Reliability Monitoring

Reliability Monitoring Benefits

• Continuous monitoring and visual indication of the reliability of each press/die combination that is being run.
• Immediate indication of the effect of material variations and the effect of thermal and dynamic changes on your long-term die and press reliability.
• Determination of the maximum running speed of a specific operation for long term reliability.
• Measurement of the effect of “minor” die and set-up modifications on your long-term die and press reliability

Example of the Ultilization of Vibration Severity Monitoring

• STEP 1: Maximum reliable operating speed for a press/die application is determined.
• STEP 2: Die modifications are made to reduce the vibration levels.
• STEP 3: Effects of modifications are measured and new, maximum reliable operating speed is established.
• STEP 4: Operation is continuously monitored to detect and flag any changes that affect reliability.
• RESULT: Significant speed increase with reduced downtime and increased tooling and press life

VIBCOACH

Continuous "Vibration Severity Monitoring"

The VIBCOACH is a vibration severity monitor that provides real-time identification of long-term press/die reliability levels and capital risk conditions for a specific press. The VIBCOACH is mounted on the press’ control console and continuously advises the operator of the current reliability of the press/die in production, and indicates any changes to this condition via its digital readout and its color coded STATUSALERT™ system. STATUSALERT is an LED light system that continuously indicates current condition and any changes in the system’s reliability.

VIBMAN

Plant Site "Vibration Severity Monitoring"

The VIBMAN is a portable, handheld instrumentation system that can be licensed from Minster and gives the user the ability to selectively monitor the vibration severity of any and all press/die applications within their plant. Features of the VIBMAN include:

• Measurement of the long-term reliability of any press/die combination in your plant.
• The ability to further analyze a press/die application by measuring Acceleration and Displacement as well as Vibration Severity.
• Diagnostic sensor lights that indicate if the VIBMAN system is being used improperly, or needs maintenance.
• Yearly instrument calibration by Minster’s research department.

VIBTRACKER

The optional VIBTRACKER data collection system collects and stores one year of VIBCOACH Vibration Severity data. This production information is logged in one minute intervals on a 24/7 basis.

VIBDOCTOR

Optional analysis software that provides daily, weekly, monthly, quarterly, or YTD evaluation of the production conditions and statistical trends present from all dies operating within the monitored press. Used in conjunction with the VIBCOACH monitor and VIBTRACKER logger.

VIBSURVEY

Scheduled "Vibration Severity Monitoring"

The VIBSURVEY is a vibration monitoring service that provides a low cost method of benchmarking the reliability of specific press/die combinations in your facility. With this program, a Minster technician will travel to your facility with a VIBMAN instrumentation system, obtain a series of vibration severity readings from specified press/die combinations, and send this information back to Minster’s research engineers. Minster’s engineers will analyze this information and provide you with a report which analyzes the readings and provides next step recommendations.

Technology Assistance Programs

Minster’s Applied Research Center has the ability to perform in-depth analysis on your specific application and help you determine how you can best increase your production capability and reliability.

Typical Factors That Limit a Stamping Application:

• Severe Vibration Issues
• Off-Center Loading Issues
• Lack of Energy Control
• Thermal Issues
• Dynamic Non-Parallelism
• Excess Punch Penetration
• Material Flow Issues
• Material Movement Issues

Typical Program Steps

In-depth, in field testing:

• Typical items analyzed include press loading, press & tooling vibration, dynamic non-parallelism, and punch penetration. Each item analyzed is measured thoughout the stroke and at differing production speeds.

Detailed analytical analysis:

• Test information along with all other available information is analyzed to determine the internal processes limiting production, reducing reliability, or adversely affecting part quality.
• Virtual tooling analysis as well as Finite Element Methodology & Flow Analysis may be utilized to more fully analyze and resolve certain applications.

Recommendation Implementation:

• When process or equipment recommendations are implemented, Minster can then analyze and continuously monitor the results of these changes.