Equipment gradually wears out during operation. As a result, breakdowns and stoppages of production lines occur. This leads to losses for the company. To avoid this, diagnostics of the state of the equipment are carried out. This procedure allows you to determine whether the equipment needs repair, even before the machine stops. For this, modern diagnostic tools are used. They will be discussed further.
Definition
Technical diagnostics is a procedure aimed at reducing the costs of the enterprise in the course of its core business. This is an integral part of the maintenance of machines, equipment, which reveals the need for targeted repairs. This area of knowledge covers the theoretical and practical methods for identifying the condition of equipment.
The diagnostic procedure can be complex, planned and periodic. It is also divided intothree categories: functional, test and express diagnostics. During the periodic scheduled inspection, a number of procedures are carried out. When placing equipment on the balance sheet of the enterprise, technologists inspect the machines, control their components and mechanisms. This minimizes sudden equipment shutdowns. Diagnostics allows you to control the degree of equipment aging.
Tasks
During the implementation of a comprehensive determination of the state of production units, a number of tasks are solved. The technical condition of the equipment is being established at the moment. This information allows you to make a decision about the need for repairs. If possible, service intervals can be extended. The consumption of spare parts in this case will be less.
Complex diagnostics reduces the number of spare parts in warehouses. This releases money from circulation. They can be directed to the development of the organization. Having received reliable, comprehensive information about the condition of the units, you can reduce the duration of the repair itself. The shutdown of the equipment will be short. Service quality is also improving.
In accordance with established standards, it turns out to extend the working life of the equipment. The safety of machine operation is increasing. With proper processing of the received information about the state of the equipment, it is possible to reduce the cost of energy resources at the facility.
Varieties
In the course of the study, certain methods and means are useddiagnostics. They allow you to comprehensively track changes in the operation of the unit. Diagnostic tools are called special equipment, programs that allow you to perform comprehensive control.
As mentioned above, diagnosis can be of three types: functional, test and express procedure. They are used for different purposes. Test determination of the state of the equipment involves the impact on the object of study empirically. Using this technique, you can determine how the equipment will behave in certain conditions.
Based on the information received, it is possible to calculate how quickly the unit or its individual components will wear out. To do this, measurements of certain indicators are carried out. Diagnostics of machines in test mode allows, for example, to determine how worn out the insulation of an electrical unit is. To do this, the tangent of the dielectric loss angle is measured when alternating current is applied to the motor winding.
During the functional diagnostics, the operation of the equipment is checked during its operation not in test, but in normal mode or under certain operating conditions. For example, the state of rolling bearings is determined during the operation of an electric machine. To do this, their vibration is measured.
Express diagnostics is performed as quickly as possible. During such a check, a limited number of parameters are checked in a limited time.
Varieties of diagnostic tools
There is a certain classificationtechnical diagnostic tools. In accordance with the scope of application, there is standard and special equipment. They have characteristic features.
Regular diagnostic tools are used mainly in the course of functional determination of the state of machines. Such equipment allows you to assess the current state of the equipment. This category of funds includes all devices and technical means of control that are listed on the balance sheet of the enterprise. The same tools can be used in the course of technical diagnostics, if the research methodology suggests it.
For example, regular diagnostic equipment for cars allows you to evaluate the dynamics of fuel filter contamination. To do this, the pressure drop before and after the purifier is measured. Regular diagnostic systems can be supplemented with various devices. For example, these can be remote monitoring devices, alarms, etc.
Special tools are used from time to time by diagnostic service specialists to determine the need for repair or the quality of the units after maintenance. Special devices also allow you to determine the reason for the stop of the machine. As a rule, such equipment does not belong to the entire enterprise, but only to its special department. Some third-party verification services may use similar technologies.
Assignment of diagnostic tools
Diagnostic equipment for cars, cars and other units is divided by purposeinto specialized and universal. The choice depends on the features of the check.
Universal technical means are used in the course of determining the state of equipment at almost any facility. This test does not evaluate hardware features. The category of such technical means includes technical means for estimating temperature, pressure, electrical resistance or magnetic field. Also, such tools include devices that determine the spectrum of noise and vibration.
Specialized technical means are needed to test only certain elements of the mechanisms. For example, these can be devices for monitoring the efficiency of rolling bearings, the tightness of engine cylinders.
Diagnostics of machines using specialized tools can turn into determining the state of equipment using universal devices. The design of such equipment may include ammeters, pressure gauges, and other measuring devices.
All tools used in the course of diagnostics can be divided into portable and built-in. Some mechanisms are built into the design of the device itself, since testing of its operation is required to be carried out during the entire period of its operation. Portable technical means mainly belong to the category of universal ones. They are used for different units and mechanisms.
Basic diagnostic tools
Technical diagnostics is carried out using different means. They are used to measurefixing the state of research objects. As a means of determining the state of equipment, special devices, stands and other devices are used.
A separate group includes electrical diagnostic tools. These, for example, can be voltmeters, oscilloscopes, ammeters and other similar devices. Electrical devices are used to measure various processes. Almost every company has such equipment on its balance sheet. It can be used to determine electrical and non-electrical indicators. In the second case, special sensors convert the received information into electrical signals.
Diagnostic tools can work in different ways. However, various sensors are most often used (induction, limit, photoelectric and others). With their help, the size of gaps, backlashes, the frequency and speed of rotational movements, etc. are determined. Also among the tools are resistance and thermal resistance sensors, thermocouples, piezoelectric sensors.
Regardless of the type of diagnostic tools, they must be accurate enough to provide reliable information about the state of the object of study. Also, such equipment should be easy to use and require a minimum amount of time for measurements during the test.
Diagnostic methods
To determine the state of the object being diagnosed, a certain testing methodology is being developed. In order to create an optimal sequence of actions for service personnel,it is necessary to highlight the main parameters of the equipment. They must provide reliable information about the reliability of the equipment. Based on the collection of certain data, method developers establish the main criteria that may be applicable to a particular fixture.
Common for almost all objects of research criteria are accuracy, performance, resistance to various adverse external and internal influences. This allows you to determine whether the equipment is reliable, whether it will be able to perform the functions assigned to it in the future.
The methods used in a study can be very different. Some of them consider, first of all, the parameters of ongoing processes (fuel consumption, pressure, power, productivity, etc.). Other methods are guided by diagnostic parameters of an indirect type. For example, it can be noise, temperature, etc.
Techniques used in production can evaluate the performance of equipment at different levels. Some of them are designed to assess the condition of all machines as a whole, others - only individual units. There are also methods aimed at obtaining information about the operation of only individual systems and mechanisms of technology. This approach allows you to accurately determine whether the equipment needs to be repaired or can be relocated.
Parametric technique
Technical diagnostics can be carried out using different methods. Some of them are designed forcertain equipment, while others are universal. Often, enterprises use a parametric diagnostic method. It consists in continuous or periodic monitoring of certain parameters of equipment operation.
The parametric method is carried out using standard tools. The result obtained is compared with the maximum permissible values. Based on the data obtained during such an analysis, it turns out to make the right decision about the need for repair or adjustment work. The assessment of the state of operation of the unit is carried out both as a whole and for individual components.
Generalized indicators that are evaluated in the course of the presented method are fuel consumption, power, etc. Particular indicators are evaluated using certain standard research instruments.
During the detection of deviations, a number of procedures are carried out to help determine the cause of the malfunction. If, for example, the engine power has increased, there may be several reasons. For example, fouling of the body is observed, certain components of the mechanism are damaged, some parts of the motor are misaligned, etc.
The parametric method cannot be the main one in diagnostics. It is always used in combination with other approaches. The diagnostic results in this case require clarification.
Instrumental technique
There are many methods of technical diagnostics. They apply under certain circumstances. One of the popular approaches is the instrumental method. During its implementation,special devices. They measure the values of certain parameters of the machine.
Often, such methods are used for units whose operation has been suspended. During the instrumental check, endoscopes are used to inspect the internal space of the unit. This allows you to detect deposits, damage to internal parts.
Vibroacoustic technique
The technical condition of some mechanisms can be assessed using a vibroacoustic technique. In this case, it turns out to evaluate the low- and high-frequency vibrations of the equipment, its individual elements. For this, different means are used. These can be seismic instruments, torsiographs, noise meters, vibrographs, etc. Each of these instruments is used to assess the condition of a particular unit.
Having considered the existing methods and diagnostic tools, you can understand the features of the work to assess the condition of the equipment. The trouble-free, productive operation of the equipment depends on the correctness of such a procedure.
