Danfoss - Condition-based monitoring (CBM) 

Optimising availability through new maintenance concepts 

Danfoss's intelligent variable speed drives provide early warning of downtime by collecting, evaluating and storing data from sensors. Results are made available in the cloud or locally, for predictive maintenance. This improves performance, efficiency and uptime, extends component life and reduces complexity. Installation is easy: the controller learns automatically or the user performs an identification run. 

Detecting wear early: monitoring mechanical vibrations 

Detecting wear early is crucial to prevent mechanical problems. With a Danfoss variable speed drive and a vibration sensor, bearing wear, shaft alignment and imbalance can be monitored. By comparing sensor signals with internal signals, the inverter can quickly detect faults and provide information to prevent breakdowns. Maintenance can thus be planned while the plant remains in operation. Vibrations are monitored according to ISO standards for machine monitoring and diagnosis, allowing data to be compared with real operating conditions such as speed and load.

Detection of motor winding faults before motor failure 

Early detection of motor winding faults prevents failure. Faults develop gradually and start with small short circuits and heating. Often, damage goes unnoticed until overcurrent protection shuts down the installation. Continuous state monitoring of the motor by electrical signature analysis prevents this. Analysis of currents and voltages identifies motor and application faults such as shaft alignment and stator winding. Existing current and voltage sensors in AC drives generate valuable information at no extra cost. This prevents failure in an effective and cost-efficient way. 

Load curve monitoring: early detection for pump fouling, among other things 

When a Danfoss variable speed drive detects a heavier load, this indicates contamination and the drive triggers a maintenance alarm. Quick cleaning measures thus prevent bigger problems and keep the plant operational. The AC drive uses current and voltage measurements to control the motor. Parameters such as motor power, energy, speed and torque are calculated and used to monitor motor load. This allows analysis of the load curve and detection of any abnormalities, such as pump fouling.

Learn more about Condition Monitoring with Intelligent Frequency Controllers in the whitepaper click here.

Want to see real-life examples? Click here for a case study on CBM at HEINEKEN Den Bosch.