mechanical fault finding techniques

Preventive Maintenance is done before a failure occurs and consists of maintenance types like: Time-Based Maintenance, Failure Finding Maintenance, Risk-Based Maintenance, Condition Based. Step 5 If a damaged wire is found, repair the wiring. %PDF-1.5 Why does MCP use a logical approach to fault finding? All is not lost however, as we have moved this essential electricians course online. Here, John Saysell, Training Director explains what was involved. Being non-static machines motors are subjected to electrical and mechanical stress.. Motor failures come in three basic types: electrical, mechanical . Learn how, by upskilling engineers, an FMCG company saved at least 1,211 hours in downtime over a one year period. How is a fault finding technique that works? 2023 Endeavor Business Media, LLC. Read on to find out more. Accurate findings from investigations require accurate knowledge. Get in touch if you need help finding the right course, or qualification, for you or your team. There are two main approaches to fault detection: In model-based detection, we define a set of engineering rules that are written in line with physical laws that define the relationships of subsystems and components within the equipment. <>/ExtGState<>/XObject<>/ProcSet[/PDF/Text/ImageB/ImageC/ImageI] >>/MediaBox[ 0 0 594.96 842.04] /Contents 4 0 R/Group<>/Tabs/S/StructParents 0>> If your company does not have a documented electrical safety program as required by NFPA 70E, you should encourage its creation. Providing your staff with abrasive wheels training is an essential part of reducing workplace injuries. Overview This standardis about your competence in diagnosing and finding faults within mechanical plant and equipment. Fault evaluation is a significant element of the overall process as it aims to understand the severity of the fault. By clicking Accept All, you consent to the use of ALL the cookies. More about in-house and tailored training. The cookie is set by GDPR cookie consent to record the user consent for the cookies in the category "Functional". h! The only thing they have left to do is fire up their computerized maintenance management software (CMMS), track the condition of their critical assets, and schedule appropriate maintenance work. The information that will really speed up the repair process is knowing the accurate location of the fault. Check the machine or system 5. Removing parts of the circuit and testing to see if the fault is still present can also be used to find ground faults. Based on these data signatures, the analysis can be made to predict the future health of the equipment. 3 Fault Diagnosis for Mechanical Drives The motion transmission systems play an important role in every engineering system because they are the ones which transfer the power developed by the actuating systems. Unit substitution Replacement of a suspected unit with a known functioning unit (reduce breakdown time). Ask someone to pick a card from a 52-card deck of standard playing cards. Is your card a queen? Another no, and we know the card is the jack of clubs. The cookie is used to store the user consent for the cookies in the category "Performance". What other benefits can a multi-skilled workforce bring. The purpose of fault identification is to understand the underlying failure mode, determine the size of the fault, and find its root cause. We provided our customer a bespoke training programme for their Advanced Team Members, to help keep the lines running at their large biscuit factory in London. For example, the result of the FDD for one piece of equipment could imply the rapidly increasing failure rates. If the cable has a discontinuity or high impedance, the portion of the signal will be reflected back to the test equipment or receiver. Analyse Information decide the probable cause. 3 What device can be used for checking electrical problems? Tell us your team's CPD needs and we'll come to you with a specialised training programme, customised for your engineering sector. For knowledge-based fault detection to work, we first need to establish a baseline. Identify which parameters need to be evaluated. Turn off the circuit breaker (the light will go out when you choose the right one). This cookie is set by GDPR Cookie Consent plugin. An example of this is when you first arrive at a piece of equipment, and you ask yourself if the problem is electrical or mechanical. Locate fault based on analysis, 4. Bag Length is too long. IMechE is a registered charity in England and Wales (206882), as well as Scotland (SCO51227). Film Unwind is Difficult. These steps include collecting evidence, analyzing evidence, locating faults, determining and removing causes, rectifying faults and running a systems check. In the early days, equipment maintenance was restricted to repairing faulty assets and performing basic routine maintenance based on rigid time intervals. CALCULATION OF FINAL MARK . Learn to risk and guarantee your work by doing something that actually works and has a solution and not only learn philosophical opinions with no solutions which are also good for. ", "Honestly - the customer support has been fabulous. In ManagerPlus, techs can see full historical records for . 4 0 obj This course suits managers and technicians responsible for the QA testing of metals and metal products. Whenever you're troubleshooting, it is extremely important that you follow all safety precautions and procedures. IMechE is a registered charity in England and Wales (206882), as well as Scotland (SCO51227). Here are six key points to consider: Collect the Evidence. Symmetrical faults. Leave one of your voltmeter leads on the relay coil opposite the switches. Visually inspect the system and look out for damaged wires and possible faulty components. Trace problems by going from plant to equipment item to sub-system. The programme explores the fundamental principles of commissioning. After analysis, the fault in the system is located with the aid of evidence analysis. 5OJ QJ ^J h! 9. This programme is suitable for engineers at all levels. Asking six questions eliminated 51 of the 52 cards. Fault diagnosis methods may differ, but the steps to follow are generally the same. How do I know my maintenance workforce is competent? Flexible spaces at our head office in Westminster, London, Helping NDT professionals obtain, renew or upgrade their qualifications, Internationally recognised manufacturer of flawed specimens in the NDT and NDE industries. Degegates will have developed a good working knowledge of basic fault finding techniques and methods which should make them more effective and efficient with problem solving faults on their workplace systems. What device can be used for checking electrical problems? This is also where I would have a quick look at the safety relay which has indication lights on it to indicate ready state or fault state. Put the other lead in the middle of the switches. Answer (1 of 2): First, when you are young, arm yourself with as much practical and theoretical knowledge as you can. Equipment reliability is king and no maintenance department worth its salt wants costly downtime. All the evidence collected must be relevant to the problem in hand. As we fully integrate Limble we expect to see more benefits and increase our response and completion times. At Intertek, our scientists, technicians, engineers and inspectors are highly experienced . Turn the electricity back on. In short, fault detection and diagnostics play a decisive role in optimizing the maintenance regime for any piece of equipment, across its lifecycle. Maintenance of plant and equipment in engineering . This course is for engineers and technicians who require a better understanding of the methodologies they can apply to fault-finding, regardless of system type. Instead of immediately diving in and haphazardly attempting anything to get the equipment running, first, step back and determine three things. This is done to improve the accuracy of isolation and reduce the impact of downtime. It is important to ensure that the machine, equipment or system is functioning normally after the cause of the fault and the fault itself has been dealt with. Half-split those by checking three, then two, then one and you're there. Our Training Director, John Saysell, is at it again! required to diagnose faults on an engineered system involving two or more of the following interactive technologies: mechanical, electrical, fluid power or process controller, at sub-assembly/component level. The third blog looks at an example of safety in the workplace. The programme explores the fundamental principles of commissioning. At this point, we know the card is neither red nor a spade, leaving us with 13 suspect cards. This is the third crucial skill for troubleshooting: half split, measure, and move. CJ( OJ QJ ^J aJ( !j he UhmH nH sH u!j h! Robin Pain was originally trained to service colour TV, and has worked as an industrial fault finder for . This obvious first step is often overlooked. FREE RESOURCES FOR PROFESSIONALS AND STUDENTS, [Tool: Work Ticket + Root Cause Analysis Worksheet], Work ticket + root cause analysis worksheet. Bag Length is inconsistent. We won't track your information when you visit our site. > J L I q` 0 bjbjqPqP 8( : : Z ^ @ @ @ @ ( ( ( ( $ L , 2 2 1( 1( 1( 42 62 62 62 62 62 62 $ 3 h O6 f Z2 1( % 1( 1( 1( Z2 @ @ o2 * * * 1( F @ 42 * 1( 42 * * 0 h 1 x $ ( w( p \1 2 2 0 2 l1 X 6 ( 6 1 6 1 T 1( 1( * 1( 1( 1( 1( 1( Z2 Z2 * 1( 1( 1( 2 1( 1( 1( 1( D ( ( @ @ @ @ @ @ Six-point Technique Six point technique Visual examination Examine gather and analyse visual evidence of the plant or process that isnt operating or functioning correctly. The Limble team is very quick to respond to any questions and they are very open to suggestions. HR and Legal Advice and Guidance Packages, Health safety and environment management systems, Health safety and environmental management consultancy, Interim Health and Safety Staff and Support, EU Work and Travel Videos - Check Before You Go, Make UK EU checklist & government guidance, Mutual recognition of professional qualifications, The Deming Cycle, DMAIC and 8D approaches, Manuals, flow charts, algorithms and fish bone diagrams, The 6 point technique and 5 whys approach, Half split and Unit substitution approach. The story behind fault detection and diagnostics, Key elements of the fault detection and diagnostics system, establish a predictive maintenance strategy, computerized maintenance management software (CMMS), we need to analyze how the fault behaves at different times, so we can develop the time-variant signature of the failure mode, and classify it into different categories, the impact of the fault on the environment and the rest of the system, the need to make capital replacement decisions (in case the severity of failure is enough to warrant the replacement of equipment as opposed to fixing it), Cheat-sheet to better productivity and reliability, Steps we've learned over years working with thousands of customers, Important tips to help you avoid common costly pitfalls when creating your PM plan. Visually inspect the machine. More about in-house and tailored training, Design and development of processes, systems, services and products - For Chartered Engineers: Apply appropriate theoretical and practical methods to the analysis and solution of mechanical engineering problems Putting this approach into practice, I remember one instance when I was called to the scene of a machine that was down. It may not always be parts of a circuit you're trying to eliminate. Removing parts of the circuit and testing to see if the fault is still present can also be used to find ground faults. The observation of safe working practices. Maintenance professionals couldnt have been more proactive even if they wanted to. Chiew Seng Chung When you cannot locate a fault in plant or equipment of which you are familiar, you need to progressively trace the failure. Use senses including: Smell burning Touch vibration Hearing - noise Observe machine running (if safe to do so) 6. This is also referred to as "fault isolation", especially when emphasizing the distinction from fault detection. Half-splitting can also be used in all types of circuits, not just series-wired switches. Our courses have been delivered across the UK and around the world. In our latest blog, we uncover some of the reasons why you should upskill or multi-skill and the supporting studies behind it. Advertisement cookies are used to provide visitors with relevant ads and marketing campaigns. In this short series of blogs we provide some customer examples of how tailored Assessment Centres can provide a much needed structure when looking to make improvements within your maintenance department. From MCPs extensive training portfolio, Lifescan selected the dedicated on-site training option for their technicians and operators this held at Lifescans facility in Inverness. More often than not, the underlying failure modes are mechanical in nature and associated with the rotary part of the motor: shorted rotor windings, bearing failures, and rotor breakdown. The next question solves the problem. We now know the card is a club (8 or higher). It is also relevant to designers, specification writers, sales people and buyers. If there is no fault, proceed to the next step. The returned pulse signal from the cable simultaneously indicates the presence and the location of fault through time and velocity of the returned pulsed signal. Once the collection is complete, an analysis to consider the validity of the information collection begins. Upon completion, the technician will display skills in methodical electrical troubleshooting and PLC fault-finding techniques. It could also save you money, especially injection would rcd testing as you inject a fault current to trip it and i thin k so testers may sample certain test mathematically. Next available: This is the first place where your knowledge of the system you are troubleshooting comes into play; if you cannot trace the path of a signal (a flow, or data, or even . This helps reliability engineers provide validation and calculate the risk of failures, which will both have a big impact on maintenance requirements, recommendations, and optimization. Locate the Fault. In an automated packaging system, errors may be rare, but they do happen. On existing plant add-in the equipment you need for problem-solving. make measurements or collect other evidence, 2. The six point fault finding technique has six steps: 1. Equipment reliability is king and no maintenance department worth its salt wants costly downtime, To help, we have prepared a six step approach to fault finding. 20% : 4. Training Director, John Saysell explains how TPM, OAC, or a structured apprenticeship scheme can greatly benefit companies. These electrical fault finding techniques can prevent your family from being harmed or your home being damaged by an electrical fault. During the course of assessing more than 1,000 candidates over a 15 year period, MCP has found fault finding to be the second biggest weakness in maintenance trade tests. In the same period, 17.9% of technicians will also retire. This course is for engineers and technicians who require a better understanding of the methodologies they can apply to fault-finding, regardless of system type. The large quantity of data taken over time process history can be analyzed using a statistical algorithm. Your next step is to half-split once again. At least, the way I see it: There are 9 types of maintenance split between Preventive Maintenance and Corrective Maintenance.
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