Extruder Condition Monitoring

Condition Monitoring

In the event of an anomaly, we swiftly take necessary measures, provide prompt support and offer clear recommendations for the next steps. Early detection of issues allows for planned and proactive maintenance, minimizing any impact on the productivity of your ZSK extruder.

The Coperion vibration monitoring system is specifically designed for condition-based maintenance and is suitable for monitoring the smooth operation of gears and motors according to DIN/ISO 20816, as well as for monitoring rolling bearings. By using an additional sensor on the process component, vibration anomalies in the process part can be detected early, and critical operating points can be identified.

Using the EpcNT and CSpro ZSK extruder controls, operators can access the data that the condition monitoring system captures at any time via web interface. Thus an immediate, comprehensive view of the extruder’s overall health and status is constantly available for the operator.

Operating principle: vibration and oil condition monitoring

Vibration Monitoring

For vibration monitoring, multiple acceleration sensors are mounted at key points on the extruder to monitor vibration. These sensors measure the vibrations that occur and attribute them to components such as the gearbox, gear teeth engagement, and screw shafts. If vibration levels reach a critical threshold, a warning signal is triggered.

Oil Condition Monitoring

The condition of the oil within the gearbox is continuously assessed using a dedicated sensor that analyzes the oil’s quality parameters. As the operating hours increase, the oil quality generally declines. When the condition approaches a defined threshold, the system alerts operators so that maintenance actions, like oil changes or repairs, can be scheduled proactively.

Service Agreement Condition Monitoring

In combination with the Condition Monitoring Service Agreement, your ZSK extruder is optimally monitored. A vibration expert from Coperion conducts regular checks of the extruder based on the data collected via remote access and prepares comprehensive quarterly reports on the condition of the system.

The condition monitoring system, together with Coperion's system expertise, enables early identification of wear and tear and helps prevent larger consequential damages. This leads to cost savings, avoidance of production downtimes, and reduction of expensive idle times.