Condition-Based Maintenance and Residual Life Prediction E-Book
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- Herausgeber: John Wiley & Sons
- Kategorie: Fachliteratur
- Sprache: Englisch
Condition-Based Maintenance and Residual Life Prediction is essential for those looking to effectively implement condition-based maintenance strategies and enhance fault detection through a comprehensive understanding of vibration data analysis and residual life prediction, addressing key challenges in the field.
Issues related to condition-based maintenance include its high initial cost, new techniques that can be difficult to implement due to resistance, older equipment that can be difficult to retrofit with sensors and monitoring equipment, and difficult-to-access equipment during production that is difficult to spot-measure. Keeping the above issues in mind, a general handbook for condition-based maintenance and residual life prediction is required to carry out in fault detection.
Condition-Based Maintenance and Residual Life Prediction aims to develop, analyze, and model condition-based maintenance and residual life prediction through vibration data. The analysis of vibration responses will aid in developing a fault detection system. The sources of vibration may be due to the presence of different types of defects, such as cracks in the shaft, a bent shaft, or misalignment of shafts. This will give designers a diagnostic tool for predicting the trends of vibration conditions, leading to early fault detection. The devised tool will be capable of quantifying the amplitude of vibration based on the severity of defects. With the features available in the devised diagnostic tool, the proposed model can be used for design, predictive maintenance, and condition-based maintenance.
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Seitenzahl: 414
Veröffentlichungsjahr: 2025
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Table of Contents
Cover
Table of Contents
Series Page
Title Page
Copyright Page
1 Maintenance
1.1 Introduction and Meaning
1.2 Need for Maintenance
1.3 Importance of Maintenance
1.4 Objectives of Maintenance
1.5 The Role of the Maintenance Department
1.6 Responsibilities of a Maintenance Engineer
1.7 Principles of Maintenance
1.8 Maintenance Planning
1.9 Management Organization and Structures
1.10 Types of Maintenance (Figure 1.2)
1.11 Economics of Maintenance
1.12 Maintenance Scheduling
1.13 Conclusion
References
2 Condition-Based Maintenance
Introduction
Applications of Condition-Based Maintenance
Advantages and Disadvantages of Condition-Based Maintenance
Various PdM Techniques
References
3 Condition Monitoring
3.1 Introduction and Meaning
3.2 Advantages of Condition Monitoring
3.3 Condition Monitoring Applications
3.4 Four Pillars of Condition Monitoring
3.5 Setting Up a Condition Monitoring (CM) Activity
3.6 Condition Monitoring Types
3.7 Condition Monitoring Techniques
3.8 Condition Monitoring and Predictive Maintenance: Cost-Benefit Tradeoffs
3.9 Conclusion
References
4 Advanced Maintenance Techniques
4.1 Introduction
4.2 Traditional Maintenance Techniques
4.3 Advanced Maintenance Techniques
4.4 Conclusions
References
5 Unveiling the Future: Residual Life Prediction for Enhanced Asset Management
5.1 Introduction
5.2 Residual Life Prediction Techniques
5.3 Applications of Residual Life Prediction
5.4 Conclusion
References
6 Analysis of Vibration
Introduction
Vibration Analysis Methodology
Categories of Vibration Measurement
Vibration Analysis: Measurement Parameters
Vibration Analysis: Tools and Technology
Benefits of Continuous Vibration Monitoring
References
7 Modeling for Vibration
7.1 Introduction
7.2 Modeling Techniques for Vibration Analysis
7.3 Conclusions
References
8 Impact of Condition-Based Maintenance (CBM) and Residual Life Prediction (RLP) on Environmental Issues
8.1 Introduction
8.2 Goals of Condition-Based Maintenance
8.3 Maintenance Strategies
8.4 Determination of CBM Failure Point
8.5 Decision-Making in Condition-Based Maintenance
8.6 Decision Models for CBM
8.7 Proportional Hazards Modeling
8.8 Maintenance Planning and Scheduling
8.9 Maintenance Concepts and Strategies
8.10 Condition-Based Maintenance (CBM) Technology Enablers
8.11 Survey of Recent Developments in CBM
8.12 Application Areas of CBM
8.13 Open Research Challenges
8.14 Residual Life Prediction
8.15 Impact of Environmental Policies on Maintenance
8.16 Conclusion
References
9 Sustainability Issues in Condition-Based Maintenance and Residual Life Prediction
9.1 Introduction
9.2 Definition and Principles of CBM
9.3 Residual Life Prediction (RLP)
9.4 Synergies Between CBM and RLP
9.5 Conclusion and Recommendations
References
Bibliography
10 Role of CBM and RLP in the Performance of the Manufacturing Industry
10.1 Introduction
10.2 What is Condition-Based Maintenance (CBM)?
10.3 Types of Condition-Based Maintenance
10.4 When to Use Condition-Based Maintenance
10.5 Steps to Take Before Implementing Condition-Based Maintenance
10.6 Challenges of Condition-Based Maintenance
10.7 Benefits of Condition-Based Maintenance
10.8 Role of Condition-Based Maintenance (CBM) on the Performance of the Manufacturing Industry
10.9 Residual Life Prediction
10.10 Role of Residual Life Prediction on the Performance of the Manufacturing Industry
10.11 Conclusion
References
11 Impact of Competencies on Condition-Based Maintenance and Residual Life Prediction
11.1 Introduction
11.2 Application Areas of CBM
11.3 Residual Life Prediction
11.4 Competency Framework
11.5 Conclusions
References
12 Sustainability Issues in CBM and RLP: Case Studies
12.1 Medium Industry Case Study
12.2 Objectives of Implementing Maintenance Improvement Initiatives
12.3 Need for Maintenance
12.4 Phase–Wise Implementation of Maintenance Practices
12.5 Small Industry Case Study
12.6 Research Methodology
12.7 Steps to Improve the Weaknesses Identified Through SWOT Analysis
12.8 Appropriate Measures Implemented for the Hydraulic Bending Machine
12.9 Results and Discussion
12.10 Conclusions
References
Index
Also of Interest
End User License Agreement
List of Tables
Chapter 12
Table 12.1 Phase-wise maintenance improvement initiatives.
Table 12.2 Cost reduction by installation of fume extractor in the machine.
Table 12.3 Cost reduction by installation of fume extractor in the machine.
Table 12.4 SWOT analysis.
Table 12.5 The preventive maintenance checklist.
Table 12.6 Cost saved by replacing the body liners in a timely manner.
Table 12.7 Month-wise breakdowns.
Table 12.8 Month-wise percentage of availability of the machines.
Table 12.9 Month-wise OEE.
Table 12.10 Timely delivery of the product.
List of Illustrations
Chapter 1
Figure 1.1 Product failure rate.
Figure 1.2 Types of maintenance.
Chapter 2
Figure 2.1 Planned maintenance vs. condition-based maintenance [2].
Figure 2.2 Proactive maintenance vs. predictive maintenance [2].
Figure 2.3 CMMS [2].
Figure 2.4 Condition-based maintenance workflow [12].
Figure 2.5 Predictive maintenance workflow [12].
Chapter 3
Figure 3.1 Trend monitoring.
Figure 3.2 Schematic layout of a condition monitoring system.
Figure 3.3 Online condition monitoring.
Figure 3.4 Vibration analysis.
Figure 3.5 Oil analysis.
Figure 3.6 Infrared thermography.
Figure 3.7 P-F diagram.
Figure 3.8 Cost-failure/time chart.
Chapter 4
Figure 4.1 Five steps of preventive maintenance plan [9].
Figure 4.2 Eight pillars of TPM [10].
Figure 4.3 Steps in implementing a CMMS plan [15].
Figure 4.4 Overview of an intelligent maintenance system [21].
Figure 4.5 Technologies used in implementing smart maintenance [24].
Chapter 6
Figure 6.1 FFT waveform.
Figure 6.2 Power spectral density.
Figure 6.3 Acceleration, velocity, and displacement.
Chapter 7
Figure 7.1 Stress optimization before and after using HyperMesh, Serrano
et al
...
Figure 7.2 The meshed model and the boundary condition model.
Figure 7.3 Stress versus frequency graph.
Figure 7.4 Displacement versus frequency graph.
Figure 7.5 Stress plot: (a) COMSOL multiphysics model (b) HyperMesh model.
Figure 7.6 Optimization models.
Figure 7.7 Strain signals.
Chapter 8
Figure 8.1 Input–output model of the enterprise.
Figure 8.2 Equipment failure behavior (P–F curve).
Figure 8.3 The V-architecture of CBM.
Chapter 11
Figure 11.1 Condition-based maintenance process.
Figure 11.2 Residual life prediction framework.
Figure 11.3 Competency framework.
Figure 11.4 Competencies (capabilities) and maintenance relationship.
Chapter 12
Figure 12.1 Maintenance practices team.
Figure 12.2 Breakdown analysis.
Figure 12.3 The cover was missing and a new one was inserted on the head guide...
Figure 12.4 The motor cover was broken and a new one was inserted on the motor...
Figure 12.5 Flow of order of a new machine with a particular specification.
Figure 12.6 Storage is modified.
Figure 12.7 Spare parts management.
Figure 12.8 Spare parts in order.
Figure 12.9 Storage of manuals and drawings.
Figure 12.10 Use of mist filter before machine air pressure to prevent moistur...
Figure 12.11 Procedure of the mean time to repair.
Figure 12.12 Mean time to repair.
Figure 12.13 Reduced mean time to repair.
Figure 12.14 New design of fixture rail to remove the play in the fixture duri...
Figure 12.15 Replacement of defective pin.
Figure 12.16 Middle end ICT-1 machine.
Figure 12.17 Standard maintenance procedure (SMP).
Figure 12.18 Decrease in breakdowns and increase in average MTBF.
Figure 12.19 Overall equipment efficiency.
Figure 12.20 Reference board stud of two different materials.
Figure 12.21 Reference board stud’s sheet.
Figure 12.22 Fume extractor.
Figure 12.23 Fume extractor in the machine.
Figure 12.24 The lubricant oil was changed.
Figure 12.25 Decrease in breakdowns and increase in average MTBF.
Figure 12.26 Increase in average MTBF and increase in OEE.
Figure 12.27 Hierarchy of the organization for maintenance.
Figure 12.28 SWOT analysis (https://www.feedough.com/swot-analysis/).
Figure 12.29 Strategic maintenance initiatives adopted by the organization.
Figure 12.30 Lathe machine halted due to gear breakdown.
Figure 12.31 Wear out of the gear teeth.
Figure 12.32 Gear replacement.
Figure 12.33 Breakdown of the bearing sheet and shaft.
Figure 12.34 Shaft replacement.
Figure 12.35 Breakdown of the rotary valve.
Figure 12.36 Rotary valve replacement.
Figure 12.37 Breakdown of the shaft.
Figure 12.38 Leakage in the hydraulic bending machine.
Figure 12.39 Seal replacement.
Figure 12.40 Leakage of gear oil in the rolling machine.
Figure 12.41 Wear out of the cutter plate.
Figure 12.42 Grinding machine with the new cutter plate.
Figure 12.43 Blower body of the grinding machine.
Figure 12.44 Wear out of the body liners in the grinding machine.
Figure 12.45 Reduction in breakdowns.
Figure 12.46 Month-wise percentage of availability of the machines.
Figure 12.47 Improvements in OEE.
Figure 12.48 On time delivery of the product increased.
Guide
Cover Page
Table of Contents
Series Page
Title Page
Copyright Page
Begin Reading
Index
Also of Interest
WILEY END USER LICENSE AGREEMENT
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Scrivener Publishing100 Cummings Center, Suite 541JBeverly, MA 01915-6106
Publishers at ScrivenerMartin Scrivener ([email protected])Phillip Carmical ([email protected])
Condition-Based Maintenance and Residual Life Prediction
Edited by
Chandan Deep Singh
Davinder Singh
Kanwal Jit Singh
and
Harleen Kaur
This edition first published 2025 by John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, USA and Scrivener Publishing LLC, 100 Cummings Center, Suite 541J, Beverly, MA 01915, USA© 2025 Scrivener Publishing LLCFor more information about Scrivener publications please visit www.scrivenerpublishing.com.
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Library of Congress Cataloging-in-Publication Data
ISBN 978-1-119-93312-0
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