Diagnostic Tools

PRODUCT LINE

Carbon

  • Electrical Application
  • Mechanical Application

Diagnostics

  • Brush Maintenance Accessories
    (BMA)
  • Commutator Maintenance
    (CMA)

Electrical Applications

  • Carbon Brush.
  • Carbon Current Collectors.
  • Metallized Carbon Panto Strips.
  • Silver Impregnated Copper Spray Graphite Contacts.

Mechanical Applications

  • Carbon Seal Rings
  • Carbon Gland Rings, Steam Joints.
  • Carbon Bush & Bearings.
  • Thrust Pad & Radial Bearing.
  • Lubricating Blocks.
  • Isostatic Graphite for High Temp applications.

Diagnostics

Brush Maintenance Accessories

  • Brush Bedding Stones (Brush Seater)
  • Glass Fiber Burnishing Sticks.
  • Brush Holders/ Br Holders Springs.
  • Brush Pressure Meter.

Commutator Maintenance Accessories

  • ProfilerTM
  • Commutator Grinding Stones.
  • Chamfers, Scrapers etc.
  • Mica Under cutters.
  • Vibration Analysers.

A New Dimension on CBM Process for Motors & Generators.

ProfilerTM

BREAK DOWN
MAINTENANCE

PROACTIVE
MAINTENANCE

Industrial Objective

To reduce Cost: Few important areas–

  • Maintenance.
  • Down Time.
  • Equipment Reliability.
  • Machine output.

An approach to Best Condition Monitoring Practices

Factors affecting Industrial applications

  • Where downtime cost is predominantly high.
  • Where a safety risk is particularly likely to arise from the breakdown of the machinery.
  • Where accurate and advanced planning of maintenance is essential.
  • Where plant/equipment is of recent design & may have residual development problems.
  • Where operators cannot be expected to detect faults in expensive equipment whose breakdown may result in serious damage.
  • Where instruments or other equipment required for condition monitoring can be used or is already being used.
  • Where the manufacturer can offer a condition monitoring service to users of its equipment.

Commutator/ Slip-Ring Maintenance

Main Objectives:

  • Measurement of Ovality accurately.
  • Keep Max bar to bar variance low.
  • Detect the segments with High Mica.

Objective

  • The primary object of reconditioning a commutator is to remove all irregularities that disturb the Carbon Brush efficiency and reduced brush and commutator life.
  • Axial error and steps, even an irregularity as small as 0.001 in (0.025mm) can disturb the brush sufficiently to result in digging and arcing as the brush reseat on the commutator surface.
  • It should be understood that the nature of Carbon Brush and Commutator are such that even these small irregularities cannot be absorbed without detracting from Carbon Brush Efficiency.

Our Needs

  • Reduce Sparking.
  • Avoid premature Carbon Brush Failure.
  • Avoid Grooving / unevenness on Commutator/Slip-ring surface.
  • Avoid Vibration.
  • Enhance life of Commutator/ Slip-ring

Meeting the Needs

Solutions:

  • ProfilerTM
  • Brush Pressure Meter
  • Brush Seater
  • Commutator Grinding Stone
  • Glass Fibre Sticks
  • Chamfer/ Scraper
  • Mica Under Cutter.
  • Many more……..

ProfilerTM Measures:

  • Total Indicated Run-out (TIR/ Ovality)
  • Max Bar To Bar Variations (High Bar)
  • Raised Mica

ProfilerTM Measures

  • Total Indicated Run-out (TIR/ Ovality)
  • Max Bar To Bar Variations (High Bar)
  • Raised Mica

ProfilerTM Analyses

  • Linear Chart
  • Histogram in MAS.
  • Radial Profile in MAS
  • TIR identifying the Segments
  • Max BTB & Mean BTB identifying the Segments
  • High Mica identifying the Segments
  • Standard Deviation
  • Suspected Bars / Segments

Industrial Objective


Linear Chart

How ProfilerTM help.

Keeps electric motors and generators operating at peak efficiency and maximize their useful life, by helping you maintaining commutators and slip rings in a perfectly round and smooth condition.

IMPORTANT

Particularly with commutators, it is bar-to-bar height variations of adjacent bars rather than simply out of roundness that can cause a significant loss of output efficiency, increase power consumption, cause premature wear and damage of brushes, and even lead to serious breakdown problems.

Options

Dial Indicators

  • TIR -
    (time consuming)

  • MBTB -

  • High Mica -

  • IBH vs. BC -

  • Radial Graph -

Profiler

  • TIR - (effortless)

  • MBTB -

  • High Mica -

  • IBH vs. BC -

  • Radial Graph -

Comparative

An instrument such as a Dial Indicator can detect out of roundness (or TIR) on commutators, such a device cannot detect the more serious problems of bar-to-bar height variations and raised mica insulation. With a precise measurement resolution of 1 micron (0.04 mils) the ProfilerTM easily produces a detailed and accurate report which can prove a clean bill of health on all counts. These measurements can also be downloaded to the MAS (Measurement analysis Software) PC application for data archiving and presentation purposes. MAS is included in the price of the ProfilerTM, not an expensive add-on.



EVERYTHING YOU NEED

  • MMS7000
  • Sensor with integrated clamp
  • Carry Case
  • Power Adapter + USB Cable
  • Sensor Protector Sleeve
  • Sensor Spacer Set
  • EVOsoft Analysis Software - including three licences
  • Quick Reference Guide

EVERYTHING YOU NEED

Select

Position your sensor


Start Measuring!

Watch the live readout as you measure in either text or graph format


Histogram Analysis



Chart Analysis



Radial Profile Analysis

Unsatisfactory
Satisfactory

Warranty & Service

  • 3 years on the Instrument.
  • servicing support from New Zealand.
  • Spare Support – Assam Carbon.
  • Application support – Assam Carbon/ New Zealand.

Cost Analysis

  • Avg. shed strength/year = 100 Motors.
  • ProfilerTM cost = Rs. 865000
  • One time Investment / TM = Rs. 865000/100
    = Rs. 8650.00
Avoiding 1 Break down of Motor saves you =Rs.???

Cost Benefit Analysis

ProfilerTM Alternative Saving
TIR/Mtr 5 mins 15 mins 10 mins
MBTB 0 mins 30 mins 30 mins
High Mica 0 mins 10 mins 10 mins
Data Capture 2 mins 10 mins 8 mins
Data Analysis 2 mins 15 mins 13 mins
Old Data Revival 1 mins 15 mins 14 mins
10 mins 95 mins 85 mins

Warranty & Service

  • Time saved/ TM = 85 mins
  • Time saved in 100 TM/ yr = 8500 mins = 141 hrs./ 18 man days.
  • Enhanced life of Commutator/ Slip Ring.
  • Proper Commutation.
  • Improves brush life.
  • Reduce pre-mature failure of Carbon Brush.
  • Documented data of individual motors/ gen.
  • Reduce Down-time losses.
  • Increases Machine Reliability.
  • Reduces Maintenance Cost.

Our Requirements

Unsatisfactory
  • Reduce Sparking.
  • Normal Brush Life.
  • Avoid premature Brush Failure.
  • Avoid Grooving / unevenness on Commutator/Slip-ring surface.
  • Avoid Vibration.
  • Enhance life of Commutator/ Slip-ring