As the complexity of applications is increasing, the need for maintenance and expertise grows. Optimizing an application goes beyond selecting the right equipment. Danfoss’ latest Condition Based Monitoring (CBM) technology offers a solution that prevents production delays as well as unexpected failure before it occurs.
This embedded drive software function monitors deviations from baseline values, using sensor data and drive edge computing. The frequency converter becomes the sensor, detecting faults and notifying users.
To make this function easier to understand, we will use a demonstration setup. An iC7 frequency converter is used to control the speed of a motor that drives a pump circulating water in a closed circuit. This setup can simulate a couple of faults, that we usually come across: fault in the motor winding, vibrations and load envelope deviations. This is achieved using a switch, handle and valve mounted in the demostration setup.
The switch can be used to create a fault in the motor winding. The drive detects this problem at an early stage, and the operation can continue without noticeable difference, but maintenance can be scheduled and prepared.
The handle on the demonstration box will lift the motor mounting plate and create a misalignment leading to an increased vibration level. With this, we are simulating mechanical faults. Besides misalignment, the feature can detect any fault that is causing the overall level of vibration to increase, e.g., fan/pump unbalance, resonances, looseness, component breaks etc.
The valve can reduce the water flow, simulating a change in the load of the pump. This application monitoring is obtained by the feature called load envelope. The drive learns the normal load curve first and then detects significant changes during operation.
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