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Detecting Critical Vibrations in Rolling Mills
Success Story
In rolling mills, many vibrations may occur that have negative effects on the life cycle and the state of the plant, but also on product quality. If wear and defects are detected early enough, appropriate counter-measures can be initiated for reducing waste and downtimes. Anyway, the user has to know exactly the vibration behavior of the plant and set it into relation to other process data from the plant.
In a cold rolling mill, the process data recording system ibaPDA has been used for process data analysis, but the vibration measurement data was evaluated separately. With ibaInSpectra as add-on to the ibaPDA system, the acquired vibration signals can be analyzed within defined frequency ranges. Simultaneously, processes with all machine, material and quality data can be monitored.
The Technology
Cold rolling mills show a complex vibration behavior, consisting of natural vibrations of the plant mechanics as well as excitations from the drive or bearings but also vibrations caused by defects. The aim of the monitoring is to detect vibrations that are caused by external excitation or faults. In this particular case, acceleration sensors on the chocks which serve as bearing for the rolls give insight into the vibration behavior of the whole stand. During normal operation, the natural vibrations of the stand are in the low-frequency range. High-frequency vibrations are an indicator for external excitation. With ibaInSpectra, these vibrations can be assigned to individual components.
The ibaMS8xIEPE samples the values of the vibration sensors at a rate of up to 40 kHz with 16-fold oversampling and make these values available to the ibaPDA system in digital form. With ibaInSpectra Expert modules, a freely configurable frequency band analysis in real time can be applied to the data. For every frequency band, characteristic values like peak, RMS and peak frequency can be determined. The system acquires data from the plant, such as speed, rolling force, torque, etc. time synchronously. The characteristic values of the frequency band and the process data can be used to draw conclusions about the cause of the undesired vibration.
ibaInSpectra can vary vibration-relevant process parameters online using the integrated alarm function, in order to keep the vibrations within reasonable limits. Additionally, the measurement data are visualized in real time with ibaQPanel on the control stand of the control system. Thus, the operator can initiate manual interventions in a targeted way.
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Vibrations in complex plants can only be understood with the unique combination of full-fledged vibration monitoring with process data.
Günter Spreitzhofer
Application & Consulting, iba AG
Used 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)Critical vibrations can be identified through high-resolution acquisition and frequency-based analysis. ibaPDA combined with ibaInSpectra enables evaluation of vibration signals across defined frequency bands. This allows differentiation between low-frequency natural oscillations and high-frequency fault-induced excitations. Specific components can be identified as root causes.
Accurate diagnostics require time-synchronous acquisition of vibration and process data. ibaPDA ensures that parameters such as rolling force, torque, and speed are aligned in time. ibaInSpectra then calculates frequency-based KPIs. This combination enables precise interpretation of vibration root causes.
False alarms often result from missing process context. By integrating process data into vibration analysis with ibaInSpectra, thresholds can be evaluated depending on operating conditions. ibaPDA provides the required contextual data. This significantly improves alarm accuracy and robustness under varying conditions.
Efficient integration requires compatible interfaces and modular extensions. ibaInSpectra can be added directly to ibaPDA as an add-on. This allows existing data acquisition infrastructures to be reused. No isolated systems or architectural disruptions are introduced.
Vibration KPIs can be used to directly influence process parameters. ibaInSpectra provides real-time alerts when thresholds are exceeded. In combination with ibaQPanel, data is visualized instantly for operators. This enables both automated and manual adjustments to stabilize the process.
Critical vibrations can be identified through high-resolution acquisition and frequency-based analysis. ibaPDA combined with ibaInSpectra enables evaluation of vibration signals across defined frequency bands. This allows differentiation between low-frequency natural oscillations and high-frequency fault-induced excitations. Specific components can be identified as root causes.
Accurate diagnostics require time-synchronous acquisition of vibration and process data. ibaPDA ensures that parameters such as rolling force, torque, and speed are aligned in time. ibaInSpectra then calculates frequency-based KPIs. This combination enables precise interpretation of vibration root causes.
False alarms often result from missing process context. By integrating process data into vibration analysis with ibaInSpectra, thresholds can be evaluated depending on operating conditions. ibaPDA provides the required contextual data. This significantly improves alarm accuracy and robustness under varying conditions.
Efficient integration requires compatible interfaces and modular extensions. ibaInSpectra can be added directly to ibaPDA as an add-on. This allows existing data acquisition infrastructures to be reused. No isolated systems or architectural disruptions are introduced.
Vibration KPIs can be used to directly influence process parameters. ibaInSpectra provides real-time alerts when thresholds are exceeded. In combination with ibaQPanel, data is visualized instantly for operators. This enables both automated and manual adjustments to stabilize the process.
