68 Mobile 2006 Condition Monitoring
Costs
Maximize the cost effectiveness of a machine by optimally using each
individual component, in every operating condition, over the entire opera-
ting life of the machine with the aid of online condition monitoring.
Function
Changes in the performance of a machine are detected in good time by
online condition monitoring. Appropriate measures can be taken before a
machine function fails. Online condition monitoring increases the functio-
nal reliability and availability of a machine.
Bosch Rexroth AG Bosch Rexroth AG Condition Monitoring Mobile 2006 69
Condition Monitoring using
Winch Drives as an Example
The brutal truth is that sooner or later everything fails. We can painstakingly
attend to producing flawless design, specify the best materials and work-
manship, and strengthen and preserve every component but, . . . the product
will one day disintegrate, end up in a heap and disappear. [1]
Detect errors and wear before they cause the entire machine to fail; incre-
ase the economical service life and simultaneously minimize safety risks:
These are the goals of condition monitoring systems. Rexroth has already
developed the first systems and taken into account the particularities of the
respective application. Online condition monitoring systems appear to hold
promise for achieving the maximum economical effects.
Dr. Peter Bort
Schwieberdingen (D)
70 Mobile 2006 Condition Monitoring
1 Introduction
Condition monitoring of a machine
or of parts of a machine is described
by the recording and observation of
measured values. An intelligent elec-
tronic system or a knowledge base
is used to interpret changes to these
measured values over time. While
it is usually possible to record the
necessary physical values in a generic
manner, the knowledge base and the
intelligence of the condition moni-
tor must be tightly matched to the
individual components, the system or
the subsystem as well as the respective
application.
The knowledge base contains the
practical knowledge relating to the
components in the form of character-
istic maps and diagrams. In addition,
it knows the rules and algorithms with
regards to the interrelationship of
interconnected components, such as
the interaction between motor, gear-
box and winch drum in a winch drive
(Fig. 1) during various load states.
The condition monitor interprets the
information from the recorded signal
sources and the knowledge base and
returns predictions about the current
state of the observed components or
of the whole system.
Bosch Rexroth AG
Fixed part of the Satellite carrier
gearbox suppor- Winch drum,
ting axle cantilevered
Frame plate
(winch frame)
Planetary levels
Counter bearing
Hydraulic motor
Winch drum with counter bearing
Fig. 1: Winch drive, gearbox and winch drum with and without counter bearing.
2 Motivations for condition With online condition monitoring
system users can push the operative
monitoring
goal of maximum economical utiliza-
In addition to the technical design,
tion of a machine closer to the tech-
the productivity of a machine is de-
nical limits of the machine, thereby
termined, above all, by its availability
increasing the working power of the
(Fig. 2). Online condition monitoring
machine.
increases the availability and the per-
formance of the machine by detect-
ing potential faults in good time and
triggering an appropriate response.
Necessary maintenance, as well as full
or partial shutdown of individual ma-
chine parts can be better planned and,
if necessary, performed together. This
significantly reduces the number and
duration of planned standstill periods
as well as the costs for operating and
maintaining the machine.
Bosch Rexroth AG Condition Monitoring Mobile 2006 71

3 Methods for conditi- Performance

on monitoring in mobile Technical

limit Potential for
equipment optimization
Operative
3.1 Self-monitoring goal
Faults Profit
With self-monitoring, the condition zone
monitor can only access information Break-even
Partial shutdown
which is available in the sensor or, as
Loss
the case may be, in the component it- zone
self. The evaluation occurs directly in Mainten-
Total shutdown ance
the component. Examples of methods
Time
for self-monitoring include switch-
ing to a reference signal or testing Normal operation Unused potential Lost profit Loss

the component with the aid of test Fig. 2: Economical operation of a working machine.
signals.

Switching to reference: Internal sensor speed signal

With this method, the entire measure-

ment value is validated for a sensor by
internally switching to a reference sig- Prebit low = AR width
Transmitted signal: AR
nal. A corresponding reference signal
must be available for this purpose.
Uncritical operation AR width = 45 s typ.

Test signals: Critical air gap Transmitted signal: DR anti-clockwise

A test signal is applied to the com-

DR-A width = 2 x AR width
ponent and the reaction will be ob-
served. With this method, the user Transmitted signal: DR clockwise

can test specific features of the com-

ponent. In most cases, the component DR-C width = 4 x AR width

must be exclusively available for the Transmitted signal: DR anti-clockwise & MP

test.
The methods for self-monitoring are
DR-A & MP width = 16 x AR width
based solely on component-internal Transmitted signal: DR clockwise & MP
variables as well as previous knowl-
edge about the measurement signal or
DR-C & MP width = 16 x AR width
the values to be measured. Therefore,
these methods can always be used. Fig. 3: Communication protocol BODAS DSM1 speed sensor with self-monitoring.
The methods for self-monitoring are
used, above all, in sensor technology.
An example: The BODAS DSM1-10 installation situations and to report
speed sensor (RE 95132), which, in them to the controller (Fig. 3).
addition to detecting the rotary fre-
quency and the direction of rotation,
is able to automatically detect critical
72 Mobile 2006
3.2 Comprehensive monitoring
Comprehensive monitoring records
dynamic information from multiple
signal sources (sensors) as well as ad-
ditional information such as setpoint
specifications which the system must
fulfill. The merging and processing of
this information occurs in a higher
order controller.
Plausibility monitoring:
The observed system is monitored for
inconsistent states. With a hydrau-
lic motor-gearbox combination, for
example, the condition monitor per-
forms this by comparing the motor
speed and the output speed for faulty
constant values while in the on state
(not idling).
Previous and practical knowledge:
Previous and practical knowledge
detects faulty signal characteristics for
a defined process state, e.g. deviations
in flow based on the association be-
tween swivel angle, speed and flow of
an axial piston motor. (Fig. 4).
100
90
80
Q/Qref [Prozent]
70
60
50
40
30
20
10
0 the inspection intervals
0 25
Fig. 4: Interplay between flow, speed and swivel angle of an axial piston motor.
Condition Monitoring
Mathematical models:
Mathematical models process and
classify the measured and recorded
input values. For this purpose, the
observed system must be described
in the form of a mathematical model
and stored in the condition monitor.
The classified data form the basis for
the estimation of the current system
state.
Empirical models / process history:
With this method, the condition
monitor stores the measured and
recorded input values as time series
in a database (process history). The
current values are compared with the
values from the past and state changes
determined on the basis of statistically
significant differences from the pro-
cess history.
The higher order monitoring is often
performed in addition to the self-
monitoring. There are a number of
methods available for this purpose.
Most of these, however, require adap-
tation to the respective application.
The many interdependencies impede
diagnostics in this case. Only through
100% max
80% max
60% max
40% max
20% max
p = p300
= const
bar
50 75 100
n/nref [Prozent]
Bosch Rexroth AG
extensive experience with both the
individual components as well as with
the system are meaningful results pos-
sible.
4 Online and offline condi-
tion monitoring
There are two primary types of condi-
tion monitoring: The continuous on-
line monitoring of the components
or of the individual system. An ex-
ample of online condition monitoring
is the ABS error lamp in an automo-
tive braking system of a car. The off-
line inspection performed at regular
intervals is familiar to car drivers in
the form of inspection intervals speci-
fied by the vehicle manufacturer. Both
methods have different strengths:
Online condition monitoring
+ Immediate detection of state
changes
+ Fast reaction is possible
+ No standstill period of the system
for the inspection
+ No additional staff necessary
+ Automatic, software-based analysis
options
Limited analysis options
Offline condition monitoring
+ Extensive analysis options
+ Detailed results
State changes are only detected at
System generally needs to be
switched off for the inspection
Greater staff requirements
Bosch Rexroth AG Condition Monitoring Mobile 2006 73

Mobile equipment is often used far they require numerous optimization design (operating time and collective
away from the next repair shop or steps in order to make online condi- loads) and the operating company
service station. Should repairs be nec- tion monitoring suitable for mobile performs inspections to ensure adher-
essary, specific machine parts and ser- applications. These include the reduc- ence to the conditions. In Germany,
vice parts are often required. The de- tion of input values, data compression specifications obligate the user to
livery times for these parts can further and the optimization of the algo- determine the used portion of the ser-
extend the downtimes. Only with the rithms. During all of this, a high qual- vice life at specific intervals.
aid of online condition monitoring ity standard must be maintained.
Adherence to the specifications for
systems can changes at the machine,
the calculation of the remaining ser-
e.g. cases of overload, be automati-
vice life always forces the operating
cally detected in good time and can 6 Winch drive example: company to confront the problem of
the user take appropriate actions. He Load Cycle Monitoring either documenting each lifting of a
can order and install the affected part
In Germany, rope and chain hoists as load in detail or of running the risk of
before the machine fails, plan the next
well as crane hoists must be classified a rough estimate. This results either in
service work or accept the increased
according to their planned operating an overestimate of the wear, unneces-
risk of failure or breakdown of the
method in machine groups by operat- sarily reducing the overall service life,
machine.
ing time and load spectra, and they or, in the case of an underestimate,
must be dimensioned according to the the result is an elevated total risk.
resulting load requirements. Machine
5 Technical requirements directive (98/37/EC) also specifies
With Load Cycle Monitoring (LCM)
for online condition moni- from Rexroth, it is, however, possible
that machines be designed and con-
in this application to continuously
toring systems structed so that failure cannot occur
electronically record and evaluate the
Online condition monitoring in mo- as the result of fatigue or aging when
data.
bile equipment places special require- used under the specified application
ments on the electronics. Methods conditions during service life. This In the case of the crane application,
based on historical values or extensive requirement can only be fulfilled if the state of a component is defined
characteristics require a large storage the manufacturer inspects the details by the service life (legal basis: BGV
capacity. Mathematical methods place of the underlying assumptions for the D8 [2]). Based on the known types
additional high requirements on com-
putational power. At the same time,
the components must be suitable for
mobile use, a requirement which has
a considerable effect on costs. Thus,
the provider of condition monitoring
systems must find a balance: He must
match both the available memory ca-
pacities to the necessary storage needs,
as well as the available computational
power to the required complexity of
the algorithms for condition monitor-
ing. For this reason, it is not possible
to directly transfer methods used in
the stationary or offline area to mo-
bile online applications. Moreover,
74 Mobile 2006 Condition Monitoring
of loading of all applications, the re-
maining service life can then be theo-
retically determined. This remaining
service life describes the time in which
the winch drive component can be
expected to be used reliably and safely
during normal operation without
failure.
Rexroth has developed and patented
a solution for winch gears with hy-
draulic motor drive. This solution
autonomously records the respective,
current load over the entire usage of
the winch drive. Based on this infor-
mation, it determines the previous
load spectrum and then calculates the
theoretically remaining service life
for the winch. The Load Cycle Moni-
tor (LCM), an integrated component
of the winch, generates an electrical
signal as well as a CAN bus signal as
a result. The theoretically remaining
service life can be easily queried by the
operating company via the CAN bus
in the vehicle cockpit. Rexroth makes
available appropriate indicator and
control devices for this purpose.
Bosch Rexroth AG
Advantages of Load Cycle Monito- New business models through Load
ring for crane owners Cycle Monitoring
When manually recording loads, With the aid of Load Cycle Monitor-
the operating company must always ing (LCM) in mobile equipment,
calculate with higher reserves due to entirely new business models can be
limited knowledge of the actual load- realized. During rental operation, why
ing. For example, load peaks, which should only the rental period be used
can occur as a result of excessively as the basis for billing when the owner
fast lifting or lowering of the load, are can now also bill by consumption of
frequently not recorded or are not re- service life and wear on the machine?
corded sufficiently. Overloads, which This means that a brief period of use
have considerably greater impacts on at the limit range could cost the user/
the service life, can also not usually renter just as much as a longer period
be manually detected and recorded of usage in the lower load range. An-
by the user. During rental operation, other possibility: If the renter subjects
the owner must trust the details pro- the machine to above-average loads
vided by the crane operator as he has during the rental period, he must then
no methods of control at his disposal. pay a special usage fee according to
This represents an elevated risk to the the given application case.
owner.
The Load Cycle Monitor (LCM) from
Rexroth automatically records all
types of load liftings, from very small
loads which do not affect the service
life to normal operation to dynamic
load peaks and overloads. On the
basis of these values, it calculates the
realistically remaining service life. By
precisely recording and calculating all
types of loading which occur, the user
is able to better use the available ca-
pacity of the components over the en-
tire service life while simultaneously
increasing operational safety.
Bosch Rexroth AG Condition Monitoring Mobile 2006 75

7 Conclusion economically meaningful for the re-

Greater complexity and efficiency of spective application.
mobile equipment increases the costs
of downtimes. For larger machines, Literature
a lost day may cost several thousand [1] Charles E. Witherell, Mechani-
euros depending on the given applica- cal Failure Avoidance, McGraw-Hill
tion case. At the same time, legislators (1994)
are tightening the safety requirements [2] German law: BGV D8
for mobile equipment. Both develop- Patent: DE 199 23 824 C2, German
ments require an even higher level Patent and Trade Mark Office, 1999
of reliability and availability of the
machines in order to ensure their con-
tinued economical operation. For this
reason, systems for online condition
monitoring are becoming an increas-
ingly important tool for fulfilling
these requirements.
An example of a pragmatic approach
to online condition monitoring is
the Load Cycle Monitor (LCM) from
Rexroth. It ensures the reliability and
availability of the machine and helps
to extend the economical total service
life of the machine by operating close
to the technical limits. (Fig. 2).
Increasingly powerful controllers set
the technological foundation for on-
line condition monitoring systems in
mobile equipment. Reliable condition
monitors require detailed knowledge
of the components and, above all,
sound knowledge of the respective
application in order to develop the
corresponding algorithms. The costs
which must be invested in order to
develop and optimize the algorithms
for mobile applications must not be
underestimated. Therefore, manufac-
turer and user must carefully examine
the potentials offered by online condi-
tion monitoring in mobile equipment
in order to determine when and in
what capacity a monitoring system is