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Aluminium Processing Plant

Vibration Monitoring System for Cold Rolling Mills and Tension Leveler

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.

Business Benefits

Correlating vibration data and machine data
by using one data acquisition system only

Easy integration
into an existing Condition Monitoring System

Avoiding
critical downtimes

The Solution


Process data cannot be excluded when doing a critical evaluation fo 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 the 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. The 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

iba Products


Measuring autonomously - Process connected - ibaDAQ
Línea ibaDAQ

Los dispositivos de la línea ibaDAQ permiten el registro de datos local con el sistema ibaPDA integrado y grabación de datos a bordo. Puede acceder a los datos e información relevantes en cualquier lugar en que sean necesarios gracias a las variadas opciones de salida.

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Analysis of vibrations - ibaInSpectra
ibaInSpectra - Monitorización de condiciones en tiempo real de las vibraciones de procesos

Con ibaInSpectra, se monitoriza de forma continua cualquier vibración y se pueden detectar posibles fuentes de errores en una fase temprana. Como ibaInSpectra está integrada en ibaPDA, no solo se pueden llevar a cabo análisis puros de las vibraciones, sino que también se pueden determinar las posibles relaciones entre los efectos de las vibraciones y el comportamiento del proceso.

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Offline vibration analysis - ibaAnalyzer-InSpectra
ibaAnalyzer-InSpectra

El ibaAnalyzer-InSpectra puede agregarse ahora para utilizar la potente librería offline de ibaInSpectra. Las configuraciones de análisis pueden ser primero diseñadas y probadas de forma offline en el ibaAnalyzer y transferidas al ibaPDA para un monitoreo de vibraciones en tiempo real.

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Key features of the used components

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.

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.

Vibration monitoring cold mill topology
|Vibration Analysis Atrás