Tài liệu Fab 12 availability reliability and maintenance strategies

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Sustainable Manufacturing and Factory Planning Availability, Reliability and Maintenance Strategies 14.04.2017 Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl © IWF TU Berlin Page 1 Table of Contents  Maintenance Development and Application  Definitions  Availability  Reliability  Methods of Reliability Analysis  Literature and References Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 2 Table of Contents  Maintenance Development and Application Definitions Availability Reliability Methods of Reliability Analysis Literature and References Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 3 Historical View on Maintenance Approaches Maintenance Low IT Systems High Repair Service Inspection Improvement TPM1 Group-oriented and quick response maintenance Conditioned & computer based maintenance Diagnosis-oriented maintenance Preventive maintenance in fix intervals Maintenance by craftmen Repair of failures Corrective Preventive Predictive Aggressive maintenance maintenance maintenance maintenance Craft 1900 Mechanization 1950 Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Taylorism 1970 Automatization 1990 Production Systems Cell Flexible 2010 Source: [Bie-11], [DIN13306], [Swa-01] Note 1): TPM: Total Productive Maintenance Page 4 Maintenance Strategy Overview Maintenance After failure Before failure Preventive maintenance Corrective maintenance Planned maintenance Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Condition-based maintenance Prognostic maintenance Source: [DIN-13306] Page 5 forbes.com autoweek.com imagejuicy.com Cost Maintenance Adapted to Individual Needs Minimal cost  Maintenance measures are ignored or inadequately performed  Minimal effort, but maximal damage Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl  Regular maintenance which depends on the condition of machine  Cost effective, while only defective parts will be replaced Time  Replacement of worn components – independent of real condition  Effective, but expensive; high reliability of machine Page 6 Maintenance Strategy: Driving Until Breaking  Corrective maintenance chh150845.wordpress.com  After failure / breakdown Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 7 Maintenance Strategy: Preventive Maintenance powerserviceinc.com terapeak.com olympicequipment.com  Before failure to prevent breakdown Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 8 Maintenance Strategy: Condition Monitoring of Machine  Identify when system will break  Targeted monitoring and information collection  Continuous monitoring evaluation systems  High expenditure  Continuously active  Use reliabilityweb.com  Firmly installed on machine measurement and  To protect against fatal damage  If just for short reaction time  Scheduled monitoring  Measurements in regular intervals on location  Systematic evaluation is implemented on a central computer, not on the machine Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Source: [Kol-08] Page 9 Motivation for Condition Monitoring  Operation of production equipment requires measures for condition monitoring to ensure proper assembly process  Downtime must be minimized for cost reasons sdt.eu  No unforeseen failure  Identification of the failure principle to act quickly to correct  Knowledge about relationships between process data to identify and predict failures  Requirement of condition diagnosis / prognosis festo.com  Physical parameters for CM  Current, voltage, humidity, temperature, pressure, acceleration, distance, position, ...  Partly already available in machines, for example machine control unit  Others can be acquired via sensors Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 10 Diagnosis, Prognosis for Production Equipment  Diagnostics and prognosis are tools  for providing maintenance decision support  to gain knowledge about the usage and status of a Photo: Kuka  applied to quantify the reliability analysis  Required knowledge  When next failure?  Why did failure occur? Photo: Bosch product in case of physical changes to plan maintenance activities Robot Assembly tool  Equipment monitoring  Get operating conditions of equipment by sensor  Product and process-integrated information systems  Diagnosis for proper therapy  Forecast for timely therapy Conveyor belts Robot tool Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Source: [Sel-08] Page 11 Example: Condition Monitoring of a Damper  Damper diagnostic by integrated strain gauge sensor (measuring deform forces on axis)  IT-based OnBoard diagnostics Strain Gauge Sensor OnBoard Diagnostic Unit Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Diagnostic Software to determine failure characteristics Page 12 Example: Condition Monitoring of a Wind Turbine  Wind Turbine diagnostic by integrated strain gauge sensor  IT-based OnBoard diagnostics  Cloud-share information system Wind Turbine Sensor Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Cloud shared information Diagnosis for the operating system net-soft.biz inhabitat.com Input Data for diagnosis Analysis and Diagnostic Software to schedule maintenance activities Page 13 Example: Condition Monitoring of a Robot Cutter Tool for Disassembly Application  Measuring  Forces on plunger (strain gauge sensor) Diagnostic unit Energy module  Distance of plunger to be moved in  If blades getting blunt, higher Cutter module forces measured  If plunger not fully moved in, process may failed Diagnostic unit Functional Schematic of Cutter Tool Evaluation Software: plunger Energy module Cutter module Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 14 Life Cycle Unit Structure of Supervision Condition Based Monitoring of Standard Components Factory Damper Bearing Brake Motor Machine Life Cycle Unit (LCU) Concept Machine module Standard components Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Source: [Buc-05] Page 15 Table of Contents Maintenance Development and Application  Definitions Availability Reliability Methods of Reliability Analysis Literature and References Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 16 Definitions  Reliability  Availability  Defined as the probability of no essential failures by keeping a unit from processing a specific function under certain conditions at a specific point of time. [DIN-40041]  Probability that system works under the required conditions for a specific time. Availability Measurement of a state to perform as and when required, under given conditions, assuming that the necessary external resources are provided Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl  Defined as the probability that an item will perform a required function without failure under stated conditions for a stated period of time. [Ber-04]  Sum of influences of a unit, according to its ability to meet the appropriate requirements during the time interval and under the given conditions it applies. [VDI-4001] Reliability Measurement for the provision to perform a required function under given conditions for a given time interval Source: [Ber-04], [DIN-13306], [DIN-40041], [VDI-4001] Page 17 Importance of Availability and Reliability  High cost for machine downtime  Life Cycle Costs  Consequential damages Periodic preventive maintenance Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl www.turbocare.com www.danobatgroup.com  About 255 billion Euro has been spent in in Germany for maintenance in 2009 [Eic-11] Gas turbine inspection Source: [Con-90], [Eic-11], [Kuh-03] Page 18 Definition and Demarcation ‘Maintenance’ DIN 31051 Maintenance Maintenance Activities to conserve and recover the nominal condition as well as to determine or assess the actual condition of the technical means of a system Preventive Maintenance Overhauling Measures to preserve the desired condition of the technical means of a system Measures to restore the nominal condition of the technical means of a system Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Inspection Inspection Measures to identify and assess the actual condition of technical means of a system Source: [DIN-31051] Page 19 Further Definitions in DIN 31051 Failure Termination of the ability of a unit to perform a required function. Functional performance Meet the defined requirements in the production of a unit under consideration. Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Functionality Error State of a unit in which it is unable to perform a required The ability of a unit for function; excluding the functional performance inability during due to its condition. maintenance / planned activities or due to the absence of external support. Source: [DIN-13306], [DIN-31051] Page 20
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