From test stand project to globally standardized vibration analysis platform
Initial situation: Complex test stand infrastructure with increasing requirements in the vibration range
A leading manufacturer of rolling bearings has been operating numerous test stands for service life monitoring and analysis for many years. A central component of these tests is the recording and evaluation of vibrations, as these allow significant conclusions to be drawn about wear, running behavior and failure mechanisms of the bearings.
The test stand infrastructure had grown over the years and was spread across several locations in Europe. The research location in the Netherlands in particular had a large number of test benches, but these were operated with different systems. These differed both in terms of data acquisition and evaluation and were only compatible and comparable with each other to a limited extent.
The existing solutions were often inflexible and made consistent vibration analysis difficult. At the same time, there was a high dependency on external service providers and individual programming. Against the backdrop of increasing requirements for data quality, comparability and automation, it became clear that a fundamental modernization was necessary.
Lack of standardization and unstable overall systems
With the increasing internationalization of testing activities, the situation became even more acute. Test stands were expanded, new systems were planned and existing systems were relocated from the Netherlands to Italy as part of organizational changes.
This showed that the challenges went far beyond pure measurement technology. During commissioning, problems repeatedly arose from the interaction between different systems. In addition to classic issues such as communication and synchronization, influences from adjacent areas - such as faulty sensor wiring, problems in the peripherals or inconsistent system configurations - were also a particular factor that impaired stable operation.
However, stable and reproducible operation is essential, especially in the vibration range, as this is the only way to make valid statements about the behavior of the test specimens.
Use of modular measurement technology and standardized software platform
For a sustainable solution, a standardized system landscape was set up step by step, which integrates both the vibration measurement and the entire test bench control system.
The following components from the Delphin portfolio were used in particular:
- Expert Vibro as a central I&C system and for precise vibration monitoring and analysis
- ProfiMessage for connecting the lubrication system, hydraulics and other peripherals
- ProfiSignal for visualization, control of the test processes and evaluation of the measurement results
These components were combined to create an end-to-end solution that covers measurement data acquisition as well as the control and evaluation of the test benches. The use of Expert Vibro enabled a high-resolution analysis of frequency spectra and therefore a significantly improved evaluation of bearing conditions, particularly in the vibration range.
At the same time, a central data architecture was set up in which all measurement data is stored in an SQL database and made available across all locations. This allowed test sequences, statuses and results to be consistently documented and evaluated.
Gradual integration and international scaling
The implementation was deliberately iterative and began at the site in the Netherlands. Existing test stands there were first modernized and equipped with the new system solution. In addition to the pure integration of the hardware, a particular focus was placed on the development of a uniform application that clearly displays all relevant measured variables - including the vibration data - and makes them analyzable.
The solution was subsequently transferred to other locations. The transfer of complete test bench systems to Italy was particularly challenging. Here, the existing systems not only had to be rebuilt, but also adapted to changed conditions.
During commissioning, the strength of the chosen approach was once again demonstrated: the combination of flexible measurement technology and open system architecture meant that problems could be identified and rectified quickly. Often the cause was not in the measurement technology itself, but in adjacent systems. However, targeted analysis - using the vibration data, among other things - enabled these faults to be clearly localized.
Stable testing processes and improved vibration analysis
Thanks to the gradual introduction of the standardized solution, the entire test bench infrastructure has been sustainably stabilized. The systems used today enable reliable and high-resolution recording of all relevant measured variables, particularly in the vibration range.
The benefits are clearly evident in daily operation. Test stands run more stably, faults can be identified more quickly and the quality of the measurement results has improved significantly. In particular, the ability to analyze vibration data in detail and link it to other process variables offers considerable added value for the evaluation of test specimens.
At the same time, the standardized platform has created a high level of transparency. Data is available across all locations and can be evaluated consistently. This not only facilitates analysis, but also the comparison of different test stands and test series.
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Long-term added value: scalable solution for global applications
A key success factor of the project lies in its scalability. The introduced platform can be flexibly expanded and adapted to new requirements. New test stands can be integrated efficiently and additional measured variables or analysis functions can also be added without any problems.
In addition, the solution has proven to be transferable to different locations and applications. Today, it serves as the basis for further projects and is increasingly being established as the standard within the company.
Successful standardization in vibration monitoring across multiple locations
This success story shows how a complex, cross-location test stand infrastructure can be successfully standardized through the targeted use of modern measurement technology and software solutions.
The focus was not only on technical modernization, but in particular on establishing consistent and reliable vibration monitoring and analysis. The combination of Expert Vibro, ProfiMessage and ProfiSignal has created a powerful platform that today enables stable testing processes, high data quality and future-proof further development.