Maintenance

Predictive Maintenance

Condition monitoring: vibration, thermal, and trend-based intervention.

Overview

Predictive maintenance intervenes on measured condition — vibration spectra, thermal images, current signatures — instead of calendar guesswork or run-to-failure.

Engineering purpose

Buy lead time: detect degradation early enough to plan, order parts, and schedule, converting breakdowns into planned work.

How it works

Baselines per machine define normal; vibration analysis localizes faults by frequency signature (1× imbalance, 2× misalignment, bearing tones); trends against the machine's own baseline beat absolute limits; alerts map to planning horizons.

• Predictive maintenance triggers on measured condition (vibration, temperature, current signature), not calendar time.
• Vibration analysis localizes faults: bearing frequencies, imbalance (1×), misalignment (2×) each have signatures.
• The value is lead time — alerts must arrive early enough to plan, order parts, and schedule.

Common faults

Absolute thresholds ignoring machine individuality; alerts arriving too late to plan; baselines never re-taken after overhauls; condition data collected and never reviewed.

Diagnostic checks

1. 1Compare current vibration spectra against the machine's baseline, not absolute limits alone.
2. 2Verify alert thresholds produced actionable lead time in past events.
3. 3Check whether past alerts actually delivered usable lead time — a predictive program is measured by planning horizon, not alarm count.

Safety notes

Condition data collection on running machines follows guarding and access rules; permanently mounted sensors exist so people don't lean into rotating equipment with magnets.

Commissioning notes

Baseline every covered machine in known-good state, define alert-to-action workflows, and integrate findings into the planning system from day one.

Related concepts

Vibration signatures, baselining, P-F interval, condition indicators, alert-to-work-order flow.

predictive · vibration analysis · condition monitoring · oil analysis · thermography · پیش‌بینانه · پایش وضعیت · آنالیز ارتعاش · ترموگرافی

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Cited for early-warning questions, vibration or thermal anomalies, and building condition-based strategies for critical assets.