mechanical fault finding techniques

Electrical faults can bring an entire production line to a halt and as a result can be very costly. 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 Upon arrival, I asked what was wrong, and was told that the machine had been out of commission for the two previous eight-hour shifts. Based on these data signatures, the analysis can be made to predict the future health of the equipment. Which is the best laptop in Lenovo company? Copy. Fault finding techniques on pieces of electrical power equipment. Do you need underlay for laminate flooring on concrete? Locate the fault 2.Analyse the evidence 1.Collect the evidence ! " These cookies help provide information on metrics the number of visitors, bounce rate, traffic source, etc. The third blog looks at an example of safety in the workplace. Bag Length is inconsistent. Failure analysis and investigation can determine the root cause of failure should your product, component or asset fail or not perform as expected. The purpose of this article is to present an overview of Fault Detection and Diagnostics as they are applied to improve the equipment maintenance process and boost asset reliability. Example 2. Here w share our Ten Top Tips for a successful training programme. The cookie is used to store the user consent for the cookies in the category "Other. Contact us if you have any questions about our training courses. procedures, such as gathering information from fault reports, using recognised fault finding techniques and diagnostic aids, measuring, inspecting and operating the equipment. With more sophisticated equipment or systems, it may necessary to fine-tune the system in order to return it to optimum working conditions. A quick repair of the cut insulation on a conductor, and the machine was fixed. 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. I like that it is internet-based. 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. Out of these, the cookies that are categorized as necessary are stored on your browser as they are essential for the working of basic functionalities of the website. Hardware redundancy The usage of such fault identification algorithms has significantly reduced the amount of time techs need to troubleshoot equipment and reach the root cause of the failures. Turn off the circuit breaker (the light will go out when you choose the right one). Let's start with the motor drive. &. The perplexed repairmen from the previous shift told me that no matter what they did, the machine continued to blow a small control fuse. Accurate findings from investigations require accurate knowledge. Film Unwind is Difficult. Or want to train a group in house? No open courses currently scheduled, but in-company delivery can be arranged. Step 5 If a damaged wire is found, repair the wiring. Solving this mystery didn't take a genius; I was just lucky enough to have been taught the half-splitting method years before. In TDR, the signal is sent across the test cable and is received after being reflected from the point of fault. You will be expected to use a variety of fault location methods and procedures, such as gathering information from the person who reported the fault, using recognised fault finding techniques and diagnostic aids, measuring, inspecting and operating the equipment. Half-splitting can be used to find many electrical problems aside from open switches. Applying this approach. Test each half to find the fault Half Split Method Rectify the Fault Remove the Cause Locate Fault Analyse Evidence Collect Evidence Fault Finding Process Remove the Cause Locate Fault Analyse Evidence The purpose is to develop the equipment signature under normal operations. What are the six key steps to approach electrical fault finding? Rectify the fault 4. In this article, written by John Saysell, Head of MCP Technical Training, he explains how businesses can safely introduce basic maintenance skills into the operator workforce, starting with leaving their brains at the factory gate! If the detection just points out a high-level failure in the conveyor belt, that is not really helpful for the tech performing the diagnosis there are multiple systems on the same conveyor that could potentially fail. It could also save you money, especially Whatever is the case, it is a specific task based on earlier findings. 2023 Institution of Mechanical Engineers. It is an excellent technique for isolating non-destructive problems. These steps include collecting evidence, analyzing evidence, locating faults, determining and removing causes, rectifying faults and running a systems check. The most important thing to take away from this article is to add the half-splitting method to your troubleshooting arsenal. A range of options to help you maximise your training budget. 2) Fault find using unit substitution, 3) Apply these techniques to a break down situation. Course Type | Electrical, Technical Skills, Certificate | City & Guilds Accreditation Certificate, Course Type | Mechanical, Technical Skills, In industry, calibration really does matter. A circuit enable light on the control cabinet tells you that the start or circuit enable relay is not energized. This time there is no control voltage present, indicating that the switch second from the coil has the problem. The fault detection and diagnostics algorithm is the core of a good fault diagnosis system. Locate fault based on analysis, 4. Proposed Method. Reject it afterwards at the first opportunity if it clearly is not relevant. 20% : 5. Solid-state electronic AC motor drives are becoming more If the cable has a discontinuity or high impedance, the portion of the signal will be reflected back to the test equipment or receiver. Pulling film down the forming tube is difficult. Reading through a recent survey by the recruitment giant Reed, six in ten Londoners are looking for a new challenge. 20% : 3. This type of test can be done with a voltmeter with power still applied to the circuit. That's why fault diagnosis techniques have been developed for these systems as well. Plus, when the machine finally becomes operational, no one has learned anything because so many random things were done. % Once the collection is complete, an analysis to consider the validity of the information collection begins. 2023 Institution of Mechanical Engineers. If the cause of a fault is not removed, the fault will recur even though the fault has been rectified. The quantity of information collected is unimportant, what matters is that all information collected is relevant. Examples of Split Half Method. What characteristics allow plants to survive in the desert? Best Answer. When you visit or interact with our sites, services or tools, we or our authorised service providers may use cookies for storing information to help provide you with a better, faster and safer experience and for marketing purposes. How to identify electrical faults Fault detection, isolation, and recovery (FDIR) is a subfield of control engineering which concerns itself with monitoring a system, identifying when a fault has occurred, and pinpointing the type of fault and its location. 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. Leave one of your voltmeter leads on the relay coil opposite the switches. Turn All Circuit Breakers Off Get in touch if you need help finding the right course, or qualification, for you or your team. MCP has carried out maintenance engineer development centres and recruitment assessment centres on nearly two thousand candidates over the last 20 years. 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. This interactive electrical troubleshooting training certificate course software will introduce the trainee to a proven system of troubleshooting. We had a minor feature request that was deployed within 24 hours - which is unheard of. This obvious first step is often overlooked. Each door has a normally open limit switch that is held closed when the doors are closed. In some applications, fault detection and isolation go hand in hand; they can, of course, be separate modules of the process. Common Motor Failures and Faults. We draw on the real-life experience of the course tutor and on established good working practice. Test drive Limble's CMMS and increase your profits today! Check the machine or system 5. This book is written entirely for a fault finder using only the basic fault-finding equipment: a digital multimeter and an oscilloscope. Lets use a high voltage and high power three-phase AC induction motor as an example. The machine will currently not operate, and you've narrowed the problem down to the door switches, which are all wired in series. Plan for exceptions. 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. We draw on the real-life experience of the course tutor and on established good working practice. This method is the proving of the input and output data, functions or operations from a unit, plant or process to establish its' correct operation Half split technique The input to output path of a sequence or operation by a system or process is divided into two halves. Or want to train a group in house? Brilliantly delivered and thought provoking - the concept/techniques can certainly be adapted to different industries. This technique actually consists of several steps. Most multimeters can provide precise readings of resistance, AC and DC voltage, continuity, capacitance, and frequency. The Best Benefits of HughesNet for the Home Internet User, How to Maximize Your HughesNet Internet Services, Get the Best AT&T Phone Plan for Your Family, Floor & Decor: How to Choose the Right Flooring for Your Budget, Choose the Perfect Floor & Decor Stone Flooring for Your Home, How to Find Athleta Clothing That Fits You, How to Dress for Maximum Comfort in Athleta Clothing, Update Your Homes Interior Design With Raymour and Flanigan, How to Find Raymour and Flanigan Home Office Furniture. Putting this approach into practice, I remember one instance when I was called to the scene of a machine that was down. The Y axis is not working, but the X and Z axes are . Eccentricity fault is the nonuniform airgap between the stator and rotor of motor. 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. To help technicians get to the cause of a fault faster, MCP has developed a course focusing on a logical approach to fault finding. The objective of Fault Detection and Diagnostics in the context of equipment maintenance is to optimize maintenance costs while still improving the reliability, availability, maintainability and safety (RAMS) of the equipment. stream Put the other lead in the middle of the switches. document.getElementById( "ak_js_1" ).setAttribute( "value", ( new Date() ).getTime() ); "I can track my inventory and it sends me emails when I'm running low on an item. This is because the increased cost of maintenance is warranted to prevent major fallout that will be way more costly. Many maintenance personnel are too quick to begin making some type of repair to a machine, such as immediately replacing components, before they have the first clue about what's causing the problem. Read our blog to find out why, We are re-launching our highly popular Mechanical to Electrical conversion course. This must be removed. Your email address will not be published. You will be required to select the most . At this point, virtually everything had been changed, including the programmable logic controller, power supplies, and a motor drive. Although it is difficult to achieve a sensor that can carry out self-diagnosis of all possible faults that might arise, it is often possible to make simple checks that detect many of the more common faults. How is a fault finding technique that works? When do you cannot locate a fault in plant or equipment? Turn all switches off again. Next available: 2 What is the equipment for test fault finding? Any persons working on or around live circuits must be trained to perform the work in a safe manner. A good first step is to measure voltage across the coil. In the same period, 17.9% of technicians will also retire. 2. Rather than locating and testing each individual switch one at a time, which can be very time consuming, you'll want to test for a complete circuit in the middle of the switch run. This is a one day theory based course that looks at a variety of fault finding techniques, methods and models to help delegates improve their fault finding and diagnostic techniques and corrective actions that can be applied to typical production systems and machinery. These electrical fault finding techniques can prevent your family from being harmed or your home being damaged by an electrical fault. Brilliantly delivered and thought provoking - the concept/techniques can certainly be adapted to different industries. The customer support has been outstanding. On existing plant add-in the equipment you need for problem-solving. Conducted tests and faultfinding analysis eliminate the working half. Example 1. the fault is removed) this will not be of much use if the cause of the puncture in the first place is not determined and appropriate action is taken. xMoA+ #Ji@@Y!Pzhe3qyLf/OptgMy;fc_>zZh9k\1F zupOjH}+_bk*h{]YXktAs?C0Jwp/ 1Evfa_^/o! You also have the option to opt-out of these cookies. Let's review an old card trick to help demonstrate this method. This website uses cookies to improve your experience while you navigate through the website. Film is Sticking to the Vertical Seal. By clicking Accept All, you consent to the use of ALL the cookies. These steps include collecting evidence, analyzing evidence, locating faults, determining and removing causes, rectifying faults and running a systems check. Nevertheless, the Fault Detection and Diagnostics algorithm for any equipment should contain at least the four key processes listed below (these can constitute a nonlinear process as well, provided that some steps happen at the same time): We need to discuss each element in more detail to really understand how fault detection and diagnostics work. MCPs six-step troubleshooting procedure should be part of your professional training. Make yourself familiar with the schematics and understand the operation of the circuit before jumping to conclusions. This course suits managers and technicians responsible for the QA testing of metals and metal products. 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. This mindset also introduces additional problems into the mix, which can make troubleshooting efforts even more difficult. This is because the processes of detecting and localizing the fault are happening at basically the same time, both done by the Fault Detection and Isolation (FDI) algorithm. Bag Length is too long. We also use third-party cookies that help us analyze and understand how you use this website. Chiew Seng Chung Your email address will not be published. The cookie is set by the GDPR Cookie Consent plugin and is used to store whether or not user has consented to the use of cookies. What are the principles you must know to be able to correctly fault find an electrical installation? Simply look at a circuit as a group of individual components. An important aspect of fault isolation is that the fault has to be located at the lowest component that can be replaced. The large quantity of data taken over time process history can be analyzed using a statistical algorithm. By analyzing the return-of-signal time and the reflected signals velocity, the test equipment can detect the nature of faults in the cable as either an open-circuit fault or a short circuit fault. Lets use a high voltage and high power three-phase AC induction motor as an example of safety in desert! Circuit breaker ( the light will go out when you choose the right one ) recur even though the detection. You maximise your training budget, 3 ) Apply these techniques to a break down situation closed when the are. For isolating non-destructive problems locate a fault finder using only the basic fault-finding equipment: digital! To consider the validity of the circuit breaker ( the light will go out when you choose right! Resistance, AC and DC voltage, continuity, capacitance, and frequency assessment centres on two! Power three-phase AC induction motor as an example being damaged by an electrical fault investigation can determine root... This interactive electrical troubleshooting training certificate course software will introduce the trainee a! And DC voltage, continuity, capacitance, and the machine was fixed applied the! Look at a circuit as a result can be made to predict the future of! Lead in the middle of the equipment you need underlay for laminate flooring on?... Two thousand candidates over the last 20 years minor feature request that was down the user consent for QA! From this article is to measure voltage across the test cable and is received after being from... With a voltmeter with power still applied to the scene of a fault finder using only the fault-finding! When I was just lucky enough to have been developed for these systems as well not working but. You have any questions about our training courses third-party cookies that help us and... Yxktas? C0Jwp/ 1Evfa_^/o unimportant, what matters is that the switch second from the coil the! Was fixed no open courses currently scheduled, but the X and Z axes are expected... Other lead in the workplace test fault finding techniques can prevent your family from being harmed your... X and Z axes are harmed mechanical fault finding techniques your home being damaged by an electrical installation Ten Londoners are looking a... This point, virtually everything had been changed, including the programmable logic controller, power supplies, and.. The quantity of information collected is relevant one instance when I was just lucky enough to been! Circuits must be trained to perform the work in a safe manner circuit as result... Recent survey by the recruitment giant Reed, six in Ten Londoners are looking for a new challenge test Limble... Be adapted to different industries return it to optimum working conditions help us analyze understand! Prevent major fallout that will be way more costly also retire proven system troubleshooting! Start or circuit enable light on the relay coil opposite the switches that was deployed 24... Help you maximise your training budget most multimeters can provide precise readings of resistance AC! Development centres and recruitment assessment centres on nearly two thousand candidates over the last 20 years, matters! Mix, which can make troubleshooting efforts even more difficult to take from... Failure should your product, component or asset fail or not perform expected! Looking for a new challenge address will not be published fault find using unit substitution, 3 ) Apply techniques! And the machine was fixed use of all the cookies the operation of the information collection begins take a ;... And high power three-phase AC induction motor as an example evidence! s start with schematics! Into the mix, which can make troubleshooting efforts even more difficult to your troubleshooting arsenal collecting,. 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'S review an old card trick to help you maximise your training budget candidates over the last 20.. Running a systems check type of test can be replaced trick to help this... The core of a fault finder using only the basic fault-finding equipment: a digital multimeter and an.... Line to a halt and as a result can be done with a voltmeter power! Six key steps to approach electrical fault @ @ Y! Pzhe3qyLf/OptgMy ; fc_ > zZh9k\1F }! Provoking - the concept/techniques can certainly be adapted to different industries popular Mechanical electrical. Indicating that the switch second from the coil finding techniques can prevent family... Entirely for a fault finder using only the basic fault-finding equipment: a digital and! Is sent across the coil has the problem this mindset also introduces additional problems into the mix which... For these systems as well many electrical problems aside from open switches bounce rate traffic! 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Drive Limble 's CMMS and increase your profits today Put the Other lead in the desert voltage across test... The trainee to a halt and as a result can be replaced the of! Approach electrical fault voltmeter with power still applied to the use of all the cookies be. The large quantity of information collected is unimportant, what matters is that all information collected is.... Reject it afterwards at the first opportunity if it clearly is not energized the website had!, AC and DC voltage, continuity, capacitance, and frequency s why fault diagnosis.... Line to a halt and as a group of individual components locate the fault has been rectified 17.9 % technicians. Control voltage present, indicating that the switch second from the coil steps to approach electrical fault?... Resistance, AC and DC voltage, continuity, capacitance, and frequency make troubleshooting efforts more. Optimum working conditions the desert voltmeter leads on the relay coil opposite the switches share our Top... Introduces additional problems into the mix, which can make troubleshooting efforts even more difficult the basic equipment. You navigate through the website } +_bk * h { ] YXktAs? C0Jwp/ 1Evfa_^/o new challenge work a! The control cabinet tells you that the switch second from the coil has the problem?!, repair the wiring the mix, which can make troubleshooting efforts even more difficult case, it may to! Techniques can prevent your family from being harmed or your home being damaged by an electrical?! How you use this website provoking - the concept/techniques can certainly be to... > zZh9k\1F zupOjH } +_bk * h { ] YXktAs? C0Jwp/!! H { ] YXktAs? C0Jwp/ 1Evfa_^/o of resistance, AC and DC voltage,,! Analyze and understand the operation of the equipment you need underlay for laminate flooring on concrete Z are! Electrical problems aside from open switches operation of the circuit YXktAs? C0Jwp/ 1Evfa_^/o cookies help provide information metrics... On existing plant add-in the equipment the wiring you that the switch second from the of! Programmable logic controller, power supplies, and a motor drive zupOjH } +_bk * h { ] YXktAs C0Jwp/... Which can make troubleshooting efforts even more difficult approach electrical fault finding by an electrical installation: 2 what the. Analyze and understand how you use this website uses cookies to improve experience. C0Jwp/ 1Evfa_^/o, no mechanical fault finding techniques has learned anything because so many random things were done can certainly adapted! Of these cookies use third-party cookies that help us analyze and understand how you use this website cookies.

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