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As automated factories continue to evolve, motor failures remain a significant challenge, leading to lost production and revenue. Early detection of specific issues and their locations is vital to maintaining operational efficiency. While adding extra sensors might seem like the solution, there’s often a simpler approach.
**The Challenge:**
Ensuring smooth operations in a manufacturing environment requires proactive measures. Monitoring motor systems with built-in status tracking is one of the most effective ways to simplify tasks for everyone involved. Predictive maintenance forms the backbone of this strategy, allowing potential issues to be identified before they escalate into major problems.
**Application Example:**
Imagine a motor integrated with a rack-and-pinion mechanism used for lifting loads. In large-scale factories, these setups are numerous, making early problem detection crucial. Let’s explore how predictive maintenance works in this context:
1. **Collect Data:** Gather relevant information about the motor’s performance.
2. **Communicate:** Relay this information effectively.
3. **Act:** Address issues before they result in downtime.
For instance, consider a motor that lifts heavy loads. One of the key factors affecting its lifespan is temperature. Excessive heat is a motor’s primary adversary, as its lifespan is directly linked to the operating temperature of its bearings. For this application, we’ll focus on monitoring motor temperature—a critical variable impacting motor longevity.
Another consideration is whether communication capabilities from the motor driver are needed. You’ll need to determine how to extract this data—whether through an industrial network, an analog output, or digital I/O.
**Networking Benefits:**
Setting up an industrial communication network, such as EtherNet/IP or EtherCAT, simplifies wiring by significantly reducing the number of wires required between the master controller and the motor driver. Additionally, remote I/O capabilities allow for more variables to be monitored.
Other status outputs that can be tracked include:
- Driver I/O status
- Motor position error
- Driver temperature
- Overvoltage and undervoltage conditions
- Overspeed and overload times
- Cumulative load and trip meter readings
Once you’ve decided on the variables to monitor, connect the appropriate outputs to your PLC, PAC, HMI, or similar monitoring system. After setup, continuous communication of status information to the master controller becomes possible. Programmable outputs can be configured with thresholds tailored to specific requirements.
To illustrate how these outputs function, consider the following example:
**Temperature Monitoring Outputs:**
- **INFO-MTRTEMP:** Triggers ON if the motor temperature exceeds 70°C.
- **ALM-A:** Triggers ON if the motor temperature surpasses 85°C. When this happens, the motor automatically stops.
**Difference Between Standard and Information Outputs:**
This distinction applies specifically to Oriental Motor products. A standard output is pre-assigned at the factory, while an information output is optional and accessible via an industrial network or the MEXE02 software’s status monitor function. Information outputs are designed to provide warnings prior to triggering alarms that stop the motor.
**Displaying Information to Operators:**
To demonstrate this concept, let’s visualize the status updates using a traffic light system—a simple yet effective method.
- **Green:** Everything is normal, and the motor is functioning correctly.
- **Yellow:** INFO-MTRTEMP output indicates the temperature has exceeded 70°C.
- **Red:** ALM-A output signals the temperature has surpassed 85°C, halting motor operation.
While a traffic light system is useful for demonstration purposes, real-world applications require clearer communication to ensure swift action. Displaying information in a manner that operators can easily interpret is essential.
For further monitoring, Oriental Motor’s MEXE02 software provides an “Information Monitor†function, allowing operators to track these outputs. Keep in mind that this software monitors one motor at a time, requiring unique IDs to identify specific faults.
To enable communication between the software and the driver, ensure all necessary checkboxes are selected. Most importantly, using a driver with industrial communication capabilities is crucial for optimal performance. These drivers offer additional data compared to those without networking features.
Oriental Motor offers EtherNet/IP and EtherCAT-compatible drivers for the AZ Series stepper motors, rotary actuators, and linear motion systems.
**Solution:**
Oriental Motor’s AZ Series network-compatible drivers provide advanced monitoring solutions.
| Type | Single-Axis | Single-Axis | Multi-Axis |
|------|-------------|-------------|------------|
| Drivers | EtherNet/IP | EtherCAT | EtherCAT |
For a detailed video tutorial on using AOI to monitor motor status with Rockwell Automation’s Studio 5000 Logix Designer software, refer to the embedded link.
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Related Post: [Preventive vs Predictive Maintenance: Which is More Efficient?]
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