Perceptiv Diagnostics And Condition Monitoring Provide Timely Insights

Customer Challege

A Michigan-based steel mill installed a new gear reducer on a roughing mill due to damage to the previous reducer. The mill was concerned that transient and steady-state torsional loads transmitted through the previous gear reducer may have exceeded its design limits. Transient torque spikes can last only a few milliseconds but can cause damage to equipment downstream and occur too quickly to be detected measuring only motor current.

Regal Rexnord Solution

In order to prevent damage to the new reducer, the mill utilized Perceptiv solutions to install torque sensors on the spindles of two mill stands. Using a custom data acquisition system, transient torque data was continuously recorded, monitored, and analyzed by the Perceptiv team as the mill operated. The initial diagnostic test confirmed the mill was operating within the design limits of the new gear reducer. The customer then requested the Perceptiv team to continue monitoring peak torque and waveform data and provide weekly reports to help identify any transient torque events.

Benefits Seen by the Plants Included

• Over $2M Cost Avoidance – Avoided catastrophic damage to equipment by planning timely maintenance.
• Optimized Equipment Reliability – Measured torque magnitudes and compared to equipment capacities in real-time.
• Enhanced Maintenance Practices – Improved maintenance strategies with access to key torque trend data.
• Reduced Inspection Labor Costs – Weekly reports pinpointed problems and led to targeted inspections.
• Transition to Proactive Maintenance – Achieved the next level of reliability where repair work can be planned and scheduled efficiently.

 

The demand for reliable assets has never been greater, yet finding the resources and knowledge has never been harder

Everyday there are challenges in labor resources, supply chain, meeting production goals and unplanned downtime. The Perceptiv intelligence team applies decades of industry and application knowledge to diagnose and design outcomes based on your needs. The team uses advanced technologies to detect issues before they become your problem to help increase profitability, efficiency, and overall plant health.

Diagnostic Services

Technical tools are applied on-site for root cause analysis to assess equipment health. Receive easy to read reports on equipment performance along with prescriptive consultation to optimize your electromechanical powertrains. Prescriptive Monitoring > Manage assets with alerts, automatic trend detection and advanced condition monitoring tools. The Perceptiv condition monitoring services team can help with design and installation as well as regular reporting with prescriptive actions. Tie this system into your automation system or easily access information via the Perceptiv dashboard.

Maintenance, Repair, and Operations (MRO) Management

Simplify MRO management for maintenance and procurement teams with the Tag-It Program. Reduce maintenance time, streamline procurement, and achieve inventory objectives by decreasing your MRO lifecycle up to 30%.

Perceptiv™ Solutions

Our diagnostic services team has developed a series of solutions for the various industries we serve. Browse our documented solutions to get a baseline for how you can achieve optimal performance.

Schedule a Time to Learn More About Perceptiv Solutions

Regal Rexnord manufactures components that span the complete powertrain, and we have decades of application and industry knowledge. It’s truly an extension of who we are to monitor applications, provide insights, and recommend appropriate actions before issues interrupt production.