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Vibration Monitoring System for Cold Rolling Mills and Tension Leveler
Aluminium Processing Plant
The iba system provides a state-of-the-art condition and vibration monitoring system. Since it had been installed, many critical downtimes have been avoided.
The Challenge
Quality certainly equals money in the Aluminium processing business.
So, when a strip rolling mill was experiencing critical vibrations, it was a major issue for a leading aluminium processing plant in the Middle East. The iba system provides a state-of-the-art condition and vibration monitoring system. Since it had been installed, many critical downtimes have been avoided.
The Solution
Process data cannot be excluded when doing a critical evaluation for any process plant. In this case the data recording is performed by a ibaPDA system while the process analysis is performed on collected data with ibaAnalyzer.
The vibration monitoring however is performed on distributed edge devices. After acquiring the vibration data from accelerometers, the ibaPDA add-on ibaInSpectra is used to analyze this data. ibaInSpectra utilizes a frequency band analysis. Consequently machine, process and product data is used to eliminate quality problems related to vibration of the system.
The ibaInSpectra Condition Monitoring solution allows Aluminum processing operators to easily monitor its entire production motors with gears and predict their maintenance needs.
Omer Akhtar
System Engineer, iba Gulf
Key Features of the Used Components
The advantage however is the fact that in combination with the ibaPDA-ibaDAQ system it’s easy to collect process and vibration data simultaneously and continuously or specifically triggered.
ibaDAQ is used as stand-alone unit to acquire and record data. ibaDAQ integrates a complete ibaPDA system and an internal solid-state disk (SSD) with sufficient memory space. The central unit is the heart of the iba modular system. It is connected with 4 Analog input modules. Which connect with accelerometers to collect vibration data directly from Gear boxes and motors. All channels are sampled synchronously with a rate of up to 40 kHz.
ibaInSpectra is used to continuously monitor any vibrations in real time in order to thus detect possible sources of error early on. As ibaInSpectra is integrated ibaPDA, not only mere vibration analyses are performed, but also possible relations between vibrational effects and process behaviour is immediately detected. By means of spectrum analysis, vibrations are monitored online and set into relation to other process parameters. When vibrations become critical to machine health or product quality, the plant operator is alarmed. In addition, a feedback in the plant control is implemented to automatically adjust the corresponding parameters.
ibaAnalyzer-InSpectra is the corresponding Add-on to ibaAnalyzer. Here it’s used to perform vibration analysis on collected data. With ibaAnalyzer-InSpectra it’s possible to search in existing collected data for anomalies and early signs of problems. It can be integrated in the vibration expert’s workflow the same way as conventional analysis software of handheld vibration measurement devices.
Test the iba System Now!
Download the demo of ibaPDA and ibaAnalyzer and start optimizing your processes today. Try it free of charge for 30 days!
Request a ibaPDA-Demo LicenseUsed Functions
The following functions of the iba system are used in this success story.
- Process Connectivity
- Acquire & Store
- Analyze
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Frequently Asked Questions (FAQ)An effective vibration monitoring system requires a combination of high-resolution data acquisition and intelligent analysis. With ibaPDA, both process and vibration data are acquired synchronously, while ibaInSpectra performs real-time frequency band analysis. The integration of edge devices such as ibaDAQ or ibaM-DAQ enables decentralized data acquisition directly at the machine. This allows early detection and evaluation of critical vibrations.
Meaningful analysis requires the time-synchronous acquisition of all relevant data sources. With ibaPDA, vibration, process, and machine data are consolidated within a single system. ibaInSpectra analyzes these data in the frequency domain and identifies correlations between vibration effects and process behavior. This enables precise identification of root causes for quality issues or mechanical stress.
Preventing downtime relies on continuous monitoring and early detection of anomalies. ibaInSpectra monitors vibrations in real time and compares them against defined thresholds. In critical conditions, alarms are triggered automatically. In combination with process data, targeted actions can be initiated before a failure occurs.
Predictive maintenance requires long-term analysis of vibration trends and their evolution over time. With ibaAnalyzer-InSpectra, historical data can be evaluated in detail to detect early signs of wear. Continuous data acquisition with ibaPDA provides the necessary foundation. This enables reliable prediction of maintenance needs and optimized maintenance strategies.
The use of edge devices such as ibaDAQ or ibaM-DAQ enables direct data acquisition and preprocessing close to the machine. This allows efficient handling of high data rates while minimizing latency. At the same time, synchronization with centrally acquired process data is maintained. This improves data quality and enables rapid response to critical conditions.
An effective vibration monitoring system requires a combination of high-resolution data acquisition and intelligent analysis. With ibaPDA, both process and vibration data are acquired synchronously, while ibaInSpectra performs real-time frequency band analysis. The integration of edge devices such as ibaDAQ or ibaM-DAQ enables decentralized data acquisition directly at the machine. This allows early detection and evaluation of critical vibrations.
Meaningful analysis requires the time-synchronous acquisition of all relevant data sources. With ibaPDA, vibration, process, and machine data are consolidated within a single system. ibaInSpectra analyzes these data in the frequency domain and identifies correlations between vibration effects and process behavior. This enables precise identification of root causes for quality issues or mechanical stress.
Preventing downtime relies on continuous monitoring and early detection of anomalies. ibaInSpectra monitors vibrations in real time and compares them against defined thresholds. In critical conditions, alarms are triggered automatically. In combination with process data, targeted actions can be initiated before a failure occurs.
Predictive maintenance requires long-term analysis of vibration trends and their evolution over time. With ibaAnalyzer-InSpectra, historical data can be evaluated in detail to detect early signs of wear. Continuous data acquisition with ibaPDA provides the necessary foundation. This enables reliable prediction of maintenance needs and optimized maintenance strategies.
The use of edge devices such as ibaDAQ or ibaM-DAQ enables direct data acquisition and preprocessing close to the machine. This allows efficient handling of high data rates while minimizing latency. At the same time, synchronization with centrally acquired process data is maintained. This improves data quality and enables rapid response to critical conditions.
