ABB's drivetrain digital solution is specifically tailored for critical machinery in ore terminals, such as ship unloaders and stacker-reclaimers. It employs a "customized" approach, combining carefully selected hardware and algorithm deployment for data acquisition and fault diagnostic analysis, based on the actual on-site conditions and equipment structural characteristics.
For ship unloader units, ABB's wired monitoring product, Smart Qube, is utilized. Smart Qube is a multi-channel condition monitoring system designed by ABB for the non-steady-state operation of critical industrial equipment.
Smart Qube Product Highlights:
- Multi-channel Data Acquisition: Supports 8/16 channels with input compatibility for various sensor types, including accelerometers, eddy current displacement sensors, current transformers, and integrated temperature-vibration sensors.
- Dual Independent 485 Channels: Enables MODBUS and PROFIBUS gateway functionality for integrating third-party signals and provides collected data to DCS and other systems.
- Dual Independent Audio Inputs: Monitors operational sounds on-site.
- Four Slow-Varying Signal Inputs: Supports 2/3/4-wire 4~20mA connections.
- Multiple Network Communication Modes: Offers connectivity via RJ45, Wi-Fi, and 4G.
- Integrated Temperature-Vibration Sensors: Feature a frequency range of 0.4Hz-13kHz (±3dB), a temperature range of -40～+120℃, and can withstand a maximum shock of 3000g.
For the monitoring of stacker-reclaimer units, ABB's wireless intelligent sensor, Smart Sensor, is implemented. This is an online condition monitoring solution that facilitates predictive maintenance monitoring for virtually all rotating equipment. It integrates four sensor types: triaxial accelerometer, magnetic field sensor, temperature sensor, and noise sensor. This enables automatic analysis, tracking, and alarming for faults in motors, gearboxes, and other related rotating equipment.
Smart Sensor Product Highlights:
- Magnetic Field Sensor: With a frequency range of 0.1~280Hz, itReal-time monitoring of the motor's magnetic flux density, providing parameters such as slip frequency, rotational speed, power, and keyphasor.
- Triaxial Vibration Sensor: Samples at a frequency of 1~20KHz, simultaneously monitoring equipment vibration acceleration signals in three directions to promptly identify abnormal force conditions.
- Temperature Sensor: Measures from -40 °C to +85 °C, tracking motor surface temperature trends to proactively detect abnormal overheating.
- Noise Sensor: With a frequency range of 100Hz~80KHz, it utilizes acoustic emission technology to acquire and analyze high-frequency signals indicative of early bearing defects and poor lubrication.
On the system platform side, ABB's proprietary fault diagnosis and health monitoring algorithms for industrial rotating equipment are deployed. Once a device fault is identified, the system, based on the equipment's condition and its application environment, along with various analysis plots (such as time-domain/spectrum/envelope demodulation/cepstrum/waterfall plot/order analysis), automatically captures fault characteristic frequencies. These are then filtered, classified, and compared within the system platform, ultimately providing algorithm-driven fault diagnosis results directly within the platform.
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