K7DD

The K7DD advanced motor condition monitoring device makes it possible to identify failure modes and defect parts of motor equipment while rapidly translating power quality such as motor current and voltage into data. This enables scheduled maintenance activities with real-time condition monitoring of motors that frequently change speed, which were difficult to identify abnormalities so far. And simplified condition monitoring device parameter configuration process is contributed to understand K7DD installation efficiency quickly .

Production sites use not only induction motors, but also huge numbers of servo motors, with various failure modes arising from motor and load combinations, requiring measures that can comprehensively capture changes. The K7DD monitors the power quality of devices (current, voltage, etc.) to ascertain at an early stage any signs of abnormality, just like experienced maintenance resources used to do by relying on their senses. Condition monitoring can be performed in real-time without having to stop the production line and it is possible to switch to condition based maintenance. The K7DD also identifies diverse failure modes by capturing various features based on power quality data obtained from the devices.

The K7DD is capable not only of monitoring the condition*1 of servo motor equipment that frequently changes speed, but also induction motors whose load changes during high-speed work movement. Condition monitoring of loads connected to motors is also possible.
*1 An interval where the frequency value is fixed will be required to ensure stable measurement.

The K7DD supports motors running at variable speeds and with fluctuating loads, making it possible to monitor the condition of various loads connected to motors.

A variety of factors may cause motor equipment failure. Configuration of the K7DD makes it possible to monitor these failure modes individually and suggest subsequent actions to be taken by maintenance staff depending on the condition.

The K7DD advanced motor condition monitoring device features high-performance sensing to deliver new condition monitoring close to user-friendly maintenance. Condition monitoring of various motor equipment, including servo motors, has been achieved through high-speed processing.

The K7DD samples 6 channels simultaneously at 2.5μs. By operating 3-phase power line current/voltage every 50 ms, it detects over 400 types of feature values. From these values, you can select the feature values you want to monitor and set thresholds for each feature value to monitor diverse failure modes of various production facilities and equipment.

Abnormalities in motor equipment (motors and their loads) can often be seen to affect the axis of revolution of a motor. Gaps between rotors & stator and torque fluctuation due to degradation appear as changes in current and voltage, leading to distorted motor current waveforms caused by uneven rotation that is unlike the smooth rotation seen in normal operation.

Harmonics are frequency components in the order of a motor􏘧s fundamental frequency. By monitoring the size of components for each frequency of vibration that occurs in the motor or its load, it is possible to determine the failure mode or position of abnormality that has occurred in the equipment. The K7DD can operate up to the 63rd order harmonic at intervals of 0.5 order.

OMRON's condition monitoring devices for motor include the K6CM motor condition monitoring device and the K7GE-MG insulation resistance monitoring device. These application coverage and effects of these devices vary, so use the respective devices that are suited to your equipment and the applications you want to run. With the K7DD, you can select the effective feature values for each failure mode and failure part, enabling failure parts to be identified.

Using clouds, data servers, or other IT devices not only requires system-building skill and coordination with IT administrators, but also necessitates specialist installation work. The K7DD is a maintenance-site self-contained model, so there is no need to learn special skills, and it can be retrofitted with minimal installation workload. After installation, you can check abnormal conditions from the K7DD display screen.

IT skills are required for both company-internal and external network connections, and on-site implementation takes a long time because there are many related departments. The K7DD is capable of advanced processing in the device itself, therefore inspection of effects can be completed purely on-site.
Note: Condition Monitoring Configuration Tool software must be used in order to set up monitoring by failure mode.

The condition of the monitored motor is displayed on top panel by color-coding as green, yellow, or red. This shows the degree of abnormality and is helpful for visual inspection near the motor without any IT tool. “Warning” and “critical” conditions are also output, and notifications can be issued by transistor output for signal lights, etc.

Various feature values and thresholds can be checked on-site for smooth decision-making regarding maintenance.

Built-in communication functions make it possible for data logging that mportant feature values at your preferred timing. (Condition Monitoring Configuration Tool software enable logging, monitoring and output to CSV files.)

50 ms arithmetic processing operation and calculation of more than 400 types of feature values are realized monitoring that is effective for various motor failure modes. However, the handling of these data requires extremely advanced data analysis skills. With the K7DD, these analyses are supported to enable rapid startup of scheduled equipment maintenance.

If abnormalities in equipment can be easily replicated reproduced, effects can be inspected visually and quantitatively using Condition Monitoring Configuration Tool software.

Note: The above-shown pictures might be different from the actual ones.

If abnormalities cannot be replicated, it is difficult to set effective feature values and thresholds.

Based on the knowledge it has accumulated through on-site inspections, OMRON provides files containing failure mode-specific feature values that are easy-to-effect and details of how to set thresholds. These can be downloaded from the OMRON website and installed to the K7DD device via Condition Monitoring Configuration Tool software.
Note: We will continue to expand our lineup of app files.
URL:https://www.ia.omron.com/k7dd_tool

Built-in function manages failure modes individually.
Linking regular maintenance results in the real and digital realms enables accumulation of maintenance knowledge. You can try various functions aimed at condition based maintenance, including extent of progress of abnormal conditions.