How can high-resolution data acquisition from VVVF drive systems in heavy-duty mobile machinery be used for fault analysis?

High-resolution, continuous data acquisition enables detailed analysis of transient fault conditions in complex drive systems, especially in VVVF-controlled motors. Using ibaPDA in combination with EtherNet/IP, PLC and drive data are captured synchronously as time series without the need for external triggers. Virtual signals can be used to generate calculated parameters for analyzing load distribution and coupling dynamics. The combination of raw and derived data enables precise identification of weaknesses in both control logic and mechanical components.

How can PLC problems in complex drive systems be systematically analyzed and resolved?

Systematic analysis is achieved by synchronously capturing all relevant control and process signals via EtherNet/IP and centrally processing them in ibaPDA. This makes it possible to clearly reconstruct temporal relationships between PLC logic, drive behavior, and mechanical load. Anomalies are identified through long-term recordings and analyzed in detail using ibaAnalyzer to develop targeted offline optimizations. The validated changes can then be verified in operation and iteratively refined.

What are the benefits of continuous, trigger-free data acquisition in industrial drive systems?

Continuous, triggerless data acquisition ensures that even short or difficult-to-reproduce events are fully captured. ibaPDA enables uninterrupted recording of all relevant PLC and drive data via EtherNet/IP, eliminating data gaps. This is particularly important for intermittent faults in couplings or load distribution systems that occur only under specific operating conditions. The complete dataset significantly improves both fault diagnosis and validation of control modifications.

How can EtherNet/IP be used to integrate PLC and drive data for condition monitoring?

EtherNet/IP enables direct integration of control and drive data into a centralized data acquisition system without additional proprietary interfaces. In combination with ibaPDA, all variables available in a Rockwell PLC as well as drive states can be captured and processed synchronously. This results in a unified data model for analysis, trending, and long-term storage in ibaAnalyzer. This end-to-end data integration forms the basis for condition monitoring and control-related optimization.

How can recorded drive data be used to optimize control algorithms?

Recorded drive and PLC data provide the foundation for offline analysis of control strategies and their impact on mechanical systems. With ibaPDA, this data is fully acquired and made available in ibaAnalyzer for detailed time and event-based analysis. By evaluating virtual signals, load distribution, acceleration phases, and fault conditions can be precisely reconstructed. Based on these insights, control algorithms can be specifically optimized and subsequently validated in operation.

Data Acquisition With ibaPDA and EtherNet/IP

Bucket Wheel Reclaimer Reeler Tuning

iba Oceania designed and implemented a data logging and analysis package to assist in fault finding and tuning of a Reclaimer Reeler control scheme. The Reelers on this machine had been historically problematic, causing production delays and damage to the drive system clutches.

Business Benefits The Technology Used Functions More Success Stories

The data analysis allowed the engineering team to clearly identify flaws in the existing control scheme. This allowed control improvements to be developed offline, designed to specifically target the issues identified in the data analysis. The new control program was installed and the iba system used to assist in commissioning and tuning the new control improvements. It has resulted in a significant improvement in machine reliability and productivity. The iba system has proved itself to be an invaluable tool for both engineers and operators to monitor and maintain their machine.

High speed data acquisition

allows for fast and accurate control system analysis and tuning

Data continuously recorded

without the need for triggering

Acts like a “black box”

for your drive system

The Technology

The Reelers are driven by VVVF drives, controlled by a Rockwell PLC. The iba system is connected to the PLC via an Ethernet/IP interface which allows monitoring of all the control system variables and drive control signals.

“Virtual” signals were used within ibaPDA to apply further processing algorithms to the raw PLC signals. Convenient and powerful data analysis in ibaAnalyzer helped to identify existing issues and to remove them.

ibaPDA is a PC-based system to centrally record data. The recording can be made to store data continuously or event based. The data is filed as so-called DAT files and can be analyzed, processed and archived with the ibaAnalyzer software tool which is free of charge. An efficient report generator allows for the creation of customized analytical reports. ibaPDA-Interface-Ethernet-IP allows for data to be captured using the Ethernet/IP protocol over TCP/IP for Rockwell PLCs.

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Used Functions

The following functions of the iba system are used in this success story.

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Frequently Asked Questions (FAQ)

How can high-resolution data acquisition from VVVF drive systems in heavy-duty mobile machinery be used for fault analysis?: High-resolution, continuous data acquisition enables detailed analysis of transient fault conditions in complex drive systems, especially in VVVF-controlled motors. Using ibaPDA in combination with EtherNet/IP, PLC and drive data are captured synchronously as time series without the need for external triggers. Virtual signals can be used to generate calculated parameters for analyzing load distribution and coupling dynamics. The combination of raw and derived data enables precise identification of weaknesses in both control logic and mechanical components.
How can PLC problems in complex drive systems be systematically analyzed and resolved?: Systematic analysis is achieved by synchronously capturing all relevant control and process signals via EtherNet/IP and centrally processing them in ibaPDA. This makes it possible to clearly reconstruct temporal relationships between PLC logic, drive behavior, and mechanical load. Anomalies are identified through long-term recordings and analyzed in detail using ibaAnalyzer to develop targeted offline optimizations. The validated changes can then be verified in operation and iteratively refined.
What are the benefits of continuous, trigger-free data acquisition in industrial drive systems?: Continuous, triggerless data acquisition ensures that even short or difficult-to-reproduce events are fully captured. ibaPDA enables uninterrupted recording of all relevant PLC and drive data via EtherNet/IP, eliminating data gaps. This is particularly important for intermittent faults in couplings or load distribution systems that occur only under specific operating conditions. The complete dataset significantly improves both fault diagnosis and validation of control modifications.
How can EtherNet/IP be used to integrate PLC and drive data for condition monitoring?: EtherNet/IP enables direct integration of control and drive data into a centralized data acquisition system without additional proprietary interfaces. In combination with ibaPDA, all variables available in a Rockwell PLC as well as drive states can be captured and processed synchronously. This results in a unified data model for analysis, trending, and long-term storage in ibaAnalyzer. This end-to-end data integration forms the basis for condition monitoring and control-related optimization.
How can recorded drive data be used to optimize control algorithms?: Recorded drive and PLC data provide the foundation for offline analysis of control strategies and their impact on mechanical systems. With ibaPDA, this data is fully acquired and made available in ibaAnalyzer for detailed time and event-based analysis. By evaluating virtual signals, load distribution, acceleration phases, and fault conditions can be precisely reconstructed. Based on these insights, control algorithms can be specifically optimized and subsequently validated in operation.