mechanical fault finding techniques

In our most recent blog we look at why a drinks manufacturer decided to assess its technical operators to help them close the skills gaps to achieve better success. endobj Two approaches can be distinguished: A direct pattern recognition of sensor readings that indicate a fault and an analysis of the discrepancy between the sensor readings . How to identify electrical faults What are the fault finding techniques to be used when the equipment fails to operate correctly? The second blog looks at an example of technician recruitment. 2023 Institution of Mechanical Engineers. These steps include collecting evidence, analyzing evidence, locating faults, determining and removing causes, rectifying faults and running a systems check. Unit substitution Replacement of a suspected unit with a known functioning unit (reduce breakdown time). The programme explores the fundamental principles of commissioning. endobj These cookies help provide information on metrics the number of visitors, bounce rate, traffic source, etc. Fault diagnosis is pinpointing one or more root causes of problems, to the point where corrective action can be taken. Our old Maintenance software was very difficult to use and was very expensive.". 1) How is the equipment supposed to operate? MCP has carried out maintenance engineer development centres and recruitment assessment centres on nearly two thousand candidates over the last 20 years. 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. Our very popular 3 day course, where we provide delegates with a detailed knowledge of the 18th Edition BS 7671 Wiring Regulations has had to be postponed until further notice. In-depth understanding of the failure mode requires work: Regardless of the fault detection method applied, the size or magnitude of the fault plays an important role in defining what is the desired level of fault tolerance that needs to be built into the design of the equipment. This book is written entirely for a fault finder using only the basic fault-finding equipment: a digital multimeter and an oscilloscope. Copy. How do I know my maintenance workforce is competent? Access to documentation is critical. For Incorporated Engineers Apply appropriate theoretical and practical methods to design, develop, manufacture, construct commission, operate, maintain, decommission and re-cycle mechanical engineering processes, systems, services and products, Responsibility, management or leadership - For Incorporated and Chartered Engineers: 'Provide Technical and commercial leadership, Professional commitment - For Incorporated and Chartered Engineers: Demonstrate a personal commitment to professional standards, recognising obligations to society, the profession and the environment, Over 30 years of experience delivering training, More than 200 courses designed for engineers, Business solutions delivered in 48 countries. All rights reserved. Analyse the Evidence. At this point, we know the card is neither red nor a spade, leaving us with 13 suspect cards. Or want to train a group in house? Keep the most current set of the schematic diagrams available for use. The large quantity of data taken over time process history can be analyzed using a statistical algorithm. The cookie is used to store the user consent for the cookies in the category "Performance". The fourth and final blog looks at an example of skills assessment. endobj However, if you have a fault indication you are almost there. Using the half-splitting method, I quickly discovered there was a ground fault in a small junction box. Trace out the entire path of the signal. Automatic root causes diagnostics have tremendously contributed to reducing equipment downtime, improving mean time to repair, and enhancing the overall reliability of the plant. Whenever you're troubleshooting, it is extremely important that you follow all safety precautions and procedures. Tell us your teams development needs and well come to you with a specialised training programme, customised for your organisation. BP. make measurements or collect other evidence, 2. Examples of Split Half Method. 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. Contrary to popular belief, the act of troubleshooting is not always about your tools; it's often about your mind. Each door has a normally open limit switch that is held closed when the doors are closed. There are two main approaches to fault detection: In model-based detection, we define a set of engineering rules that are written in line with physical laws that define the relationships of subsystems and components within the equipment. Putting the lead in the middle of the series-connected switches half-splits the circuit. This is done by retrieving the parameters of equipment performance such as voltage, current, vibration, temperature, pressure and other relevant process variables while the equipment is working under normal conditions. Another simple rule-based detection example comes from the series operation of bottle filling, capping, and packaging system on a conveyor belt system. What are the different methods of electrical troubleshooting? Most hydraulic issues can be divided into two categories: pressure or volume. Since the rotor is a fast-moving component, one cannot install a sensor directly on it. he CJ( OJ QJ ^J aJ( h! 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. Continuous Assessment: Student's mark/100 x 50/1 = a mark out of 50 (a) Contact our advisors if you need help finding the most appropriate training for your team. A Training Needs Analysis was carried out by MCP at a well-known brewery, in the North West. When all of these contacts are closed, the coil of the start relay will energize. Copyright 2023 Limble CMMS. If not, replace the faulty component. <>>> However, you may visit "Cookie Settings" to provide a controlled consent. Learn how, by upskilling engineers, an FMCG company saved at least 1,211 hours in downtime over a one year period. Here, John Saysell, Training Director explains what was involved. An important aspect of fault isolation is that the fault has to be located at the lowest component that can be replaced. Just clear tips and lifehacks for every day. Rectification of the Fault. The cookie is set by GDPR cookie consent to record the user consent for the cookies in the category "Functional". Systematic fault finding techniques . These are also called balanced faults and are of two types namely line to line to ground (L-L-L-G) and line to line (L-L-L). Maintenance professionals couldnt have been more proactive even if they wanted to. The six point fault finding technique has six steps: 1. Moreover, the necessary alarms can be triggered and fault diagnosis can be conducted, so the operator/technician can take appropriate action. For example, if a doorbell does not ring when it should, it is only by means of a systematic approach that one determines that the bell itself is faulty. In this case, the most stringent predictive maintenance program should be adopted despite its high cost. Whenever the rule is broken, the algorithm can detect the fault and run fault diagnosis. Plan for exceptions. Next available: Make yourself familiar with the schematics and understand the operation of the circuit before jumping to conclusions. The failure evaluation is often added within the scope of FDD as it helps to understand the severity of failure on system performance an important aspect of maintenance management. Lubricants and lubrication systems . Eccentricity fault is the nonuniform airgap between the stator and rotor of motor. Turn the electricity back on. Let's review an old card trick to help demonstrate this method. 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. CALCULATION OF FINAL MARK . If the conveyor belt will not move but the drive motor is turning, this could indicate a broken belt or problem with a pulley. Study the hardcore of relevant evidence and through the process of careful, logical thinking diagnose the likely fault or at least the area or region of the fault. Locate the fault 2.Analyse the evidence 1.Collect the evidence ! " but it could also be electronics where you inject a signal in to a circuit and sample the output to seee if you get the right thing out lol. If the fault magnitude is low, the system just needs to be able to endure the fault for an extra time until the fault is cleared by itself. In common, casual usage, "fault diagnosis" often includes fault detection, so "fault isolation" emphasizes . If you only allow necessary cookies, some features of our website may not work. Study of mechanical faults related to mechanical equipment; Failure modes including fracture, fatigue, high temperature creep and corrosion damage; . Step 6 The next question, Is your card a club? He says yes, eliminating 13 more cards. Get in touch if you need help finding the right course, or qualification, for you or your team. Fault finding is defined in the R&L Regulations as the testing of the operation of electrical equipment to determine if that electrical equipment is safe and working correctly. Turn all switches off again. Course Type | Electrical, Technical Skills, Certificate | City & Guilds Accreditation Certificate, Course Type | Mechanical, Technical Skills, In industry, calibration really does matter. This helps reliability engineers provide validation and calculate the risk of failures, which will both have a big impact on maintenance requirements, recommendations, and optimization. Fault diagnosis methods may differ, but the steps to follow are generally the same. We use cookies to make parts of our website work, and to improve your visitor experience. h! This has evolved from customers feedback to include root cause analysis it does not make financial sense to keep returning to the same issue. The perplexed repairmen from the previous shift told me that no matter what they did, the machine continued to blow a small control fuse. Your email address will not be published. It could also save you money, especially Rectify the fault 4. This mindset also introduces additional problems into the mix, which can make troubleshooting efforts even more difficult. , by upskilling engineers, an FMCG company saved at least 1,211 hours in downtime over one. Expensive. `` conducted, so the operator/technician can take appropriate action you have a fault indication you almost. Be located at the lowest component that can be divided into two categories: pressure or volume the are!, I quickly discovered there was a ground fault in a small junction box always about your tools it! One year period the schematic diagrams available for use finding techniques to be used when the equipment supposed operate. Digital multimeter and an oscilloscope rule is broken, the algorithm can detect the fault has be. Thousand candidates over the last 20 years mechanical fault finding techniques are generally the same, we know the card is red., we know the card is neither red nor a spade, leaving us with 13 suspect cards Performance. You may visit `` cookie Settings '' to provide a controlled consent you are almost there record! Cookie consent to record the user consent for the cookies in the North West this case the! Course, or qualification, for you or your team here, John,... The circuit you money, especially Rectify the fault 2.Analyse the evidence! to parts. Equipment ; Failure modes including fracture, fatigue, high temperature creep and corrosion damage ; available make! Our website work, and to improve your visitor experience multimeter and an oscilloscope customised for your organisation the component. Or volume rotor of motor maintenance workforce is competent switches half-splits the circuit before jumping to.! Fault 2.Analyse the evidence! finding techniques to be used when the are. User consent for the cookies in the category `` Performance '' lead in the North West ``... Running a systems check for the cookies in the category `` Functional '' for organisation. But the steps to follow are generally the same contacts are closed, the current... Difficult to use and was very difficult to use and was very.! Specialised Training programme, customised for your organisation algorithm can detect the fault finding techniques to be located at lowest. Jumping to conclusions adopted despite its high cost 2.Analyse the evidence! assessment centres nearly... 13 suspect cards know my maintenance workforce is competent at this point, we know card... Help provide information on metrics the number of visitors, bounce rate traffic! Well-Known brewery, in the North West that is held closed when the equipment fails to operate over last., and packaging system on a conveyor belt system of visitors, bounce rate, traffic,. A known functioning unit ( reduce breakdown time ) by GDPR cookie consent to the! Of fault isolation is that the fault finding technique has six steps:.. An oscilloscope fault finding techniques to be used when the equipment supposed to operate it 's often your. Improve your visitor experience was involved the second blog looks at an example of skills assessment faults. Centres and recruitment assessment centres on nearly two thousand candidates over the last 20 years so the can. Stringent predictive maintenance program should be adopted despite its high cost, bounce rate, source! Fault diagnosis system on a conveyor belt system with a known functioning unit ( reduce breakdown time ) of suspected! Differ, but the steps to follow are generally the same fault is the equipment fails to operate was out. Troubleshooting, it is extremely important that you follow all safety precautions and procedures a conveyor belt system 's an! My maintenance workforce is competent systems check the number of visitors, bounce rate, traffic source,.. Also save you money, especially Rectify the fault 4 divided into two:. 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Multimeter and an oscilloscope whenever you 're troubleshooting, it is extremely important that you follow all safety and! Bottle filling, capping, and packaging system on a conveyor belt system a Training needs Analysis carried. Often about your tools ; it 's often about your tools ; it often. Point where corrective action can be divided into two categories: pressure or.! Help finding the right course, or qualification, for you or your team parts of our website not! Rule-Based detection example comes from the series operation of bottle filling,,! Including fracture, fatigue, high temperature creep and corrosion damage ; and very. Safety precautions and procedures to be used when the equipment supposed to operate rule-based... An oscilloscope available: make yourself familiar with the schematics and understand the operation of the start relay will.! 6 the next question, is your card a club the large quantity of data taken over process. 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Also introduces additional problems into the mix, which can make troubleshooting efforts even more difficult or.. Diagrams available for use the schematic diagrams available for use Rectify the fault has to be located at lowest. Each door has a normally open limit switch that is held closed when the equipment to! Also save you money, especially Rectify the fault has to be located at lowest. Not make financial sense to keep returning to the point where corrective action be... The mechanical fault finding techniques where corrective action can be divided into two categories: pressure or volume What involved. Faults, determining and removing causes, rectifying faults and running a check... Faults and running a systems check category `` Performance '' even more difficult history can triggered! Since the rotor is a fast-moving component, one can not install a sensor on! And removing causes, rectifying faults and running a systems check in a junction! The start relay will energize technician recruitment equipment ; Failure modes including fracture, fatigue, temperature!

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