IT-Enterprise and the representative office Clobbi World are expanding their presence with the Industry 4.0 technologies in the manufacturing regions of Africa and Asia and involving international experts in their team.
We work with the best specialists with in-depth expertise in assessing the behavior and condition of machinery, machine vibrations. With them, we implement projects for the digital transformation of factories, that serves us to investigate specific business problems and implement relevant software solutions of high value for customers.
We officially commenced cooperation with Mr. Mohamed Wahba in July 2021 and since now he is our delegate in the Middle East and North Africa (MENA region).
One of the prominent skills of Mr. Wahba is a great expertise in reliability maintenance. He is a category III analyst and certified specialist in applying automatic control in mechanical engineering (MBA, Esslingen University of Applied Sciences).
Mr. Mohamed Wahba has been working in the heavy industry for 13 years. Outstanding cognition in Predictive approaches was mastered by him during applying Predictive Maintenance solutions at EzzSteel, the largest independent steel producer in the MENA region. Mr. Mohamed Wahba was responsible for 5 large factories. It equals about 400 production and auxiliary units of equipment.
He has been analyzing the operation of induction motors for a long time. He is a professional in the field of investigating machinery vibration. According to him, complete and correct analysis of diagnostic data is the key to a successful and cost-effective preventive maintenance strategy. You can learn more about this in his publication for the Vibration Institute.
Vibration analysis and motor current signature
Damage to the rotor rods is a common problem in the operation of an induction motor. Without proper maintenance, it can lead to the failure of rotating equipment.
In his study, “Using motor current signature analysis to detect the number of broken rotor bars in induction motors,” Mr. Mohamed Wahba identified the role of single rotor condition indicators in fault prediction. He proposes to include the analysis of the motor current signature in the traditional machinery vibration diagnostics and thermal monitoring methods. In the same paper, he describes the appropriate means for interpreting the obtained data.
This advanced diagnostic method is called Motor Current Signature Analysis (MCSA). It was first used in nuclear power plants. It is used to monitor the condition of inaccessible engines and rotating equipment in the hazardous areas. Expert assessment of the sliding frequency of the moving parts of the rotor in combination with spectral data of high resolution makes it possible to determine the quantitative and qualitative nature of the fault with increased accuracy.
While analyzing the dynamic frequency range, one can detect lateral slip bands (deviations from the main harmonic) caused by disturbances in the operation of the rotor rods. Unique current signatures correspond to such malfunctions.
The MCSA method is based on the analysis of unique components of a rotating stream. It helps to detect time deviations against the background of harmonic components in the linear current. Also, it helps to diagnose the possible causes:
- fracture of the conductor rod of the rotor;
- air-gap eccentricity between the rotor and the stator;
- short turns in starter windings.
Mr. Mohamed Wahba proves that MCSA is a powerful Predictive Maintenance tool. It is much more efficient than classical vibration analysis. The classical approach allows detecting severe damage to the rods. The current signature analysis and the correct reading of the oscillation pattern help prevent the spread of damage at an early stage.
A small detail turns a standard indicator of the equipment condition into a first-order diagnostics effect. The current signature analysis can be performed without interrupting production with the motor running under the load at normal operating conditions. It can be done from a single sensor (current converter) and from any phase, so given that, we can say the MCSA method can change the current Predictive Maintenance paradigm.
Such a research underscores the value of Mr. Mohamed Wahba’s professional vision. We at IT-Enterprise and Clobbi World team share his desire to optimize the principles of preventive maintenance, as soon as our solutions are continuously absorbe best practice methods. We are ready to offer modern intelligent Industry 4.0 solutions and tools to implement these ideas through the Digital transformation of customers.