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
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