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Predictive maintenance

The focus is on machine availability: Use the condition monitoring features of our positioning systems and other functions.

Predictive maintenance is designed to keep our products and the connected components in good condition and thus ensure your machines operate with the minimum trouble possible. Our 3-series positioning systems generate a wide range of diagnostic messages that enable you to take action quickly, identifying and solving the problem before a fault occurs in machine operation. A selection of the diagnostic messages can be found here.

Condition monitoring | self monitoring

The availability of the machine is the focus – supported by condition monitoring. If the control unit detects that a machine could have a problem before a malfunction occurs, it can take pre-emptive action. The 3-series positioning systems therefore generate a wide range of diagnostic messages for predictive maintenance. A selection of these are presented on this page.

Possibilities of condition monitoring

Diagnostic messages of the positioning systems PSx 3 series

Temperature monitoring

The temperature is monitored to protect the drive and other components. If the temperature exceeds or falls below a limit value, the motor is switched off immediately.

Number of changes of direction

Number of changes of direction: This function counts the number of changes in the direction of rotation during a movement or when a new movement starts in the other direction.

Continuous monitoring of the voltage level

The PSx 3-series positioning systems deliberately ignore very short “spikes” but report all over- and under-supplies that exceed a specified duration. Thus, they can detect faults in the power supply before damage or downtime occurs.

Continuous monitoring of power consumption & torque

This function prevents the positioning system from being overloaded and protects the application in specific ways, e.g. against the effects of excessive torque. Basically, any deviation from the normal values stored in the control system can indicate a malfunction.

Minimize drag error

Optimum adjustment of the actual position with regard to the specified target position is a central quality feature of the PSx 3-series. If the control unit detects that one positioning system is falling behind, it accelerates it in order to minimise “drag error”. The drag error monitor is also used to provide early warnings.

Current-active time integral

This value shows the load that the drive has had to provide so far. Every second during a run, the control unit adds up the latest motor current values, i.e. the torque that the drive currently has to provide.

Number of errors

The control unit counts the number of error bits set in the status.

Possible errors:

Blocking error
No motor voltage
Manual rotation
Temperature too high
Incorrect target value
Invalid positioning specification

Maximum torque

This value indicates the maximum torque that has occurred so far, i.e. the highest value measured since the drive was delivered.

Active operating time

This specifies the time in minutes during which the control voltage was applied.

Number of positioning run

This value indicates the number of times that the drive has started from a standstill.

Active time

This value indicates the number of times that the drive has started from a standstill.

Distance travelled

This counts the number of revolutions that the drive has run so far.

Simulation models for positioning systems PSx3xx

Faster development and commissioning of machines with simulations are possible with our positioning systems PSx3xx. Find out more about the FMU provided by halstrup-walcher.

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