Early warning of conveyor belt bearing problems
Latest FLIR Si2-series acoustic imaging cameras help maintain uptime and reduce operational expenditure
MAJOR manufacturing facilities often contain thousands of industrial components such as hydraulic pumps and industrial gearboxes, some of which may seem like unimportant ancillary pieces of equipment but are often vital to production and can bring the whole complex to a grinding halt when they fail.
A good example of this is a quarry, where aggregate is conveyed to a loading point via a series of conveyor belts. The belts themselves are driven by electric motors utilizing gearboxes with each conveyor containing a multitude of roller bearings that support the belt as the aggregate is transported to its destination.
The roller bearings supporting long belts may seem insignificant elements when compared with huge crushers, screens, and other major parts of the overall process, and yet if a number of these bearings seize or fail, then the entire production can come to a halt.
Potential failures of these bearings can be identified utilizing thermal imaging cameras, a technique that has been successfully used for many years, saving millions in terms of lost production and catastrophic failure. However, a more recent approach is to utilize acoustic imaging cameras which can provide a much earlier warning signal when it comes to bearing failures.
The latest FLIR Si2-LD acoustic imaging camera has two different operation modes: first, the Leak Detection mode (LD) that is used for detecting minute gas and air leaks in pneumatic, vacuum or speciality gas systems; and secondly, Mech Mode, which can detect mechanical problems with bearings and gears long before they fail.
This early warning tool is easy and quick to use, which means that even long conveyor belts with hundreds of support bearings can be analysed very quickly on a regular basis, providing an in-depth health check and an early warning system, hence potentially avoiding expensive downtime.
The FLIR Si2-Pro acoustic imaging camera comes loaded with a multitude of additional features. Its improved performance means the new camera is capable of detecting problems at much greater distances. It shows a 70% improvement in acoustic performance compared with previous Si124 models. The camera is, therefore, more adept at detecting multiple mechanical sources thanks to its improved multi-source mode.
The camera features a 2x and 8x digital zoom which provides images to a 5in colour touchscreen boasting a resolution of 1,280 x 720 for both video and images, with GPS, image tags, and comments potentially added to images for further analysis to be conducted.
Still images can be produced in both .nlz and .jpg format, whilst videos can be formatted in .nlz. Data transfer can be conducted via Wi-Fi or USB with automatic over-the-air wireless updates ensuring the camera is always up to date. Up to 128GB of measurement data can be stored on the internal SD card, whilst unlimited cloud storage is available with FLIR Cloud.
Whether detecting developing faults in high-voltage applications, leaks from pneumatic equipment or speciality gas installations or mechanical issues such as bearings in conveyors, the FLIR Si2 series of cameras can provide the insights needed to maintain uptime and reduce operational expenditure.
