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Founded in 1945, the Association of Electrical and Mechanical Trades is an International Association representing companies in the electrical and mechanical service and repair industry.
Welcome to the latest issue of Renew.
We are well into the Association of Electrical and Mechanical Trades’ 80th anniversary year, and our plans to recognise this significant milestone are moving apace.
Our conference, which has been moved to a new stand-alone date in September, is really starting to take shape and there are details on page 10 of this issue. I’m particularly looking forward to hearing Mark “Billy” Billingham, former SAS Warrant Officer and star of SAS: Who Dares Wins, speak on the power of teamwork, leadership, and resilience, and of course the opportunity to network with friends and colleagues from across the industry is always a highlight.
The annual AEMT Awards will present another opportunity to celebrate the Association’s eighth decade. In the past, I have been involved both as a sponsor and entrant in these awards and can attest to the value this initiative brings to the industry in recognising and celebrating the organisations and individuals who are truly shining. Entries for the 2025 awards, which are being held in November, can now be submitted, and you will find details on page 14.
Finally, I’d like to draw your attention to a piece on page 34 from Thomas Marks, the Association’s general manager and secretary. In it, Thomas explains why, in the electromechanical repair sector, certainly, repair shouldn’t be seen as a compromise option and can indeed bring notable benefits.
I hope you enjoy the issue.
James Stevens, President, AEMT
Renew is a controlled circulation journal published quarterly on behalf of the AEMT by Touchwave Media and G and C Media. For a copy of the magazine’s terms of control and to request a copy please email circulation@renew-mag.com
The content of Renew magazine does not necessarily reflect the views of the editor, publishers, or the AEMT. The publishers accept no legal responsibility for loss arising from information in this publication and do not endorse any products or processes mentioned within it. No part of this publication may be reproduced or stored in a retrieval system without the publisher’s written consent.
ROTARY ENGINEERING HELPS LOCAL STUDENTS SECURE THE PRESTIGIOUS INSPIRE AWARD
SHEFFIELD-BASED
ROTARY
Engineering, a manufacturer of machinery and equipment for the motor rewind industry and the production of high voltage coils, was approached by Derby Grammar School to assist with a robotics project for the First Tech Challenge competition which sees young people aged 12-18 design, build and compete with a robot to take on a global challenge.
Alongside a financial contribution to the project, the company’s engineers, Kevin Tate and Jack O’Neill, were made available for advice if needed. However, the team at Derby Grammar School was confident in its project and needed no assistance.
At the event, held at Sheffield Hallam University in March, the team of students confidently completed the challenge of picking up a brick and hooking it onto a metal tube with a robot, and as a result, won the Inspire Award. The team, which included aspiring engineers, lawyers and doctors who demonstrated excellence in engineering, teamwork, perseverance and innovation, will attend the international finals in London in June.
The design included a clamp with helical teeth, several 3D printed components and extendable lanyards for cable management.
Rotary paid for the main chain drive, linear guide for raising the arm and expansion box for extra IO.
Recognising the essential role engineering plays in the future success of the business, Rotary is keen to inspire children to consider engineering as a future career and has previously supported the Primary Engineer initiative, working with younger children.
The company is firmly rooted in its home town of Sheffield, having been based in the town since it was formed in 1952; as such, it has been a proud carrier of ‘Made in Sheffield’ accreditation for its products. It has now taken this a stage further and has recently achieved recognition for ‘Made in Britain’ status.
The Made in Britain mark recognises the provenance of goods manufactured in Great Britain and Northern Ireland and reflects the quality and desirability of
British-made goods while uniting British manufacturing sectors, and helping consumers, buyers, and specifiers identify products made by its members. Indeed, a survey carried out in 2024 found that 79% of UK companies today recognise the official Made in Britain Trademark, amid rising business demand for British products, while a growing 56% of consumers recognise the mark, with more than half of those surveyed preferring to buy goods produced in Britain where possible.
INNOMOTICS AND DANFOSS DRIVES STRENGTHEN PARTNERSHIP
TO DELIVER COMPREHENSIVE MOTOR AND DRIVE SOLUTIONS
INNOMOTICS GMBH, A GLOBAL provider of electric motors and large drive systems and Danfoss Drives A/S, a global supplier of low-voltage drives, have announced the next phase of their strategic, non-exclusive partnership. The collaboration is designed to meet the growing demand for comprehensive motor and drive solutions, ensuring customers receive high-quality, efficient, and compatible products.
By joining forces, Innomotics and Danfoss are offering customers the flexibility to bundle low-voltage motors from Innomotics with Danfoss lowvoltage drives in a seamless package. This approach is particularly beneficial for customers seeking a specific combined
motor and drive solution as part of a delivery or project.
While both companies are aligning their go-to-market strategies for common customer approaches, they continue to provide separate quotes for their respective products, ensuring transparency and flexibility for customers. Additionally, both companies remain committed to brand independence, ensuring customers have the flexibility to choose the best motor-drive combination for their needs.
Michael Reichle, Innomotics CEO, commented: “The strategic partnership with Danfoss Drives allows us to further extend our offering. Many of our customers require very specific motor
and drive combinations with the highest standards of reliability and efficiency. This applies in particular to fast-growing sectors such as the water industry. By combining our strengths, we can increase the competitiveness of both brands and conquer new markets.
Mika Kulju, President of Danfoss Drives, added: “We are excited to take this next step in our collaboration with Innomotics. By offering tailored motor and drive packages, we are delivering competitive, efficient, and convenient solutions that directly benefit our customers. Our goal is to provide the best possible solutions while giving customers the flexibility to select the right motordrive pairing.”
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SULZER STRENGTHENS ITS MIDDLE EAST PRESENCE
SULZER HAS ANNOUNCED THE acquisition of Davies and Mills, an electromechanical services (EMS) provider based in Bahrain. With this acquisition, Sulzer expands its regional footprint in the Middle East to six service locations, welcoming 53 former Davies and Mills employees to the Sulzer family. The acquisition was concluded in January 2025.
Sulzer is continuing to invest in the Middle East, adding its sixth service centre in six years and significantly expanding its regional footprint. The expansion underscores its commitment to establishing full-service, in-region capabilities supporting the
needs of industrial customers. The new facility offers maintenance and repair services for rotating equipment, including generators, alternators, motors, and pumps, while strengthening its footprint in Bahrain and Saudi Arabia.
Ravin Pillay-Ramsamy, President of Sulzer's Services Division, emphasised the company's broader vision: "This acquisition supports Sulzer's long-term strategy to strongly position our service capabilities in growth markets such as the Middle East. Davies and Mills brings exceptional expertise to our portfolio. Combined with Sulzer's regional footprint and global network, we create a powerful partner that benefits our customers. We're excited to welcome Davies and Mills employees to Sulzer –their can-do spirit perfectly complements our commitment to excellence and customer-focused culture."
QUARTZELEC OPENS MADRID-BASED OPERATION
AS PART OF ITS ONGOING GROWTH strategy across Europe and globally, the independent electrical engineering group, Quartzelec has established a new subsidiary in Madrid, Spain. According to the company, this expansion marks a strategic step forward in Quartzelec's commitment to growth and service excellence within the European power generation sector. Stephen Densley, International Business Development Leader at the company, stated: "As we continue to pursue new opportunities, including multiple framework agreements, this move reflects our determination to stay ahead in a highly
competitive landscape. Our new Madridbased subsidiary also underscores our long-term dedication to our clients and enhances our ability to deliver seamless, responsive service across Europe and beyond."
Andrea Vona, who has been appointed the subsidiary's Operations Manager, added: "With a stronger local presence, we are poised to overcome the challenges of cross-border operations, ensuring smoother logistics and more efficient project execution and this streamlining of operations will provide our clients with the benefits of faster, more cost-effective solutions.
"This expansion also enables us to tap into a broader pool of talent, allowing us to attract and retain experienced professionals in the industry; ultimately ensuring that we meet and exceed the expectations of our clients across the region."
The Spanish subsidiary will also serve as a hub to support the sales of the Quartzelec Group's products, which include LIFEVIEW condition monitoring, developed and manufactured by Quartzteq, and HV stator bars and rotor coils from Quartzcoil. Spare parts and related products will also be available, further bolstering Quartzelec's presence and service capabilities in Europe.
GLOBAL GEARED PRODUCTS MARKET CONTRACTED 3.7% IN 2024
ACCORDING TO A REPORT FROM research specialists Interact Analysis, after 1.9% growth in 2023, the global geared products market contracted by 3.7% year-on-year to $12.4 billion in 2024. The contraction of the market was caused by sluggish demand in the APAC region, as well as continued challenges caused by previous over-stocking in the EMEA and Americas regions.
However, the global geared products market is expected to show signs of recovery in 2025 and return to slow growth.
And the long-term forecast to 2029 is looking much more positive.
The Asia Pacific market for geared products performed the weakest among the tri-regions in 2024 due to sluggish demand in the Chinese and South Korean markets.
At the same time, average prices dropped after rising from 2021 to 2023, driven by lower raw material costs and increased
competition. This price pressure was felt strongly in the APAC region, where vendors were forced to cut prices to stay competitive.
Sales of geared products in the EMEA region fell by 4.4% in 2024, primarily because of de-stocking in the machinery sector. Similarly, the Americas’ geared products market was also affected by de-stocking, largely affecting material handling products.
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UPDATE FROM THE AEMT GENERAL MANAGER
THIS YEAR MARKS THE 80TH anniversary of the Association of Electrical and Mechanical Trades (AEMT), a milestone that invites both reflection and a renewed sense of purpose.
Founded in 1945, in the aftermath of the Second World War, the AEMT was established to support the rebuilding of critical infrastructure during a time of global instability. Fast-forward eight decades, and the parallels with today's landscape are striking. As international tensions rise and protectionist policies take root, equipment owners are once again facing disruption – this time due to escalating trade disputes and tariff escalations between major manufacturing economies.
These supply-side challenges are increasingly felt across the UK and global markets. Delays in sourcing new equipment, rising costs for OEM parts, and concerns over availability have added pressure on operators striving to maintain uptime and performance. In such times, the repair, refurbishment,
and remanufacturing sector proves its value.
AEMT members have consistently played a critical role in keeping industry operational. Whether repairing
electric motors, overhauling pumps, or reconditioning gearboxes, their services offer a reliable, responsive, and resource-efficient alternative to full replacement. With many engineering
Forthcoming AEMT led Courses & Events
firms now facing lead times stretching into months, the ability to return a machine to service in days or weeks can be transformative.
Our members are well-prepared for this moment. Decades of experience in reverse engineering, access to precision manufacturing capabilities, and strong regional coverage mean that support is never far away. Importantly, this is not just about making do with legacy equipment— the standards applied by AEMT members meet, and often exceed, those of the original equipment manufacturers. Consequently, our sector is increasingly seen as a strategic partner in asset management and lifecycle planning, not merely an emergency stop-gap.
November will serve as centrepieces to our 80th Birthday celebrations – a moment to recognise the contributions our members have made and continue to make to industry worldwide.
The conference will bring together users, repair specialists, manufacturers,
strategies, struggling with component availability, or simply want to know who you can trust when things go wrong, the AEMT community is ready to help. Our members operate under codes of practice that emphasise safety, integrity, and quality – and they are increasingly supported by digital tools, training, and guidance to ensure consistent service delivery.
In this context, the AEMT's upcoming Annual Conference on 18 September 2025 at the British Motor Museum carries particular significance. This year's event and the AEMT Awards in
and innovators to explore pressing topics: supply chain resilience, conditionbased monitoring, sustainable practices, and workforce development. These aren't abstract discussions; they're practical, grounded sessions that reflect the real-world concerns of today's maintenance and reliability teams.
For equipment owners, this is an ideal time to engage. Whether you're exploring more sustainable maintenance
In closing, while 80 years is a momentous milestone, we're firmly focused on the future. Our founding mission –to keep industry moving, even in the face of uncertainty – is more relevant now than ever. As the global landscape shifts, we believe the repair and refurbishment industry is not just ready to respond, but to lead.
We look forward to welcoming many of you to our celebrations later this year. Until then, if you're seeking dependable partners in reliability, sustainability, and resilience, look no further than the AEMT.
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NEW-LOOK AEMT CONFERENCE TO ENGINEER A SUSTAINABLE FUTURE
AS THE ASSOCIATION OF ELECTRICAL and Mechanical Trades (AEMT) celebrates its 80th anniversary, it has announced an exciting, fresh new approach to its annual conference, which takes place at the British Motor Museum on 18 September this year.
Based on feedback from across the Association's membership, the conference has been given a new date and an exciting new venue, operating as a standalone event for the first time in 2025. A completely refreshed programme and expanded exhibition floor will give delegates the opportunity to connect with the key players shaping the future of electromechanical engineering as endusers, rewinders, repair specialists, and industry leaders come together for a day of insightful thought leadership, technical presentations, discussions and networking.
As part of the conference's new look, the main programme will be split into two key themes. There will be the technical themes the event has become known for, addressing the latest innovations, insights, challenges and opportunities specific to the electromechanical repair sector. Meanwhile, the programme will address several key business issues many organisations face, including those operating in the electromechanical repair sector.
Commenting on the programme developments, Scott Haslam, Head of Membership at the AEMT, said: "The AEMT conference has always brought together excellent technical content, but I'm talking to our members daily, and one thing that has become clear is that our members are running businesses, and they are facing the challenges that a lot of businesses face today. So, we wanted to ensure that while we continue to deliver the technical content, we also focus on some of the other challenges they're facing.
"Because we recognise this, we have titled the conference 'Engineering a Sustainable Future', as it encapsulates
what the AEMT represents. Sustainability is at the heart of what our members do; the repair sector is very much part of the circular economy. But we also want to ensure our member's businesses have a sustainable future."
Highlights of the planned morning session include a keynote from Billy Billingham, a former member of the SAS, discussing effective teamwork. Further sessions focussed on the business theme will cover business culture, staff retention, and succession planning.
Alongside the main conference programme, the event is also drawing together a collection of content aimed at apprentices working in the sector. Organisations attending the main conference are encouraged to bring their apprentices along, free of charge, for this unique opportunity to enhance their knowledge and understanding of areas related to their roles.
Reflecting the support for this new approach to the AEMT conference, the event's launch sponsors include fluid engineering specialist Sulzer, business management software developer
EMiR, pumping systems, solutions and services specialist Hidrostal, and leading motor and large-drive systems supplier Innomotics, with additional sponsorship opportunities available. The number of organisations operating in and with the electromechanical repair sector who are already confirmed exhibitors is growing weekly, with remaining stands available but limited. Anyone interested in either sponsoring or exhibiting at the event is encouraged to contact Scott Haslam via scott@theaemt.com
The new-look AEMT conference – a key element of the Association's anniversary celebrations alongside the AEMT Awards in November – promises to be a pivotal moment for electrical and mechanical engineering professionals wanting to future-proof their businesses. To find out more about the event and to register your attendance, please visit the AEMT website.
www.theaemt.com
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BIG COMPRESSOR MOTOR CUSTOMISED
MENZEL ELEKTROMOTOREN HAS designed a compressor motor for modular installation, observing the maximum crane capacity of 15 tons at the installation site.
A gas producer ordered the motor to replace a 1957-built gas compressor motor. Since structural changes in the plant were unwanted, Menzel replicated the mechanical interfaces of the existing motor. The motor’s outstanding feature is its massive base at 3 tons. Base, motor (14.7 tons) and cooler (2 tons) were installed one after the other.
Menzel built the three-phase squirrel cage motor based on its MEBKSW series,
which is characterised by high power density and offers flexible equipment options such as various cooling types.
The motor, with its bespoke base plate, features a total shaft height of 1,120mm, 6MW rated output, 11kV rated voltage, 57,995 rated torque and 988rpm rated speed. It has an IP54 protection rating with air-to-water heat exchanger (cooling type IC 86W).
Like all Menzel machines, the compressor motor underwent comprehensive inspections in the manufacturer’s load test field before shipping.
www.menzel-motors.com
SIMPLIFIED INDUSTRIAL DEVICE MAINTENANCE WITH GENERATIVE AI
ABB HAS LAUNCHED MY Measurement Assistant+, which the company says is the first AI-powered digital solution for maintenance and troubleshooting of measurement devices at industrial sites. Leveraging generative artificial intelligence (GenAI), cloud computing and Augmented Reality (AR), the web application brings together data from multiple IT and operational technology sources, and provides a single access point for information retrieval, device diagnostics, and remote support in industrial operations.
My Measurement Assistant+ is integrated with ABB Ability Genix Copilot, a GenAI solution developed by ABB in collaboration with Microsoft to help industrial companies improve efficiency, productivity and sustainability by contextualising vast amounts of data. ABB estimates that with rapid access to information and communication channels, My Measurement Assistant+ can help resolve most technical support issues in minutes, boosting first-time fix rates by up to 50%.
"My Measurement Assistant+ is now at the heart of ABB's comprehensive digital measurement offering," said David Lincoln, Global Digital Lead, ABB Measurement & Analytics. "It is a GenAI-powered solution that provides 24/7 support for industrial customers' measurement devices. It empowers frontline workers by offering the right information at the right time and the
right place, reliably."
"The collaboration between Microsoft and ABB demonstrates the positive impact GenAI can have on industries," said Sonja Meindl, Enterprise Commercial Director, Microsoft Switzerland. "Through the Genix Copilot integration with Microsoft, My Measurement Assistant+ provides insights that transform how maintenance and service is performed, empowering industrial customers to work smarter and more efficiently."
My Measurement Assistant+ enables easier, more efficient access to remote support for measurement devices. The integration of ABB's AR-based Visual Remote Support allows customers to make secure video calls with ABB experts for remote issue resolution, reducing the need for on-site visits and increasing uptime by helping solve issues quickly and efficiently.
The Genix Copilot integration enables a specific role-based experience, allowing users to manage their installed base with maximum efficiency. For example, in My Measurement Assistant+ a maintenance manager can assess information from relevant documentation, error codes and spare part details, receiving clear and concise responses.
With an intuitive user interface and accessibility from any device, My
Measurement Assistant+ empowers technicians and engineers to instantly access troubleshooting guides and video tutorials while in the field, enabling them to handle complex issues with confidence and efficiency.
Further integration of digital solutions such as ABB's Dynamic QR codes, Condition Monitoring and Genix Datalyzer make it easier for customers to access actionable insights from one place. Leveraging Dynamic QR Code capabilities, maintenance engineers can point their camera at any device, scan the code, and immediately get access to a detailed health report and analysis as well as resources for the specific device. The solution also makes detailed root cause analysis based on live device data possible.
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UK-MANUFACTURED TRACTION MOTOR REAPS
EFFICIENCY GAINS FOR HEAVY DUTY APPLICATIONS
ADVANCED ELECTRIC MACHINES (AEM), A UK-BASED manufacturer of sustainable, magnet-free electric motors, has unveiled the second generation of its solution for heavy duty and commercial vehicle applications. The new HDRM300C provides customers with an enhanced motor that offers stronger performance and greater efficiency.
Building on the success of its HDRM150 motor, where AEM introduced its coil compression technology, the HDRM300C represents an advancement in electric motor design, achieving conductor slot fill rates exceeding 80%. This proven technology, now evolved and scaled up from the smaller HDRM150, delivers measurably better power density and efficiency compared to conventional wire layouts that typically achieve less than 60% fill rates.
“The HDRM300C represents more than just an incremental improvement in motor technology," said James Widmer, CEO of Advanced Electric Machines. "By combining our patented coil compression technology with enhanced thermal management and improved speed capabilities, we're delivering a motor that sets new benchmarks for efficiency and performance. For the transportation industry, this means more capable electric vehicles that are more cost effective to operate and maintain."
The motor’s practical benefits extend beyond pure performance. The HDRM300's increased speed capability provides greater flexibility for system integration across diverse applications.
New plug-in connectors have replaced traditional gland fittings, simplifying the installation and maintenance process, while maximising overall reliability. Internal components, including upgraded bearings and robust busbar connections, have been strengthened to support the motor’s higher operational speeds.
An improved motor cooling system, which works similarly to a car’s radiator, allows the machine to work harder for longer without overheating. This is particularly important for commercial vehicles, where consistent performance throughout the day is crucial. For fleet operators and vehicle manufacturers, this translates to vehicles that can carry heavier loads, climb steeper hills, and operate in more demanding conditions without compromise.
Sample units began trials with select partners in March 2025, with full production scheduled to commence in Q4 2025.
ELECTRO DYNAMIC SENSOR FOR MONITORING WIND TURBINES
A KEY REQUIREMENT IN MAINTAINING AND OPTIMISING the performance of slow-rotating wind turbines is reliable and effective vibration measurement. Recognising this, Sensonics has developed the low-frequency VEL/GLF velocity vibration sensor.
This electro dynamic sensor provides a superior performance to piezoelectric devices by combining high measurement sensitivity with a frequency response down to 0.1Hz. This level of sensitivity, along with excellent noise performance, provides the dynamic range required for detailed analysis of gearbox vibration, so it is ideal for measuring velocity vibration on equipment with speeds below 300rpm.
The VEL/GLF has further advantages over piezoelectric-based velocity vibration sensors, which are susceptible to many forms of interference in low-frequency applications. As a result of its robust design, the sensor offers high noise immunity due to the low impedance electro dynamic nature of the sensor assembly. In addition to the filtering of high frequency events and since no electronic integration is required, the design of the sensor is immune to the saturation problems that impair the reliability of other piezoelectric devices.
www.sensonics.co.uk
Entries are invited for the 2025 AEMT Awards
As part of its 80th anniversary celebrations, the Association of Electrical & Mechanical Trades has announced the launch of the 2025 AEMT Awards Programme, the presentation dinner for which is set to take place on the evening of 20 November at the Doubletree by Hilton Hotel in Coventry. This prestigious annual event celebrates the remarkable achievements of businesses and individuals within the electromechanical repair and service industry..
Now in its 9th year, the AEMT Awards continues to spotlight the innovation, dedication, and exceptional standards upheld by the sector. The 2025 ceremony promises to be the most exciting yet, with several returning categories and new additions designed to reflect the evolving landscape of engineering repair and maintenance.
Award Categories include:
• Product of the Year
• Project of the Year
• Service Centre of the Year
• Supplier of the Year
• Contribution to Skills & Training Award
• Rising Star Award
• Diversity In Engineering Award
• Sustainable Engineering Award
• Special Recognition Award
Entries are now officially open and can be submitted via the dedicated section of the AEMT website at www.aemtawards.com. The deadline for submissions is Friday, 1 August 2025 and all entrants are encouraged to showcase their achievements and contributions to best practice, sustainability, and technical excellence.
A panel of independent industry experts will judge the entries, ensuring transparency and integrity in the selection process. Winners will be announced at the blacktie awards dinner, which brings together key players from across the sector for an evening of celebration and networking.
Thomas Marks, Secretary and General Manager at the AEMT,
said: "The AEMT Awards are a highlight of the industry calendar, offering a platform to recognise those who go above and beyond in engineering excellence, innovation, and service delivery. We are excited to welcome entries for 2025 and look forward to another memorable night celebrating our industry's best."
The 2025 AEMT Awards are proudly supported by leading industry sponsors, including EMiR Software, DFA Media (publishers of Drives & Controls and Plant & Works Engineering), Innomotics, Megger, Menzel, Renew, Sulzer and WEG, whose collective commitment helps make the event possible. Several sponsorship opportunities are still available for those wishing to align their brand with excellence in the sector.
Commenting on his longstanding engagement with the awards, Martin Rooney, Managing Director of Menzel UK said: "Having supported the AEMT Awards for a number of years now, through sponsorship of the gala dinner entertainment, Menzel is delighted to be uplifting its support in this, the 80th Anniversary Year of the AEMT, to full category sponsor.
This not only underpins our belief in the importance of highlighting great achievements across the sector, but also the valuable work of both the AEMT and its members.
"The awards evening is always a thoroughly enjoyable evening with the opportunity of meeting many friends and colleagues from across the industry. And this year, through our sponsorship of the Rising Star Award, we look to support and encourage the emerging young talent, which is so crucial to the future success of the electromechanical sector."
For more information on categories, sponsorship, and to submit an entry, please visit the awards website.
www.aemtawards.com
Customised motor in under 24 hours
WHEN A CUSTOMER placed an order for a Brook Crompton W Series IE4 132kW 4-pole WSPDF315SPF motor with supplier BAWCo, specific modifications were needed to meet a unique set of requirements.
The customer's application required the ball bearing at the drive end to be changed to a roller bearing, and the motor's terminal box needed to be moved to the right-hand side of the motor.
Time was of the essence, and rather than wait for a pre-configured motor delivery from Brook Crompton UK, BAWCo's modification specialist was brought into play.
The first step was to remove the feet and re-fit them in the correct position to
reorient the terminal box. The end shields and the original drive end ball bearing were then removed before a new SKF roller bearing was installed, using Brook Crompton's unique bearing conversion kit.
Both end shields were then reapplied
and positioned in the upright position so that the correct amount of Mobil N3 grease could be supplied to the bearing. To finish off the cooling fan and fan cowl were reattached and the IE4 efficient motor was given a new nameplate and water blue finishing coat to hide the modifications and give it the classic BAWCo look.
After testing, the new motor was delivered directly to the customer's site, with the entire job taking under 24 hours.
bawco.com
CUSTOM SEAL SOLUTION REDUCES DOWNTIME FOR CHALLENGING PUMPING APPLICATION
VULCAN SEALS HAS PROVIDED A solution for a global manufacturer facing severe slurry substance challenges on positive displacement pumps. This innovation significantly reduced clogging, pump downtime, and maintenance costs while enhancing overall system reliability.
A multinational manufacturer faced persistent issues with traditional cartridge mechanical seal designs that employed multi-spring technology on positive displacement pumps. The application involved a challenging slurry substance of fine, soft, sticky particles interspersed with cellulose-based fibres. These conditions caused the mechanical seals’ moving parts to become quickly clogged, preventing the seal faces from correctly adjusting. As a result, leakage occurred shortly after installation. The result was frequent pump downtime with extended operating hours being interrupted by the need for unscheduled maintenance. Due to the cartridge mechanical seal’s short lifecycle (replacement needed after 72 hours), regular pump strip-downs and seal repairs and replacements significantly raised operating expenses.
Vulcan Seals introduced the Vulcassette custom solution design – a
product that completely removed the springs used to energise the primary seal surfaces.
Removing springs meant there were fewer surfaces and mechanisms for slurry particles to accumulate, thereby reducing clogging.
The design simplified the energisation method and integrated carefully selected sealing materials to overcome chemical incompatibility and inadequate wear resistance, key issues that led to failures with traditional mechanical seal technology.
The new design also allowed the seal faces to re-adjust automatically, even after minor impacts or blockages.
And, although on this occasion, the manufacturer did not utilise the builtin seal cleaning system, the option to circulate cleaning water around the sealing face area further improves performance by preventing particle deposition.
The introduction of the Vulcassette enabled extended run times with the pumps operating for much longer periods between maintenance
strip-downs, reducing process downtime.
With less frequent seal replacements and repairs, overall operating expenses were substantially lowered.
The self-adjusting capability ensured that minor leakages caused by oversize contaminants or impaction were promptly corrected without manual intervention. While the Vulcassette design now allows adjustments to be made when the equipment is not rotating, eliminating the need for complete removal from the shaft during planned maintenance.
www.vulcanseals.com
Advanced technology and robust support secure hydropower project
THANKS TO ITS EXPERTISE IN THE HYDROPOWER SECTOR, WEG has supplied complete equipment for the Paredinha hydropower plant.
Small hydroelectric plants play a fundamental role in renewable energy generation, harnessing the hydraulic potential of rivers to produce electricity sustainably and efficiently. To ensure the reliable operation of these plants, it is essential to have high-tech and durable equipment.
This was one of the reasons that led Ibemapar to choose WEG solutions. With its expertise in the hydropower sector, WEG develops complete solutions for small hydro, combining cutting-edge engineering, advanced technology, and experience in manufacturing electrical and mechanical equipment.
For Paredinha hydropower plant, WEG supplied three hydraulic turbines of 7,292kW, three generators of 7,788kVA, as well as electrical panels, ten transformers totalling approximately 50,000kVA, a substation, and all electrical installation.
This is the second project of this nature that Ibemapar has carried out with WEG. Previously, two hydraulic turbines of 8,287kW and two generators of 8,935kVA were supplied, including electrical panels, transformers, a substation, and electrical installation for the Boa Vista II Hydropower Plant. The quality of the products supplied for Boa Vista II was decisive for consolidating the partnership with Ibemapar, resulting in the contract for Paredinha hydropower plant.
With high-performance equipment, the client has security in the return on investment, ensuring operational stability and predictability in energy generation. The reliability of WEG solutions reinforces the company's commitment to the hydropower sector, offering advanced technology and robust support for long-term operations. www.weg.net
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Overcoming challenges in MDI production with ATEX-certified motors and drives
Lenzing Filtration was tasked with supplying its customer, a Chinese manufacturer, with systems for the hazardous production of Polymer Methylene Diphenyl Diisocyanate (MDI). However, the supplied automated backflush filtration systems required ATEXcertified explosion-proof motor and drive systems that could withstand the rigours of such an environment. A bespoke solution from WEG Gear Systems was able to meet the exacting safety standards required.
Over 270 hazardous chemical incidents – including fires, explosions and harmful chemical releases – occurred in 2023 alone, according to data published by the Coalition to Prevent Chemical Disasters. In chemical production, the risk of explosions is always present and creates a pressing need for stringent safety measures. Over four decades, the Austrian manufacturer Lenzing Filtration has developed filter devices, specialising in automated backflush filtration systems, which are deployed across diverse industrial applications.
However, the company faced a big challenge when a Chinese chemical company sought its expertise for the production of polymer MDI, which is hazardous due to its toxicity, potential for explosions, and chemical reactivity. MDI poses health risks to individuals through inhalation or skin contact, can create explosive atmospheres, and its reactivity with other substances can lead to hazardous by-products.
Effective safety measures and proper handling procedures are crucial to mitigate these risks and protect both human health and the environment. In addition, all manufacturing systems involved in the process – ranging from drives to motors – should meet the stringent provisions of the ATEX Directive 2014/34/ EU, the certification for equipment used in potentially explosive atmospheres.
The Chinese polymer MDI producer approached Lenzing Filtration to draw on the latter company's experience, and the company put forward its own OptiFil backwash filters as the best solution.
ATEX-CERTIFIED
Lenzing Filtration's backwash filters are engineered to filter all kinds of lowviscosity media found in production processes, with seamless precision. However, propelling these automated systems into action would require robust and ATEX-certified motor and drive systems that were capable of guaranteeing reliability, safety and endurance, particularly in harsh production environments.
Zone 1 and Zone 21 ATEX requirements with a 660V voltage supply.
Lenzing Filtration turned to WEG Gear Systems for a holistic solution that was engineered to overcome these challenges, and the supplier was able to draw on its drive solutions, including explosion-proof motors and drives conforming to the exacting ATEX specifications.
Lenzing Filtration opted for WG20 helical geared motors with flameproof encapsulated W22Xde ATEX motors, capable of withstanding pressures up to 14.1 bar and temperatures of 80°C. Special Viton shaft seal rings and a corrosionresistant epoxy resin finish would help ensure the motors' durability.
For the OptiFil-250-0720 filters, a WG20 helical bevel gear motor with a torque of 308Nm and 1.10kW output was employed. Larger OptiFil-350-1080 filters utilised a more powerful solution with 696Nm torque and 2.20kW output. Both setups featured thermal monitoring and complied with ATEX requirements.
In all, WEG Gear Systems supplied 21 drive systems for use in China, meeting
Lenzing Filtration praised the robustness and cost-effectiveness of WEG's solutions. Johannes Kneissl, Technical Manager Filtration & Separation at Lenzing Filtration, commented that WEG Gear Systems: "was able to design a very robust drive solution for us from a single source, which was able to meet all challenges and at the same time contributed to a significant reduction in overall costs."
The solution also reduced personnel needs and ensured operational efficiency in the Chinese chemical company's hazardous environments.
SAFETY STANDARDS
By leveraging WEG Gear Systems' expertise and drive solutions, Lenzing Filtration effectively met the stringent safety standards required by the industry, which remain as important as ever, as illustrated by the Coalition to Prevent Chemical Disasters report. TIMES-CIRCLE
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Having a breakdown? Let’s talk about it
In an increasingly digital world and now with the potential impact of AI on all our futures continuing to grab global headlines, Steven Turner, European Head Of Production and Engineering at Radwell International, argues that when production lines break down in the real world, talking to a human being can still offer the best solution.
With downtime now costing businesses more than a quarter of a million Euros per hour, on average, there is nothing more stressful for manufacturing and production managers than finding themselves in a breakdown situation.
Even with the best preventative maintenance systems in place, breakdowns still happen. And when they do, as the clock ticks away and the system stays eerily silent, the old adage ‘time is money’ is truer than at any time in history. Every minute counts to get the breakdown fixed, and the race is on to find the solution, which usually becomes an event in three stages.
Stage one involves identifying the problem. In many scenarios, the entire system can be held up by the breakdown
of a single part. Once the production manager has worked out which one is to blame, the race moves to stage two: sourcing the required replacement part.
This stage can be simple if the production line is still supported by the OEM. But, if you’re one of the approximately 70% of companies worldwide using equipment with no OEM spares availability, it is in this second stage where the drama really begins.
One way to avoid stress at this stage is to have completed an obsolescence analysis and lifecycle report and to have identified the most likely source of problems in advance, and then to have ensured sufficient stock of the most appropriate replacement parts, or to have upgraded where necessary.
But otherwise, or in any scenario
where you find you do not have the required part in stock, for most people, the next move is to search for the part number on the internet, using mainstream search engines like Google or specialist marketplace websites.
However, the problem with a purely digital approach is that the outcome is, by nature, binary. Either the part is available, and the world carries on as you move to stage three of fixing the problem. Or, it’s not, and your world stops.
But what if the options weren’t binary? What if there was another way?
THE POWER OF CONVERSATION
In the age of the smartphone, the world seems to have become so used to being able to find the answer to almost any question from a little screen kept in a
pocket, that putting the same device to an ear has started to feel almost like an action from a bygone era.
This is especially true with younger generations joining the workforce, with one further education college in the UK making headlines recently by launching classes to help students overcome their fear of actually talking on their phones.
But, even for highly experienced production managers, imagine there was no internet. In a breakdown situation, what would you do? In all likelihood, you would actually pick up the phone and call your trusted spare parts supplier to see if they have the part you need.
Unlike a search engine or any digital marketplace, the supplier might ask you some questions about the issue you are having. Can you describe the fault? What is the machine? What is the issue? What make and model of PLC or drive is showing the fault?
Suddenly, rather than searching for a single answer, you are having a conversation; not with a digital chatbot linked to common FAQs, but with a fellow engineer, whose job it is to keep factories up and running.
Having a conversation at the start means that, if the engineer needs to come to the site to look at the problem in person, they can come with the correct equipment, the correct manuals, the correct laptop if necessary, with the correct software and cables, and perhaps a replacement unit if it is appropriate.
Spending five minutes on the phone getting accurate information to begin with could save hours of downtime through driving back and forth or unnecessary fault-finding.
The same attitude can be applied to purchasing spare parts as well as repairs. Imagine again that there is no internet, only human beings to talk to. Working together with a fellow expert, it is actually possible to discover that the solution to your problem is not the one you were thinking of.
Inverter faulty? We may not have the exact model number, but maybe we have a higher kW rating in the same frame size. PLC problem? Maybe we have the exact CPU, or maybe we have one with more memory. Maybe we have your exact HMI, but it is under a different part number simply because it has a different colour bezel or a plain membrane instead of a branded one.
A search engine would never know this, and would never suggest the alternative in the way an expert in spare parts can. And no matter how smart AI gets, it can only base what it knows on what it can find on the internet. The thing it will never have is real-world experience.
All of the examples above are drop-in solutions, not complicated retrofits. But knowing about them comes from experience, not data.
Rather than focusing on one solution, having a conversation opens up your options. It is easy to rely on the speed at which technology can give a potential answer, but it doesn’t work if you’re asking the wrong questions. Having a conversation that starts with an open-ended question, with a real human being, can be the quickest, or even the only way, to solve a problem.
So, when you’re having a breakdown, try breaking the norm by picking up the phone and taking a few minutes to talk. It might be the answer to all your problems. TIMES-CIRCLE
Electric machine repair in the UK: Will EV motors be included at scale?
As part of research carried out by the Government-backed High Value Manufacturing Catapult into maximising material recovery for electrified components, Alexei Winter, Lead Engineer, Electrification at the University of Sheffield AMRC (Advanced Manufacturing Research Centre) has reviewed the landscape for the repair and remanufacture of electric machines in the UK, and looks at how the growing electric vehicle sector might fit into it.
Acomment from Simon Swallow,
Managing Director of Rotary Engineering,
one of the companies we spoke to as part of our research, sums up the role of the electromechanical repair sector very well: "The motor repair and rewind industry invented the circular economy 80 years before the phrase became commonplace."
The conceptual simplicity of an electric motor means that it is wellsuited for repair and remanufacture. Breakdowns are rarely terminal, with a majority caused by simple problems such as bearing failure. Motor windings are relatively straightforward to replace, and it would take a very serious event to mean that a valuable electric motor was unsalvageable.
As implied by the quote above, the industry for the repair of electric machines in the United Kingdom is a mature one, and visits were made to a number of repair/refurbishment/ remanufacture facilities to assess the landscape for these activities when it comes to electric machines in the UK.
Electric machines from a wide range of industries/applications are repaired in the UK, from the largest, multi-megawatt machine down to small, precision servomotors. Very large submersible pump motors that have been in operation since the 1970s or 1980s were seen, as were
wind turbine generators (DFIGs) and blade pitch motors, Intercity 125 alternators, bus and truck traction motors, and even a fan motor that had finally failed after running undisturbed since the 1950s.
The industry exemplifies the philosophy behind the idea of the circular economy, in that recycling and replacement are seen as the options of last resort. At one facility, the case of a large pump motor was given as an example: what might at first have seemed like a catastrophic failure, resulting in the burn-out of the windings, was used to compare repair with the purchase of a new item – while a new motor might cost £1.5 million and take three months to be delivered, rewinding the motor (while still a major piece of work)
might cost £250,000 and take six weeks. This example shows clearly that the economics of this industry are supportive of repair rather than replacement, especially as advances in insulation and joining technology have allowed refurbished motors to perform better and be more robust than when they were first manufactured. Waste materials such as copper from discarded windings, steel from shafts and laminations, and aluminium from casings are sent to segregated recycling streams, so that their value is not lost. However, it is uncommon for potentially highvalue electrical steels to be separated from general ferrous scrap – it would take significant quantities of specific grades entering these streams to change this, as it is not economically
viable for these materials to be kept separate at present.
The question of economic viability is the dominant factor at play when considering the repair of an electric machine, but this calculation involves many factors, including the cost of parts and labour, and also the cost of downtime that is the result of a broken motor. For some customers, being prevented from operating because of a failure is so costly that the fastest solution – almost always repair for large machines – is the most economically attractive, even if a new purchase would be cheaper in terms of outlay (which, in many cases, would be unlikely anyway). Many repair facilities operate 24 hours per day in order to offer emergency repairs.
Where cost calculations for large machines often strongly favour repair, the situation may be different for smaller, lower-value motors. In several visits to repair facilities, only one Electric Vehicle (EV) motor (a rather unusual axial flux machine) was seen. It is clear
that the industry that has repaired industrial motors for decades is not particularly involved with repairing EV motors. This could be due to the fact that service contracts on EVs (so often now purchased on a PCP basis) require that they be returned to the OEMs for repair, or that these mass-produced motors are not of sufficient value to justify repair work. EV motors are also more likely than large industrial motors to use permanent magnet (PM) rotors. During the visits to repair facilities, a huge number of motors were seen, only a very small number of which were permanent magnet machines. These were the smaller servomotors from automation and motion control applications, and they were of a similar size or smaller than a normal radial-flux, PMSM EV motor. It is clear that the skills and equipment for repairing PM motors
exist within UK industry, but they are not yet being widely applied to the repair of EV motors.
"The industry that has repaired industrial motors for decades is not particularly involved with repairing EV motors."
There is a good diversity of players working in this space, with various degrees of specialised focus. The Association of Electrical and Mechanical Trades (AEMT) is the trade body that represents organisations in the electrical and mechanical service and repair industry, and Thomas Marks, its General Manager, was interviewed as part of this work. He was keen to point out that the industry is healthy and growing. However, it is well known that engineering as a whole in the UK is suffering from a lack of skills and a difficulty in recruitment, and the refurbishment industry is currently feeling this keenly. It was also pointed out that the industry is starting to be bought by foreign interests, for example,
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Repair companies range in size and specialism. Services offered by these companies cover almost every conceivable operation that is required to repair an electric machine. For machines manufactured decades ago for which there are no drawings, geometry can be assessed with laser metrology systems and CAD models produced; windings can be stripped out and replaced; insulation papers and wrappings can be reapplied; lamination stacks can be cleaned, replaced and loss-tested if necessary; impregnation of machines can be carried out with VPI equipment; bearings can be replaced and the system rebalanced; terminations can be refurbished; and even power electronics can be assessed and repaired, down to the level of individual components on boards. Where facilities are not present in house (for example for casting of new housings), relationships with subcontractors allow this to be arranged.
In other words, should a repair be needed on an electric motor or generator in the UK, there are many companies that will be able to support this. Not every repair facility has every capability, but the UK industry as a whole is able to handle any situation.
Finally, while this study has concentrated on specialist electric motor repair and refurbishment establishments, it can be contrasted with the model for the repair of internal combustion vehicles. Rather than a relatively small number of large repair facilities around the country, one is free to take one's vehicle to a local repair shop, of which there are tens of thousands, widely distributed. There are already a smaller number of these garages offering repair services for EVs and it seems inevitable that this number will grow as EVs continue to proliferate. However, some local garages stated that, although they may have been interested in reskilling to handle EVs, they were deterred by the required outlay on specialist tools and training for working on electric machines, as well as the requirement to segregate them from the rest of the workshop. Despite this hesitancy on the part of some garages, the number of garages that are able to handle EV repairs is growing. When it comes to the motor inside the EV, the picture is different. Unlike the situation with larger industrial motors or servos, it appears that the motor of an EV is currently considered a replaceable component. One garage explained
"It appears that the motor of an EV is currently considered a replaceable component."
that, while they had not yet encountered any problems with the motor itself (demonstrating their high reliability), if they did, it would simply be replaced with a new item, rather than repaired. Indeed, it was explained that these items carry a surcharge that is recouped when they are returned to the manufacturer, incentivising replacement over repair, but encouraging the transfer of the motor to a facility that can recycle specialist materials appropriately. Considering the amount of equipment used by the dedicated motor repair facilities to carry out the various repair activities, it is highly unlikely that these activities will be handled by the standard vehicle repair network.
In conclusion, the repair and refurbishment industry for electric machines in the UK is healthy and well-equipped for the repair of a wide variety of machine types. The focus is primarily on larger, highervalue machines. Whether the focus will alter to include the repair of EV motors depends on the economics of those operations. TIMES-CIRCLE
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Begin your condition monitoring journey
Reliability engineering and in particular condition monitoring is a mature and complex engineering subject and for those not from a reliability background, establishing where to start can be challenging. Jim Fowlie, Director of Operations at Sensor-Works, explains how to approach the introduction of condition monitoring to a facility, the key steps that should be taken, and how to ensure the wider company benefits are appreciated.
Agood place to start with condition monitoring is to understand how best to identify failure. There are many techniques available, and where possible, it is best to use a combination of approaches. Ultimately, the more information available in an investigation, the more accurate the outcome will be.
The widely used I-P-F Curve (Installation – point of Potential failure – point of Failure) highlights the instance when a specific method will start to identify an emerging issue. Ultrasonic techniques are the first to identify a failing condition. However, this is a relatively difficult and skilled technology to master, and it does not lend itself to an online monitoring approach. The next and most widely used approach is vibration monitoring. This technology is mature and cost effective, and is used in both in-person (usually done with ultrasonics) and with online (continuous) monitoring.
Generally, the earlier the detection of an issue and the appropriate intervention take place, the lower the cost to repair. For example, the catastrophic failure of an asset may well be uneconomical to repair and require replacement.
Vibration is considered the best operating parameter to judge dynamic conditions such as balance, alignment, bearing stability, and stresses applied to components. Vibration is a
symptom, not the cause of the problem itself. It is inherent in all machinery, and an increase in vibration is generally a symptom that something is going wrong. Problems which manifest as a change in vibration include mechanical looseness, structural resonance, soft foundation, misalignment, bent shafts, or damaged or broken rotor vanes. Vibration analysis as a method of diagnosing machinery problems can determine the severity of those problems and help with scheduling the most appropriate time to correct them.
TREND ANALYSIS
Extending beyond the principles of carrying out a single measurement, the condition-based maintenance concept is simple. Here, using technologies like those outlined
above, physical parameters such as vibration, temperature, pressure, lubricant condition, etc., are measured and used to determine which combination provides the best indication of machine health.
From these baselines, alarm limits can be established that will trigger during ongoing routine monitoring. Periodic or continuous monitoring readings are taken on the machinery. If a measurement exceeds its alert or alarm limit, the system could be set up to automatically detect the exception and display plots and produce reports that help analyse the problem.
As the problem is likely detected early in its failure stage, the maintenance team has time to schedule the most efficient and effective repair prior to any component failure.
Ideally, the alarm limits are set
Figure 1. The I-P-F Curve shows the deterioration in a rotating element over the operating interval.
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high enough to minimise extraneous alarms, yet conservative enough not to miss a critical deviation in machine condition. And they can also be continuously adjusted as more is learned about the machinery from the predictive maintenance program.
PREPARATION
Before any condition monitoring program is implemented, preparatory work must be done. It is important to have an up-to-date asset register in place, including where assets are located, their serial numbers and model details. It is also strongly advised that an asset criticality review be carried out.
The higher the criticality of an asset, the more important it is to gain full visibility and predictability of the equipment’s health with continuous monitoring, ideally online.
For semi-critical assets or on assets deemed necessary, you can trend and apply exception reporting, only analysing and diagnosing machine problems with a more advanced portable setup for understanding the underlying sources of machine issues as and when appropriate.
Running a criticality review requires a systematic approach; Figure 2 is a sample of a flow chart that may be used in this process. Other process flows are used and can be similarly applied; the key is to have a structured, repeatable, consistent and purposeful outcome.
It is helpful if there is a documented history of machine failure, and if so, make good use of this information. Where there is no historical failure information, it may be worth undertaking machine assessments of assets throughout the plant as one-off vibration and temperature health checks. This will give a baseline and help to identify which machines to monitor in which phase of implementation.
It is also good practice to implement any condition monitoring system using a scalable approach. Start small and build the system and learn as you go, rather than having to rebuild each time an improvement is realised.
The monitoring solutions employed can be a simple route-
based (as part of an in-person walk around a facility) or an online (and continuous) schedule-based implementation, or, as is often the case, a combination of both based on the criticality of the machinery. At the very minimum level, a facility manager might want to know when something is about to fail. This can be done with periodic vibration and temperature checks, usually monthly but generally no longer than quarterly, carried out by operators or maintenance personnel. These tend to be cost-effective and easy to understand when used with common traffic light concepts.
(Spectrum) indicates the source of the problem.
"The higher the criticality of an asset, the more important it is to gain full visibility and predictability of its health."
Usually, a combination of both is done: trending with alerts and alarm levels set to trigger more in-depth spectral analysis. The setting of the levels for alerts and alarms can and will vary. The use of standards such as ISO 20816 is a reference to start; however, if the history of a machine’s operating condition is known and the point of failure is understood, this can be a better reference. A common practice is to trigger an alert when a 10% increase from the baseline occurs, with an alarm signal when a 30% increase is measured.
DETAILED ANALYSIS
Relating back to the reliability process flow, it is possible to understand what complexity of surveillance is needed. Basic vibration measurements, as outlined above, will indicate when a failure condition has begun to occur. For more detailed insights, a spectral analysis can show what the failure mode is and possibly what component in the asset is causing the issue.
A trend of the vibration level indicates the severity stage of a problem. The frequency
SENSOR TECHNOLOGY
Sensors used in today’s vibration monitoring systems are accelerometers, which give a live signal. The sensors will generally use either MEMs or piezo technology: MEMs has a different sensing frequency range – usually DC to 6kHz (for the better devices) – and a piezo sensor usually has a 0.2Hz to 10KHz range.
To understand the accelerometer output, each rotating element produces a sine wave at a defined frequency. However, all of these
Figure 2. A criticality review should be structured, consistent and repeatable.
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rotating elements combine to produce a signal that is very difficult to understand as it is outputted from the vibration sensor.
By employing a mathematical technique known as the Fourier Transform, the raw signal can be converted from the time (or spatial) domain into the frequency domain. This method takes a complex waveform and breaks it down into a sum of sine and cosine functions, each with its own amplitude and phase.
Using this approach, the live signal can be displayed as a number of peaks at the rotational (or running) speed of each element of the machine, along with the interaction, to display conditions such as imbalance, misalignment, gear mesh, bearing issues, and even lubrication problems as demonstrated in Figure 3.
With this much more detailed information, an emerging issue can be more readily identified, and the appropriate remedial action can be triggered.
MOUNTING VIBRATION SENSORS
One of the challenging areas of condition monitoring implementation is how and where to mount the sensors.
Ideally, a vibration sensor should be mounted inline and closest to the load zone of all rotating supports, i.e. the bearings. Where analytics are
required (spectrum analysis), the sensors are typically mounted in the horizontal, vertical and axial positions, or alternatively, triaxial sensors are available for semi-critical and small to medium-sized assets.
For a basic monitoring setup, a single sensor on the drive end in vertical orientation is ideal. If misalignment is a concern, then an axial sensor gives useful information.
It is helpful to have both the drive end and the non-drive end monitored. However, if this adds too much from a cost perspective, then the drive end is the best to monitor as this is likely to be the part of a motor that can experience the highest amount of loading, especially on a belt or chain coupling arrangement.
of a stinger, however, if this is needed due to the material of an asset being non-magnetic, then use as short a stinger as possible which reduces the bending effect on longer probe devices.
"Ideally, a vibration sensor should be mounted inline and closest to the load zone of all rotating supports."
Once the condition monitoring journey has begun, it is critical to record progress, document what worked, calculate the savings –including not just reduced maintenance costs but also from areas such as lost production or material waste avoided – and present this to management. I would also recommend that users record what did not work so well and learn from it.
It is best to mechanically fix the sensor using a stud mount, which gives the greatest transfer of energy (a good time to do this is during a refurbishment or repair). Where this is not so practical, a suitable adhesive will work. A magnetic mount can also be used for temporary or workaround operations. Split face magnets with suitably strong pull force are preferred. I would recommend that you avoid the use
It is important that within a company, this approach is seen as a value to the business and not a cost. Done correctly it will bring savings; it is estimated that for every 1% of improved operational equipment effectiveness a 2% increase in profit is generated on the company’s bottom line and this should be widely understood. TIMES-CIRCLE
Figure 3. Using the Fourier Transform, a complex, raw signal from a vibration sensor can be converted from the time (or spatial) domain into the frequency domain. This breaks it down into a sum of sine and cosine functions, each with its own amplitude and phase relative to a specific element of the machine.
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As the Association of Electrical and Mechanical Trades (AEMT) celebrates its 80th anniversary, Thomas Marks, the Association’s General Manager and Secretary, outlines why repairing electromechanical equipment should not be seen as a compromise solution for more reasons than just supporting a circular economy.
When you think of repairing something, you may view it as a less positive option than replacing it with like for like. The age-old phrase ‘make do and mend’ makes it sound like a compromise, like the least favourable option. However, that is often not the case where electromechanical equipment is concerned. Yes, there are energy efficiency gains to be made when replacing old low-voltage motors with modern alternatives. But, across the spectrum of electromechanical equipment, there are many ways that a skilled repair centre can improve a device as part of the repair process. This might mean improved performance, improved efficiency or improved reliability.
Take motors as an example. A competent repair shop can do a number of things to improve a motor’s performance. Modern rewinds often use insulation materials with higher thermal ratings than the original, improving motor thermal tolerance and, in turn, the expected lifespan. Tighter winding tolerances can be applied where the repair shop can optimise the winding pattern, reducing losses and improving efficiency beyond the original specs. In some cases, after a rebuild, a motor can be dynamically balanced to tighter tolerances than when it originally left the factory, while bearings can be replaced with higher-quality, low-friction, or insulated bearings to reduce heat and extend life.
Where some smaller motors are concerned, the cost of upgrades may not be viable, but as the size increases, so does the motor’s replacement cost, and long lead times may have their own knock-on costs caused by operational delays.
Pumps are another area where improvements can be made. During the repair process, impeller and volute geometries can be optimised to improve efficiency. If appropriate, bronze or castiron parts can be replaced with stainless steel, duplex, or hard-coated surfaces
to improve corrosion and wear resistance. Modern machining can allow tighter tolerances, reducing internal recirculation and improving pump efficiency. And newer mechanical seals and sleeve designs can be utilised to drastically reduce leakage and maintenance requirements.
There are also ways in which electronic equipment, such as variable speed drives, can be improved. The most common is with component upgrades. Capacitors can be replaced with longer-life, higher temperature-rated versions. Critical resistors or diodes can be replaced with precision, low-drift, or higher-rated variants. While uprated semiconductors can offer faster switching speeds, lower losses, and better thermal performance. Proper reflow ovens or hot air stations can create better joints than some mass-produced boards. And advanced diagnostics, thermal imaging, and incircuit testing can ensure the repaired board is performing better than factory tested.
Next time you are weighing up whether to repair or replace your electromechanical equipment, remember that technology has advanced since many machines were originally built, a third-party repair shop isn’t necessarily limited by mass production cost constraints and repairs can allow optimisation to meet your specific operational parameters.
Servo motors can be upgraded with modern digital encoders with higher resolution than older analogue or lowresolution units. Rewinding can improve electrical symmetry and torque ripple, and higher-strength permanent magnets can be retrofitted for increased torque density.
In addition to these productspecific enhancements, lubrication and cooling systems can be enhanced, surface treatments and coatings can improve anti-corrosion and anti-friction performance, and, of course, condition monitoring sensors can be added to improve ongoing performance and reliability.
And all of this is before we even touch on the environmental benefits. The carbon footprint of a repair is generally much lower than that of a new replacement. Plus, waste materials are minimised, and the demand on natural resources is reduced. This is, of course, the circular economy. While it is right that this phrase has grown in popularity in recent years, the practices have been around for millennia. Indeed, the AEMT has been championing, representing, and supporting the electromechanical sector, and in turn the circular economy, for 80 years this very year.
So maybe we shouldn’t say make do and mend and instead say make better and mend. TIMES-CIRCLE
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