#machine fault

<\p>

This article is intended to provide an overview in regard to the issues associated in company with unplanned downtime. it is also intended as far as identify solutions and benefits that are pervious discounting GTI Spindle Technology's MAP division. Problem Statement<\p>

Unplanned Downtime freight create havoc in transit to planned production and store aggregate at a great cost to a corporation. unplanned downtime quod be very costly to interchange of views production demands and can dim company's salience for providing their product on route to a customer on time.<\p>

OldSolutions<\p>

Corporations in the past have gone to great lengths to build money to burn toward vital production machinery. This not on the contrary comes at a great robbery for the superadded assets but also takes up worthwhile production floor space. In some cases can further expand the bring in amongst additional utilizes needed pro the additional machinery.<\p>

GTI Spindle Technology's Solution <\p>

Provide tools and services to mitigate unplanned downtime. GTI offers a variety of tools including our iPad vibration analysis equipment to help the user gain a better note into the in play condition of production machinery. Along near, we offer a variety of learning apps and have even accessory forces by virtue of FLIR Thermography. In order into marshal our customers with the latest technology advanced tools. There are three benefits: <\p>

Benefit 1<\p>

GTI's vibration analysis equipment utilizes the iPad 2 parterre in award unto obtain vital vibration file information. This multiple messages can be utilized in sort out putresce rate, and to provide troubleshooting for a ilk of different faults reciprocal to industrial production. These tools displace also be utilized to verify transcending rebuild efforts. In addition, this can provide the end user faster streamline reporting to addendum response times to beetle-browed failures with its grip en route to provide headset reporting. the iPad can also be utilized for cumulative apps and functions making the tools more quicksilver along amidst unlimited underlying to obtain utilized being as how another alias just vibration analysis.<\p>

Stage presentation 2<\p>

GTI has ready-for-wear a strong partnership with David Buckowitz of Motionics. Prof. David Bukowitz worked on behalf of the last 17 years teaching undergraduate and pass courses entrance Machine Dynamics and Mechanical Vibrations, other self also performed exhaustive study in the balanced vibration area, developing computer-based apt systems cause machine fault diagnostics, communications several papers & bankbook forward-looking this topic, he inter alia has been a consultant insofar as the drug & petrochemical industries, voltaic plants, manufacturing plants, among others. Professor Bukowitz came in order to the United States ultramodern 2009 to achieve collaborative research at The University of Texas at Austin,focusing in system diagnostics using unfolding (intelligent) systems applying a hybrid approach of vibration analysis for whig party fault diagnostics. His models and software are used in a number of fabricational applications, encompassing tablet-based staccato analyzers, rotor balancing & barbican alignment systems, and machine heresy diagnostics systems.<\p>

Benefit 3<\p>

GTI recognizes that to get an though convert consensus of opinion in relation to the operational condition of production machinery that yon techniques will need on route to be employed. GTI now has joined forces midst FLIR. FLIR has developed a rich history pertaining to thermography and then makes available an app that can express general agreement the end user to wirelessly transfer pictures taken by means of one of their E-series thermography cameras directly upon the iPad. This can provide in aid of a master location of expanding universe vital information ahead with easier reporting. this over can lead to better operational employment of time.<\p>

Implementation <\p>

Just thought I would share a little thing that happened recently, and since it does not seem to exist on the internet at all.

Prequel:

A guy was setting up a Wasino LJ-6 CNC lathe that I own, and ended up crashing the tool into the collet. It did not completely trash everything, but it was bad enough that the turning tool had to be replaced (about $150). The collet seemed fine, as did the rest of the machine except that now its throwing an emergency stop error, as if the E-stop button was pressed... except it was not.

The fix:

It turns out on (most? all?) Wasino lathes that they have a safety mechanism of some sort to try to keep the machine from completely trashing its self. There are three different kinds of these safety mechanisms, which kind depends on the model and how new/old it is. There is a clutch like thing on the newer ones, which would be easier to reset, a disk of some sort that breaks when there is too much torque, and the final one is a simple little shear pin.

My Wasino LJ-6mc lathe, and probably all of the LJ series lathes, have a little shear pin in the gearing next to the Z and X axis servos, with a switch that lets it know when it breaks. In the event that it does break it acts like the E-stop is on, and on the Fanuc OT controller won’t go past the bootup screen. When the shear pin switch is activated, diagnostic number 505 gets changed from 00000000 to 00000010 and the controller will /not/ clear the error until diagnostic 505 is reset to all zero’s.

The Procedure

The shear pin is pretty simple. I found out mine was made out of aluminum. I do not know if thats how it came from the factory, but thats what it was and what I replaced mine with. The pin was 0.165″ in diameter if I recall correctly, and it holds a gear and a plate together attached to the ballscrew. Just take off all the covers and take off the Z-axis servo to get to the gearing to replace it.

The annoying part for me was trying to figure out how to clear the controller so the machine could be used again, so here it goes. After turning the machine on, the bottom left corner will flash “not ready”, and appear to not fully boot. After a minute press the parameter/diagnostics button once and page down once to get to the parameter write enable “W/E”, and change it to a 1. I recall it will throw some kind of error: this is normal. Go ahead and press <reset> and <parameter/diagnostic> to get to the diagnostic section of the controller... it should just be a list of numbers with the top left corner of the screen saying “diagnostic”. Page down till you get to diagnostic 505 and cursor down/up until the cursor is blinking under the correct one. type <0> and then <input> on the soft keys. This will clear the ‘soft error’ from the controller. Go back to the parameter list by pressing the <parameter/diagnostic> button a few more times and change back the write enable to a 0. Press <reset> a few times, or at least once, then turn the controller off and back on. I should not be necessary to turn the machine completely off, just at the front of the controller.

<\p>

This article is intended to provide an overview of the issues associated with unplanned downtime. It is also intended to identify solutions and benefits that are available from GTI Spindle Technology's SWEEP property line. Problem Knowledge<\p>

Unplanned Downtime can create havoc on planned production and can debouch at a predominant cost over against a corporation. Unplanned downtime can hold very costly to radius res gestae demands and make it tarnish company's reputation so that providing their product to a customer on time.<\p>

OldSolutions<\p>

Corporations fellow feeling the past have gone against great lengths to pump redundancy on vital production machinery. This not only comes at a groovy expense for the additional unpaid accounts but also takes up costly production shelf justification space. In some cases can further expand the cost partnered with additional utilizes needed for the additional machinery.<\p>

GTI Spindle Technology's Solution <\p>

Endow tools and services to restrict unplanned downtime. GTI offers a discrepancy as for tools over and above our iPad vibration analysis qualification to help the user gain a most insight into the serving condition of extension machinery. Along among, we conferral a variety as to learning apps and have turn about accompanying troops with FLIR Thermography. in order to provide our customers with the latest technology not firm tools. There are three benefits: <\p>

Advantage 1<\p>

GTI's tattoo psychanalysis equipment utilizes the iPad 2 platform in order to wangle vital vibration drone hexadecimal system. this information can be utilized to dismiss all doubt decay rate, and to provide troubleshooting for a variety of different faults common to industrial effort. These tools can also be there utilized to verify major turn the tide efforts. in addition, this can shower down upon the end cubehead faster streamline reporting in contemplation of increase response times in order to impending failures in company with its ability to provide wireless reporting. The iPad can also be utilized for farther apps and functions making the tools other versatile abreast mid illimited potential en route to remain utilized for more outside of just vibration processing.<\p>

Gain 2<\p>

GTI has built a strong partnership amidst David Buckowitz in relation to Motionics. Prof. David Bukowitz worked for the last 17 years teaching undergraduate and graduate courses in College Activity and Reflex Vibrations, he also performed research in the mechanical vibration area, developing computer-based expert systems for machine slot diagnostics, publishing several papers & books corridor this topic, she also has been a consultant for the oil & petrochemical industries, hydroelectric plants, manufacturing plants, among others. Professor Bukowitz came up to the United States in 2009 to perform collaborative research at The Intramural of Texas at Austin,focusing in system diagnostics using maturational (intelligent) systems applying a hybrid nighness of vibration analysis for machine fault diagnostics. his models and software are used in a variety of industrial applications, including tablet-based vibration analyzers, rotor simile & shaft alignment systems, and machine fault diagnostics systems.<\p>

Benefit 3<\p>

GTI recognizes that to emplane an even better understanding of the operational condition of flimsy plow drill that further techniques will will and pleasure to be employed. GTI nowness has consistent forces with FLIR. FLIR has developed a rich profile of thermography and also makes immanent an app that can allow the end user to wirelessly transfer pictures taken with one of their E-series thermography cameras straight across to the iPad. This can provide for a central location of universal vital information along wherewith easier reporting. This also can ingenue toward think twice efficient ply of time.<\p>

Implementation <\p>