctioning parts have led to overheating and greater risks.
Thermal imaging preventative maintenance takes a lot of effort and training.
The subtle signs of developing problems often don’t show up to the untrained eye. Experienced users with the right training can spot these anomalies with ease. Dedicated technicians are essential when dealing with these problems and pieces of equipment. It takes time for skilled employees to gain experience and knowledge to better determine problems.
Users need a strong understanding of radiometry, heat transfer and other functional capabilities. There is a choice here. The first option is to continue to bring in these skilled workers to run these predictive maintenance checks. This is a tried and tested solution with good results. The other is to turn to a new form of technology with some extra benefits.
How can semi-fixed thermal sensors help with modern approaches to thermal imaging?
Semi-fixed thermal sensors are a new approach for improved predictive maintenance. The approach above relies upon technicians. They detect and analyze problems with their specialized equipment. The benefit here was expertise and high-end equipment for the best results. The downside was the wait between scans. Problems only arose when technicians looked for them. It was predictive, but only within a short time frame.
Semi-fixed systems change all that. These solutions provide round the clock surveillance of a site. Technicians and managers on-site can deal with issues as they arise. This could lead to improved response times and better maintenance in the long run. The best systems are adaptable to suit the site’s needs.
The benefits of this approach include:
- better troubleshooting
- improved data monitoring
- hands-free systems with long lives
- greater ease of use
Better troubleshooting-
The use of a semi-fixed system means regular feeds of information about the machinery. There is a clear timeline of data, with a greater range of individual images over a longer time frame. This level of accuracy and context means it is much easier to spot the problems. This leads to a better understanding of plant productivity and machinery in action. This, in turn, means better troubleshooting. Problems are then identified with ease for better solutions.
Improved data monitoring-
These ongoing feeds allow plants and factories the ability to monitor data from these feeds more easily. This should help to provide a better idea of the health of the productivity of machinery over time. The more that technicians know about there machinery and system more generally, the easier it is to make changes. This could lead to some important long-term improvements to the site as a whole. There is also the chance for a greater amount of data on different factors too. Users can look at temperature, voltage and other aspects of performance.
Hands-free systems with long lives-
These semi-fixed sensors are portable battery-powered devices that require minimal human interference. They can run for up to 10 hours at a time, which is enough for a full day of productivity within a plant. The small size of these battery-powered options means that they stay out of the way wherever required. So, users don’t have to do much with them except change the battery and upload the data.
Ease of use-
These sensors are also much easier to use. There isn’t the hassle of calling in technicians with their own personal tools, or in using more high-tech systems now and then. These sit in an ideal location and get on with the task. They are also easily mounted to different surfaces. Users can mount them with magnets, brackets or whatever else is convenient. Magnets often make the most sense here because of all the metal machinery in the plant. A small, strong magnet extends installation possibilities.
The Future of Thermal Imaging
There are some key areas of technological development that manufacturers can use, meaning that these thermal imaging sensors can further improve. Developers that harness all components should ensure that the advantages of the technology are improved.
We can lookout for the following:
- smaller devices for portability and ease of use
- good battery lives
- improved imaging
- better software for data correlation
- improved connectivity
1. The Size Changes
Technology has a trend towards smaller, more convenient pieces of tech. This is sure to be as true for these sensors and thermal imagers as other components. A smaller size increases the potential for placement and portability. These smaller devices will fit in gaps and allow for better angles to monitor important equipment.
2. The battery-Life
Battery life is also very important here. It is essential that these devices can last as long as possible without the need to change the battery or recharge a device. Removable batteries are preferable in this situation, as it means the device can stay in place. Longer battery life means that there is less chance of the camera powering down and for any lost images. Developments in nanotech mean that batteries now last significantly longer, but shrink in size. Therefore, we can expect some long-life, portable thermal imaging cameras in the future.
3. Improved imaging
This all allows for more time and power to produce more images of the machinery in action. Improvements in software mean that the image capturing capabilities should also improve. The clarity of the image is one key area to consider. The sharper the definition and the clearer the area of interest, the better the chance of detecting problems. Then there are the colors and tones that the cameras detect. It is important to have a broad spectrum to work with. It isn’t enough to have a red patch, yellow patch, and white patch. This only leads to three categories of the health or failure of the machine. The tones between, and a noticeable shift in time, means a clear signal of degradation of machinery.
4. Better data correlation
Then there is the chance to turn the readings into usable data. Skilled technicians have the knowledge to understand the readings of different colors. Improves data readout and software from these systems make the devices more accessible to other users. The technicians and plant owners want a concise report on any problems and solutions in the shortest possible time frame.
5. Wireless thermal imaging sensors
Wireless thermal imaging sensors send captured images to the cloud via Bluetooth or Wi-Fi connectivity. This makes it easier to help with data transfer, shared knowledge, and remote solutions to see all the data. Devices send images to off-site technicians and experts that can analyze problems without looking at the machine. They can send data to managers in head offices, so they can understand plans and costs without coming on site. This speeds up processes and keeps people on the same page. Therefore, this should mean a better chance at fixing problems in a time-efficient, cost-effective manner.
Where possible, it is better to take workers out of the equation, rather than bring them in. One choice here is a technician with specialized equipment. This means checking potentially dangerous machines with site supervisors. The alternative is to let the devices capture data remotely, with no need for human interaction. The latter is clearly preferable for many reasons. It cuts down the costs of manpower, saves time wasted waiting for call outs and improves safety.
Source: FLIR Systems
Interpreting Thermal Readings
Every object has a distinct heat signature. An object’s infrared radiation is used in thermal imaging to improve the visibility of objects in the dark. Thermal imaging receptors detect an object’s rendition and create an image based on that information. Thermal imaging can penetrate any obscurants such as smoke, haze, and fog. Thermal imaging works for Maintenance & Repair without ambient light since it detects the heat signature of an object. The thermal camera (Thermal imager) is a heat sensor that is capable of detecting the slightest differences in temperature.
Since objects are rarely precisely the same temperature as other objects in their immediate environment, the thermal camera catches them, and they appear as a clear thermal image. Thermal imaging is, therefore, a powerful way of monitoring rotating equipment due to the heat they produce.
Using Thermal Imaging To Monitor Gearboxes
Gearboxes are used in many industrial machines to vary the speeds of electric motors. Thermal imaging comes in to detect and protect overheating which is caused by a lack of lubrication due to small amounts of lubricating oil. In the past, the maintenance method for gearboxes entailed a regular check on oil levels and replenishing when approaching critical levels. Checking oil levels in machines is a dangerous affair since the gearboxes are often in hazardous locations or inaccessible.
A thermal imager can be used to scan the surface temperature of the gearboxes on every critical equipment as determined by key operations, safety personnel, and maintenance. With this scan, it is possible to assess all assets whose malfunctions would threaten people, product or property. It is important to capture thermal images as well as digital images of the vital gearboxes. Even inaccessible gearboxes can be assessed by thermal imaging involves no contact.
The highest priority for repairs should be given to equipment that poses a safety risk. Monitoring provides an analysis of the cost of repair lost labor costs and lost production opportunity. When an overheating gearbox is discovered the thermal image provides hints as to why there is an abnormal operating temperature. Thermal imagers provide images using color to each pixel in an electronic image with particular surface temperature. For these gearboxes and motors, overheating indicates a looming breakdown.
Using Thermal Imaging To Monitor Motors
A motor should be monitored while it is working under normal operating conditions. The exterior surface temperature captured by a thermal imager is indicative of temperatures inside the motor. The motor gets hotter on the outside with each rise of temperature inside. Most motors are designed to work in temperatures below 40 degrees Celsius.
Each motor monitored has a nameplate which indicates the maximum temperature allowed beyond the ambient temperature of that motor. For each motor, monitoring should be based on the cost of the motor, labor required to change the motor and the time lost on a particular line because of motor failure.
Troubleshooting Gearboxes and Motors
Troubleshooting is a way of fixing common problems especially applied in the repair of failed processes after monitoring and identifying the possible causes of failure. There are different reasons why motors and gearboxes malfunction and the possible solution for each failure is different.
A motor might fail due to voltage overload. It typically happens due to a high-resistance connection in the switchgear or motor connection box. It can be pinpointed through infrared and confirmed using either a power quality analyzer or a multimeter. The other problem that would cause motor failure is bearing failure. When monitored, impending bearing failure is shown in images that indicate an overheating bearing.
Vibration analysis helps to determine the best course of action which would be to replace or lubricate the bearing. If the gearbox is found to be overheating, maintenance personnel can organize for follow-up measures by checking levels of oil, the metal content in the oil and oil quality. Alternatively, they can perform vibration analysis.
The Need For Preventative Maintenance in Factories and Plants
No matter how much we develop machinery, we still need to maintain it and keep plants and worksites safe. This means that these ongoing developments in thermal imaging for rotating machinery are welcome. These improvements to wireless capabilities and semi-fixed system are game-changers. Ongoing upgrades to imaging, battery lives, software, and fixtures are vital. They will help to increase efficiency and data analysis. The more remote and intelligent these devices, the better the chance of preventing disasters in the workplace.
It is important to have a regular inspection routine and save the thermal images on a computer to track measurements over time. That way it is easy to pinpoint hot spots and give them special attention while in the case of repairs, it becomes easy to follow up and know whether they have been successful.
I love the thermal imaging camera and have searched about that for a long time. It’s no doubt that it brings many benefits even sometimes, it can help to detect the cancer disease. It will become much more prevalent in the future, for sure.