ConAUTO

Condition Monitoring for the Automotive industry

February 2013
PRFTECHNIK Condition Monitoring GmbH

Why PRFTECHNIK?
PRFTECHNIK has many years of experience in automobile
manufacturing facilities:

PRFTECHNIK is global player: Europe, Americas, Asia, Africa, Middle &

Far East, etc

Very skilled and experienced employees, continuously trained

Has proven and real application know-how, as well as great experiences

with proven and properly performing portable instruments & online
systems installed in many reference plants around the world,

On critical assets: conveyor drives, presses, lift and carry units, fans,
pumps, motors, etc.

Offers reliable and professional condition monitoring devices:

Online condition monitoring systems

Offline (portable) condition monitoring instruments

Provides a software platform that handles all data: from online and offline
vibration measurements, alignment measurements, oil particle counter,
etc

Supports customer with its Service & Diagnostic Center experts,

analyzing customers measurement data, giving certain diagnostics that
locate the source of damages and therefore increase productivity and
decreases still stand time.

PRFTECHNIK Condition Monitoring

Products & Services

Condition Monitoring instruments & software:
Online condition monitoring systems

Offline (portable) condition monitoring instruments

Provides a software platform that handles all data: from
online and offline vibration measurements, alignment
measurements, in addition also IR pictures, oil analysis
data, etc

Online misalignment monitoring with PERMALIGN

Reliable expert support and services for your mine

Diagnostic services
Special measurement tasks
Torque measurement
Telediagnostic services
Temporarily telemonitoring with online CMS*
Online torque measurements

PRFTECHNIK Condition Monitoring

*CMS = Condition Monitoring Systems

Products & Services

Measurement instrumentation

Offline data collection: VIBROTIP, VIBSCANNER and VIBXPERT.

Online protection systems: VIBREX, VIBROTECTOR

Online monitoring systems: VIBNODE, VIBROWEB XP, VIBROWEB and

VIBRONET Signalmaster, WEARSCANNER Particle Counter, VIBCONNECT
RF and VIBGUARD

Correction solutions: balancing tools & alignment systems

OMNITREND software

Storage of measurement data, evaluation and reporting platform

One multi user database and graphical user interface for all the field systems

Additional condition information like oil analysis data, alignment data,

thermographic pictures etc. are stored in the same database

Interface to Maintenance Management systems using Web Services

Ideal tool for big co-operations as data can be exchanged and reporting can be
done over the Internet using Web Services. This will help a great deal for groupwide reliability engineering

Fully compatible to WIN 98, 2000, NT, XP, Vista, 7 and open for the future

Diagnostic Services

Services provided by the experts of PRFTECHNIKs Service & Diagnostic

Center (SDIC)

PRFTECHNIK Condition Monitoring

Application Examples

PRFTECHNIK Condition Monitoring GmbH

NISSAN Sunderland Plant (UK)

Paint Shop
The plant is the UKs largest car producer and exporter

PRFTECHNIK Condition Monitoring

NISSAN Sunderland Plant (UK)

-

Application

On line trend monitoring and FFT analysis of key air handling systems, air re-circulation fans for ovens, air supply fans
and variable speed fans.
All systems are crucial to the operation of the paint shop, and to the quality of the finish on the cars. Parameters to be
measured at all motor drives and fan bearing housings were vibration and bearing condition.
VIBRONET was chosen because of the ability to measure both parameters from one transducer thus cutting down the
installation time and costs dramatically. Also the ability of the system to measure on line the FFT spectra from each
point was important.
Installation
The complete online CMS includes 132 points, using 2 VIBRONET Master systems, 16 multiplexer, 1 Signal Master,
VIB 6.122 insulated transducers. Maximum cable run in this application were 750 meters, all cables run in instrument
cable trays or 25 mm stainless steel conduit. The online CSM were located in the paint shop control room. Alarm
violations are flagged up on the PRFTECHNIK software and analyzed using FFT online by engineers accessing the
CMS on the local Nissan Intranet. Nissan HTML pages were supplied by PRFTECHNIK as the front-end picture for the
Signalmaster software.

PRFTECHNIK Condition Monitoring

NISSAN Sunderland Plant (UK)

PRFTECHNIK Condition Monitoring

BMW Conveyor drive (Dingolfing /

Germany)

Measurement points on the

planetary 2-stage low
speed gear: assembly line
drums

PRFTECHNIK Condition Monitoring

BMW Paint Shop (Dingolfing / Germany)

Exhaust fans 1-4
2)

3)

Air intake fans 1-3

LAN

1)

Ethernet
TCP/IP

1)

4)

3)

MUX 111

VIBRONET
Signalmaster
VIB 5.901

5)

4)

Warning
System o.k.

MUX 112

SPS

PRFTECHNIK Condition Monitoring

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AUDI Paint Shop monitoring

(Germany)

A total of two VIBRONET Signalmaster installed

in the paint shop covering about 170
measurement points. Installation of first online
system was in 2002.

PRFTECHNIK Condition Monitoring

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Daimler AG - Test rig for four axis

45
46

VIBNODE 1

VIBNODE 2

VIBNODE 5

MS 1 -12

MS 13-22

MS 45-52
47
48

11

17
18

13

15

14

16

35

37

36

38

19
20

10

12
21
22

Fahrtrichtung

23

25

27

29

39
40
33

31

41
42

24

26

28

30

32

34

43
44

49
50

VIBNODE 3

VIBNODE 4

MS 23 -34

MS 35-44

51
52

-BA_Beschleunigungssensor (52 Stck)

PRFTECHNIK Condition Monitoring

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Body Shop Condition Monitoring

Body shop line from
Volkswagen Passat

PRFTECHNIK Condition Monitoring

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Sample GUI of online CMS

VIBRONET - Online Condition Monitoring

Verbindung

Transferpresse TP4 - Hauptantrieb

System

Schwingungsaufnehmer
B-Seite

Riemenscheibenlager 2
Antriebswelle 2

Zusatzbremse
Antriebswelle 1
Riemenscheibenlager 1

YE1131

Riemenscheibenlager 1

C-Seite

-00000.0 [mm/s] -00000.0 [m/s-2]

YE1132

Riemenscheibenlager 2

C-Seite

-00000.0 [mm/s] -00000.0 [m/s-2]

YE1133

Riemenscheibenlager 1

D-Seite

-00000.0 [mm/s] -00000.0 [m/s-2]

YE1134

Riemenscheibenlager 2

D-Seite

-00000.0 [mm/s] -00000.0 [m/s-2]

YE1111

Antriebswelle 1

C-Seite

-00000.0 [mm/s] -00000.0 [m/s-2]

YE1112

Antriebswelle 2

C-Seite

-00000.0 [mm/s] -00000.0 [m/s-2]

YE1113

Antriebswelle 1

D-Seite

-00000.0 [mm/s] -00000.0 [m/s-2]

YE1114

Antriebswelle 2

D-Seite

-00000.0 [mm/s] -00000.0 [m/s-2]

YE1121

Zusatzbremse

C-Seite

-00000.0 [mm/s] -00000.0 [m/s-2]

YE1122

Zusatzbremse

D-Seite

-00000.0 [mm/s] -00000.0 [m/s-2]

YE1123

Reserve Schwingung

-00000.0 [mm/s] -00000.0 [m/s-2]

YE1124

Reserve Schwingung

-00000.0 [mm/s] -00000.0 [m/s-2]

SE1002

Drehzahl

-00000.0 [RPM]

A-Seite
Maschinendaten

C-Seite (vorn)

D-Seite (hinten)

Alarm

PRFTECHNIK Condition Monitoring

System

Signalanalyse

Zurck

Startseite

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DaimlerChrysler AG
Sindelfingen (Germany)
VIBRONET - Online Condition
Monitoring System

Hauptantrieb

Headpiece 1

Headpiece 2

Headpiece 3

Headpiece 4

Headpiece 5

Transfer press TP4

Transfer press TP4

PRFTECHNIK Condition Monitoring

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Press Shop: MllerWeingarten

Kompakt Press DC Sifi
Control Cabinet

VIBRONET
Signalmaster

-BA_Accelerometer

Steuerung

-BN_RPM Sensor

AK6-1

AK1-1

AK1-2

AK6-2

AK6-3

AK6-4

AK2-1

AK2-2

AK2-3

AK2-4

AK2-5

AK2-6

Kopfstck 1

Kopfstck 2

Kopfstck 3

Kopfstck 4

Kopfstck 5

Kopfstck 6

AK1-3

Conection
box
AK1-4

AK1-5

Driving
mechanism 1

Driving
mechanism 6

Transfer press TP31_1 Jumbo 114 203

ca. 37m

PRFTECHNIK Condition Monitoring

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GM in Europe
-

VIBCODE
Patented automatic
measurement location
recognition system
Allows low skilled employees
do the data collection
GM uses PTCM in all Europe
plants

PRFTECHNIK Condition Monitoring

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NISSAN, Plant in Barcelona (Spain)

Project: Paint Shops Fans Monitoring

Application: Air intake and outtake for
two paint shops.
3x VIBRONET Signalmaster and 36
multiplexers to be installed in a period
of three years.
RPM, vibration and temperature
readings for each bearing.
Critical machines: ventilators and their
drives
If only one ventilator fails the air
supply is affected which leads to a
complete stop of the paint shop
section

PRFTECHNIK Condition Monitoring

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NISSAN, Plant in Barcelona (Spain)

PRFTECHNIK Condition Monitoring

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NISSAN, Plant in Barcelona (Spain)

PRFTECHNIK Condition Monitoring

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Fiat, Plant in Betim (Brazil)

Main motor and

gearbox of each
press line
30+ Vibnodes
Project sold
thanks to a demo
installation on
only 1 press!

PRFTECHNIK Condition Monitoring

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Fiat, Plant in Betim (Brazil)

PRFTECHNIK Condition Monitoring

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Motor Test Rig

ACTIVE RUNNING MOTOR OR
DRIVEN MOTOR VIA
GENERATOR

VIBRONET
VibNode

Brake generator

1)

Prfling
Verbrennungsmotor

2)

Test bench 1...11

PRFTECHNIK Condition Monitoring

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Motor Test Rig

Mestelle
-BA11101
-BA11102
-BA11103
-BA11104
-BA11105
-BI11112
-BN11201
-BD11203
-BD11204

Bezeichnung
Schwingung Generator B-Lager RH
Schwingung Generator A-Lager RH
Schwingung Generator A-Lager AX
Schwingung Zwischenwellenlagerung RH
Schwingung Zwischenwellenlagerung AX
Moment
Drehzahl
Freigabe 1
Freigabe 2

Erluterungen:
VIB 6.122
Industrial accelerometer, 1 Hz 20 kHz, LineDrive
VIB 303065-x Sensor cabel, TNC angled, Triax, 30 cm, Protective cap Viton, 30 cm PES-Protective sleevel.,
-10 - +80 C, Length x m
VIB 90080-x
Triaxial cable, -10 - +80 C, Length x m (100m, 500m)

Aufnehmer
VIB 6.122
VIB 6.122
VIB 6.122
VIB 6.122
VIB 6.122
4-20 mA von SPS
24V Puls von SPS
24V binr von SPS
24V binr von SPS

Sensorkabel
VIB 303065-12
VIB 303065-12
VIB 303065-12
VIB 303065-12
VIB 303065-12
mehradr.geschir.
mehradr.geschir.
mehradr.geschir.
mehradr.geschir.

Volkswagen

Motorprfstand Halle77 Prfstand1

1)
-BA11101, -BA11102:
-BA11103, -BA11104, -BA11105:

Brake generator

Screwed sensor, M8/90Grad

Glued Sensor with glued adapter

Torque
measurement

Klemmenkast.

=<Funktion>
+<Ort>

=<Funktion>
+<Ort>

-X1:

VIBNODE VW

-BA11101
-BA11102
-BA11103
-BA11104
-BA11105

A_1
A_2
A_3
A_4
A_5

-BI11112

A_12

-BN11201

N_1

-BD11203
-BD11204

IN_1
IN_2

Tested Motor
Pillow block

-BA11105

-BA11103

-BA11101

-BA11102

-BA11104

-BA_Accelerometer

PRFTECHNIK Condition Monitoring

Triax-Kabel

* D-SubKabel

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Motor Test Rig

Is the Timing of the spark
correct?
VIBGUARD can be used
to monitor the actual motor
during the test!
Measure vibration levels
on each cylinder
simultaneously

PRFTECHNIK Condition Monitoring

26/05/2011

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Paint Shop:
fresh air supply fan

Digital OUT
PCS

Fresh air supply fans

installed in a paintshop

Bearing condition
Machine vibration

PRFTECHNIK Condition Monitoring

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More online references

Nissan, Sunderland Plant, United Kingdom
3x VIBONET Signalmaster online for Paint Shop
(100+ Measurement locations)
3 VIBROCORD
BMW, Germany
VIBRONET for Press Shop (Mller Weingarten
press)
VIBRONET Signalmaster for Conveyor Drive in
Assembly line
VIBRONET Signalmaster for lifting mechanism
(scissor table)
VIBROWEB XP for lifting mechanism
8 VIBNODE for Paint Shop

Audi, Germany
3 VIBRONET Signalmaster for Paint Shop (40 fans)
in Ingolstadt Plant
10 VIBNODE for Paint Shop (other plant)

PRFTECHNIK Condition Monitoring

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More online references

Daimler AG, Bremen Plant, Germany
VIBRONET Signalmaster for motor testing
aggregates
Daimler AG, Wrth Plant, Germany
3x VIBNODE
Volkswagen Paran Plant, Brazil
VIBRONET Master online CM system
Renault Flins Plant, France
VIBRONET Master online CM system for Paint
Shop, 20 measurement locations

PRFTECHNIK Condition Monitoring

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Some offline references

Renault, Cleon Plant, France
VIBSCANNER

Volkswagen, Salzgitter Plant, Germany

1 VIBSCANNER and 1 VIBXPERT
Volkswagen, Emden Plant, Germany
1 SmartSCANNER

Volkswagen, Wolfsburg Plant, Germany

1 VIBROTIP with VIBCODE, 1 VIBXPERT and 2
VIBXPERT II
Volkswagen, Osnabrck Plant, Germany
1 VIBROTIP with VIBCODE and 1 VIBSCANNER
Volkswagen, Kassel Plant, Germany
2 VIBSCANNER and 1 VIBXPERT II

PRFTECHNIK Condition Monitoring

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Some offline references

AUDI, Neckarsulm Plant, Germany
VIBROTIP

Daimler AG, Stuttgart Plant, Germany

VIBSCANNER
Daimler AG, Bremen Plant, Germany
VIBROTIP and VIBSCANNER with VIBCODE

Daimler AG, Wrth Plant, Germany

VIBSCANNER and VIBROCORD
Daimler AG, Mannheim Plant, Germany
VIBSCANNER with VIBCODE

General Motors: VIBXPERT for 1 plant in UK, 1 plant

in Russia, 3 plants in Germany (Rsselsheim, Bochum,
Kaiserslautern), 1 plant in Belgium Antwerpen (1x VSC), 1
plant in Spain (Zaragoza), 1 plant in Poland (Glwice)

PRFTECHNIK Condition Monitoring

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Some offline references

Kia Motors, Korea
VIBSCANNER

Skoda Auto A.S., Czech Republic

VIBXPERT II for machining tools
Volkswagen, Russia
VIBROTECTOR for Paint Shop

PRFTECHNIK Condition Monitoring

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Thank you

PRFTECHNIK Condition Monitoring

Thank you for your attention!

- www.pruftechnik.com

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