Fault analysis for machines and systems
Fault and malfunction analysis is an important part of the maintenance of machines and systems. Fault analysis involves identifying and eliminating the cause of a fault or malfunction. This is particularly important in order to avoid unplanned downtimes or production losses. Through systematic analysis, possible weak points in the machine or system can be identified and rectified in order to avoid future faults. Various methods and tools are used, such as fault tree analyses, cause-and-effect diagrams or statistical procedures. The aim is to increase the availability and reliability of machines and systems and thus increase the productivity and quality of production.
Machines and systems are usually controlled and regulated by PLC systems or industrial PCs. Digital and analog signals are linked in a complex way via the implemented program sequences and algorithms. But what to do if the program does not work as intended or if sporadic errors or undefined behavior occur? For analysis purposes, it often makes sense to record digital and analog signals in parallel with existing systems. This is exactly where the Delphin Measuring and testing devices can be used. By scanning digital and analog signals quickly and in parallel, faults that would otherwise remain undetected can be found. In combination with the measurement technology software ProfiSignal and the logic analysis diagram contained therein.
Application highlights of the fault analysis
- Parallel scanning of analog and digital sensors and actuators
- Time-synchronous scanning
- High temporal resolution down to the µ-second
- Independent operation of fault value detection also possible without a PC
- Comprehensible and appropriate evaluation of data with logic analysis
Practical example of a fault analysis
Fault analysis in the chemical production plant
During the production of a chemical precursor, sporadic effects caused unscheduled downtimes at irregular intervals - with correspondingly high costs. Conventional data loggers were initially used for troubleshooting. However, the operator was unable to find the fault. Either the time resolution was insufficient or the device failed in the event of a fault. A message device from Delphin was then used for diagnosis. In addition to digital inputs and outputs, analog signals were also recorded. After a recording period of several weeks, the fault occurred again and, thanks to the Delphin system with its clear evaluation options, could be narrowed down to a fluttering digital contact and finally eliminated.
Typical areas of application
error and fault analysis
- Error detection in chemical production plants
- Error detection in control systems and controls
- Error detection on paper and printing machines
- Diagnosis of sporadic faults
- Error detection in flow and batch processes
- Fault detection in start-up procedures
- Mobile system for error diagnosis
Hardware and software for your measurement and testing solution
Flexible, scalable and expandable solution for seamless data acquisition and monitoring
The Loggito device is a compact data logger system designed for the acquisition and recording of measurement data. It has a variety of analog and digital inputs to connect different sensors and signals. The device records the data with high accuracy and stores it on an internal memory or external storage media such as SD cards.
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Data acquisition and analysis
With ProfiSignal Go you can display online data from the Message and Expert hardware in diagram form. Numerous analysis functions, such as zoom, cursor, movable axes, flags, ASCII export and calculation channels, enable fast display of measured values and post-processing.
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Precisely record, autonomously store, automatically transmit and evaluate measured values.
The FPGA-based Expert Logger device is particularly powerful and enables the processing of up to 46 analog input channels, both at low and high sampling rates. Measured values can be recorded precisely, stored autonomously and transferred automatically via USB or LAN to the Internet or PC for evaluation.
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Operating and monitoring
ProfiSignal Basic combines the functions of ProfiSignal Go with operating and monitoring elements of process visualisations, e.g. digital and analogue displays, switches, buttons and signal lamps. With Basic, you can create everything from simple visualisation diagrams to complex visualisation systems.
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Modular measuring, monitoring and automation in one device.
The ProfiMessage D device is a state-of-the-art data logger system that has been specially developed for industrial data acquisition and analysis. It offers a wide range of functions such as the recording and storage of measurement data, monitoring of process parameters and alarms in the event of deviations.
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Automate and control
ProfiSignal Klicks supplements ProfiSignal Basic with functions for process automation. Structural diagrams for mapping the process as well as a script language (completely operable with the mouse) enable even the non-informatician to create complex test stand and automation applications with automatic report generation.
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State-of-the-art processor technology and extreme precision for vibration measurement.
The Expert Vibro device is a powerful vibration analysis device that has been specially developed for monitoring and analyzing machine and system conditions. It enables vibration data to be recorded and evaluated in order to detect potential problems or signs of wear at an early stage.
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Fast project planning and analysis of measurement data
With ProfiSignal 20 Go you can visualise your measurement data in just a few steps, both online and offline, in various diagram types, monitor, analyse, archive as a measurement file or export directly in the appropriate file format.
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Intelligent data recorder for synchronous recording of transient and periodic events.
The Expert Transient device enables the recording and evaluation of transient signals over a certain period of time and provides important information for the optimization of processes and systems. The device is characterized by its high accuracy, fast sampling rate and simple operation.
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Visualisation and operation
With ProfiSignal 20 Basic you can create individual diagrams using a wide range of operating and monitoring elements. Both continuous processes (e.g. production data acquisition) and discontinuous measurement tasks (e.g. test measurements) can be visualised, operated and monitored without any programming effort. You can create the operating and monitoring diagrams by assembling and configuring the prefabricated elements.
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Modular system for use as a measuring, control and monitoring device.
The ProfiMessage devices are a modular, expandable and easy-to-use system for measurement data acquisition, monitoring and automation of machines, systems or test benches. ProfiMessage can be used wherever measured values need to be recorded quickly, precisely and electrically isolated, as well as intelligently pre-processed or monitored.
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Central measurement data management
The Delphin Data Center is the solution used for the worldwide measurement networking and control of plants, machines and test stands.
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PC-supported data acquisition and test stand
The Expert Key device is a measuring and control device that can be used in various applications. It enables the acquisition and evaluation of measurement data as well as the control of processes. The device has various interfaces and can be connected to a wide range of sensors and actuators. It is often used in automation technology, mechanical engineering and research.
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Compact and flexible measurement data laboratory with precision measurement technology.
The LoggitoLab device is ideal for use in laboratory environments, research projects, quality control and other applications where precise data acquisition and analysis is required. It offers a reliable and user-friendly solution for monitoring and recording measurement data.
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Test stand for measurements with potential using an internal data memory.
The LogMessage device is a powerful data logger system designed for the reliable acquisition and recording of measurement data. It offers a variety of analog and digital inputs to connect different sensors and signals. The device records the data with high accuracy and saves it to an internal memory or external storage media.
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