Mô tả:
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
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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
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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
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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
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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
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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]
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