blog Archives - Page 15 of 19 - Reckers Mechatronics pvt. ltd.

Vibration and Temperature Based Machine Condition Monitoring Solution

Reckers Mechatronics provide Vibration and temperature based machine condition monitoring solution Faridabad, Haryana Based. Accurate, highly reliable, easy to use, and cost-effective real-time condition monitoring solution. Our condition-based monitoring solution is ideal for any kind of rotating machinery such as electric motors, gearboxes, pumps, etc. Measure and monitor vibration, and temperature with the greatest possible precision and get the right results. Vibration monitoring is very essential for the dynamic as well static machines in the industry point of view. In a running plant over the same platform every machine feels vibration under the tolerable limits. Hence monitoring of such vibration is very much required for long term use of machinery. Vibration and Temperature based Machine Condition Monitoring.

Highly integrated hardware and software that just works out of the box.

Vibration Based Condition Monitoring (VBCM) is a technique used to monitor the condition of machinery and equipment by analyzing vibrations. It is a non-invasive method that can detect faults and defects in machinery before they cause damage or failure. While vibration is recorded using frequency and amplitude, it is measured in terms of acceleration, velocity and displacement. These characteristics can be monitored with sensors and vibration analysis equipment. This equipment can vary regarding the elements it measures, as well as how it is measured. The five key elements of condition monitoring are data collection, data analysis, alert generation, maintenance planning, and continuous improvement. Data collection involves gathering information from sensors or monitoring devices.

Displacement of shaft with respect to its real axis, rotaional path displacement, x-axis/y-axis displacement of turbine shaft are very critically observant parameters for any rotational machine and we provide all such monitoring and control in our CONDITION MONITORING SECTION.

Vibration and Temperature Based Machine Condition Monitoring Solution

We provide condition monitoring in following type-

Solution

Developed a highly flexible & cost effective, designed for real time monitoring of overall (direct) vibration levels & we guarantee measurement accuracy within ± 2 microns with Allen Bradley world class Automation control system.

Hydropower(horizontal/vertical) turbine
Thermal power turbine
Extruder machinery
FMCG industries
Blower in heavy industries
Power motors
Diesel Generators turbines

An Ability to Track and Trace : Traceability

Traceability is the ability of a system to track and trace the every single part, product or batch through the complete manufacturing process. It starts from the movement when a raw material is entered into the manufacturing unit/ factory to the movement a final and finished product is ready for shipping.

This process of Traceability helps/allows the manufacturing units to digitally connect their each and every single part, product or batch to the Sub-assembly, the Main assembly and finally to the Final assembly. This is required and very much in need of the industries to maintain their products quality to save their brand image along with the sustenance in the markets competitive environment and to gather Customers Loyalty.

In Manufacturing Traceability systems are found in both part and batch production. There are four elements connected to the design of a lot-tracing system or batch-tracing-system:

Physical lot-integrity – This refers to the size of the batch of raw material and how good the integrity of the considered batch is maintained. This will determine the the perfection of the traceability solution considered.
Data collection – For Data collection there is requirement of Two types of data. One is Process data which will provide the process information and second is Lot-tracing data that will provide the information related to the movement of product batches.
Product identification – This refers to the connection of identified product data and process data.
Reporting – It is the use of generated data and visualization of same .

Soap and Detergent Process

Process Control

The process of controlling a series of events to transform a material into a desired end product is called Process Control.

Initially Industrial process control was performed manually by operators. Their sense of sight, feel, and sound were their sensors, which was making the process totally operator-dependent.

Industrial process control is now refined with computerized controls, automation, and accurate semiconductor sensors.

Soap Production Flow Chart

Soap Batch Process Dashboard

RM Section:

Ingredients are kept in DAY tanks and dispensed accordingly to Batch sequence as per selected Recipe by operator. User can Monitor and Control Both with the installed Load Cell as shown.

Dosing Process:

After Start Auto Batch / Auto Weighing time material discharge from DAY tank to fill weigh hopper and also controlled according to Batch step sequence as per selected recipe which is customized by user with specific Login ID.

Mixing Process:

All ingredients are mixed in predefined proportion and for particular time duration as per selected Recipe. Whole process controlled and monitored via SCADA or HMI.

Detergent Boon Mixer Process Dashboard

BOON Mixer

In BOON Mixer, Auto Batch Process are totally depends on the customized selected and controlled recipe which are filled from customer R&D department depending on product. Because user can use these type of Mixer for more than 3 products.

All Ingredients are dispensed and controlled by the selected recipe. User developed the mixing steps from SCADA as per Recipe and also depends on environmental condition.

Final product after completion of BOON mixing are transfer to Packaging line through Multi discharge conveyors which are also work on Priority based concept as per no. of Packaging Machines.

Batch Report:

This is the sample Report format which are normally used in Batch Process Plant and also customized as per End user requirement.

What is Digital Transformation ?

Digital transformation

The incorporation of digitizing the data introducing digital technology to the processes is known as digital transformation.

As per the words of Greg Verdino,

Digital transformation closes the gap between what digital customers already expect and what analog business actually delivers.

Digital transformation is a matter of survival. Nowadays, every industry wants to digitize its processes since it will result in their growth and thus will increase the revenue.

Benefits of Digital Transformation:

Technology is evolving at an exponential rate thus making the processes digitize will help to increase the revenue.
Through digital transformation, the data has become more useful, predictive maintenance is one of the key factors.
The importance is of data, not just big batches of data in fact real-time data, the data related to your ongoing processes and history of processes which helps the concerned person to make the right decisions which lead to innovation and success.
By using the information from real-time data, industries have transformed their process for improved customer satisfaction.

Digital transformation depends on data but the informative data depends on the collection of data, proper analysis of data, data security and also the application. Thus, the steps for digital transformation are:

Reasons to leverage IIOT Solutions

REASONS TO LEVERAGE IIOT SOLUTIONS

IIOT refers to the Industrial system which connects machine, people, systems of an Industry. It helps to create a new prototype. IIOT is the basic concept for Industry4.0. It is not about connecting the device with individual users. IIOT is about creating a connectivity system between machines, users, data,inventory, processes etc.

This connectivity system is connected to cloud where data is saved and data analysis done for required reporting and analysis of data.

Data can be provided to multiple users from the cloud and when the analysed data is available with concerned persons they can take required preliminary actions for more efficient processes.

Following are few reasons to leverage IIOT solutions in the Industry:

1. It helps to make system sustainable:

Since the concerned persons get real time information, report analysis etc.,they can take preventive decisions much on time, which in turn will effect the sustainability of the system.

2. Improvement in Operations:

The information received help in changing the operations if required for better performance and high reliability.

3. Customer Satisfaction

When the process systems works smoothly and efficiently it leads to better productivity and thus gains customer satisfaction.

4. Maintenance- No issue

With the help of analysed data, one can do preventive maintenance. Preventive maintenance helps to reduce the uncertain shut downs which had a huge impact on cost and production.

The Historical data is also helpful for preventive maintenance.

5. Remote Access:

To check the process data, reports, one need to be there in plant near the desktop. With the IIOT Application, one can check the information from anywhere through any device say mobile, tablet, laptop, the only thing required is user id and password of the required portal. This relates to time saving.

When the Industry works hand in hand with digitization, it brings to innovative changes in Industry which are Industry friendly as well as gains customer satisfaction.