In our Sintering Plant, we utilize a Shaker assembly to discharge Hot sinter return. This assembly features a 1500 RPM Motor with Drive and driven eccentrics, connected by a KARDON SHAFT. Unfortunately, Kardon shaft failure is a common occurrence due to coupling failures. One major issue we encounter is that even after the coupling fails, the motor continues to run, leading to material jamming. We are seeking suggestions for a method to automatically trip the motor when the coupling fails. Is there a monitoring device available for this purpose? Any advice would be greatly appreciated.
Alok, the frequent breaking of the coupling presents an interesting challenge. It is important to understand why this is happening and to proactively find a solution. While there may not be a ready-made device on the market, utilizing the physical characteristics of the breakdown can help in creating a custom solution. For example, when the coupling shears and one shaft continues to rotate while the other stops, sensors can be used to measure the difference in rotational speeds to automatically trip the motor. Additionally, if one shaft physically drops when the coupling shears, this drop can also be measured to trigger a motor shutdown. Another option is to monitor the change in electrical current, although this may present some challenges with the circuitry. By taking these factors into consideration, it may be possible to create a more reliable system to prevent future coupling failures.
Alok, consider utilizing an affordable speed sensor to optimize motor performance. If the motor is running but the speed is registering as zero, it could be an indication of a potential shaft issue. It's important to address coupling failures proactively or implement a system to detect and prevent them before they result in costly breakdowns. - Walt
Is there a possibility of tripping due to low current draw in the motor? Thinking about Vibmaster. This will help prevent any potential issues with the motor drawing less current than usual.
You might want to look into integrating a torque monitoring system into your assembly. These devices can measure and monitor the torque in the Kardon shaft in real-time. If the coupling fails, it will result in a sudden decrease in torque, which the system should be able to identify and initiate a shutdown of the motor. Though I haven't got a specific brand to recommend, I suggest looking for a system that is robust enough to withstand the working conditions in your plant and offers a near instantaneous response to prevent jamming.
It sounds like a vibration monitoring system might be the solution for your issue. These systems can detect abnormal vibration patterns which can indicate potential failure. If the coupling on the Kardon shaft fails, there would be a noticeable change in the assembly's vibration patterns. The system then could be programmed to trip the motor in response to this, preventing further material from clogging up your system. You would also want to investigate why the couplings are failing regularly in the first place to stop this issue from recurring, perhaps due to lack of maintenance or an incorrect component spec.
In my experience, one possible solution could be the installation of a torque monitoring system. This device monitors the amount of torque being applied to the shaft and, in the event of a coupling failure, a sudden drop or shift in the applied torque is very likely. This could then trigger an automated system to immediately shut down the motor, thus preventing material from jamming. Additionally, consider regular preventive maintenance of the coupling to mitigate failure. It may seem costly initially but could save significant downtimes, which are more expensive in the long run.
It sounds like a torque monitoring system might fit your needs. These systems can sense the torque on the motor shaft and when a sudden drop (such as a coupling failure) occurs, they can interrupt power to the motor to prevent further damage. One such system on the market is the TorqueTrak Revolution from Binsfeld Engineering. It's non-contact and maintains constant monitoring, thus it could potentially help predict failures before they occur by tracking changes in torque trends. You may want to explore similar products or consult an expert to ensure compatibility with your specific setup. Best of luck!
It sounds like you've run into a frustrating but common issue with your setup! One potential solution could be to install a vibration monitoring system that can detect significant changes in vibration patterns indicative of coupling failure. These devices can be programmed to shut down the motor automatically if vibrations exceed a certain threshold, which would help prevent jamming. You might also consider using a proximity sensor or a torque limiter that can detect slippage in the system and trigger an emergency stop. It could be worth looking into smart sensors that can integrate with your existing controls for real-time monitoring and alerts as well. Hope this helps!
It sounds like you're dealing with a tricky issue there! One option you might consider is implementing a vibration monitoring system. These devices can detect abnormal vibrations that typically occur when the coupling fails, triggering a relay to automatically shut down the motor. This way, you can prevent material jamming and potential damage to the equipment. Another approach could be using torque sensors that monitor the load on the motor; if it exceeds a certain threshold due to coupling failure, it can send a signal to trip the motor. There are various solutions on the market, so it might be worth researching a few to find the best fit for your setup!
✅ Work Order Management
✅ Asset Tracking
✅ Preventive Maintenance
✅ Inspection Report
We have received your information. We will share Schedule Demo details on your Mail Id.
Answer: - The common issue faced in a Sintering Plant related to the Shaker assembly is Kardon shaft failure due to coupling failures.
Answer: - The major concern when the coupling fails in the Shaker assembly is that the motor continues to run, leading to material jamming.
Answer: - Yes, there are monitoring devices available that can automatically trip the motor when the coupling fails in the Shaker assembly.
Answer: - The automatic motor tripping device can prevent material jamming by stopping the motor when the coupling fails, avoiding further operation that may lead to material jamming.
Answer: - Some suggestions for implementing an automatic motor tripping device include exploring monitoring devices specifically designed for this purpose and ensuring proper installation and maintenance of the device.
Join hundreds of satisfied customers who have transformed their maintenance processes.
Sign up today and start optimizing your workflow.