PROGNOST®-Predictor

© PROGNOST Systems 01/2018

Patented, automated health diagnostics

 Component centric
diagnostic view
 Compares vibration
signatures against
failure modes database
 Specialized for bearing
and gearbox monitoring
Product history
Patented since July 28th 2015

 Patent for the

“Method of mechanical
fault detection”
featured as
“Confidence Factor”
 US Patent 9,091,588 B2

4
References

incl. Smart Advisor and Espresso references

System architecture

 PROGNOST®-Predictor
 Data Acquisition
 FPGA configurable
real-time analysis
 Monitoring and
Communication Unit
 Modbus, OPC interfaces
 Mobile services
Hardware features

 12,800 lines FFT

 FFT <1 millisecond
 96 channels
 768 DSP cores
 Simultaneous data
acquisition on all
channels
Data reduction

 For each component the update interval (determines how

often a new analysis result is stored) can be customized
 Long term data is minimized
 Analysis data during threshold violation will NEVER be
deleted!
Standard and High Frequency Envelope
(HFE) spectral analysis
 Spectral resolution from 400 to 12,800 lines
 Spectral bandwidth from 50 to 40,000 Hz
 Confidence Analysis to provide accurate fault detection
Spectral analysis
High Frequency Envelope (HFE) spectral analysis
Gap, shaft centerline, and orbit analyses

 For sleeve
bearing
analysis
 Saves start-up,
coast down
events, and
steady state
data
Time Synchronous Averaging (TSA)
 Used for gear vibration imaging to detect developing faults
on gears such as pitting, spalling and tooth cracks
 Performed for each gear using both the direct vibration
signal and the high frequency envelop (HFE) signal
 Synchronous vibration produced by the gear adds to the
average while vibration from noise and other components
is suppressed
Time Synchronous Averaging (TSA)
 Acts as a filter which isolates the vibration produced by
each gear as it rotates while rejecting other vibrations.
 The resulting time waveform is referred to as a
 “Gear vibration image”
 and represents the vibration produced by the gear
through 360 degrees of shaft rotation
Time Synchronous Averaging (TSA)

 Isolates
synchronous
vibrations from
gears, nipped
rolls and felts
 Direct and HFE
averages
Gear Imaging
Bearing fault signature

 Defects cause periodic impacts as

the rolling element passes the defect
 Important frequencies:
 Repetition frequency
 Internal pulse ring frequency
typically in the 5-40 KHz range
 Pulse amplitudes are small
compared to the dominant drive
frequencies
Bearing fault detection

 Comprehensive
database of
bearings including
fault frequencies
 Comparison of
signal analyses
with the fault
frequencies
Alarm logic
 Configurable consecutive threshold crossing logic
 High vibration must be measured a consecutive number of
times before the alarm condition is declared
 The number of consecutive threshold violations to trigger
an alarm is freely configurable

37
Confidence Factor
 US Patent
9,091,588 B2
 Measures how
Confidence near 0
many current band
peaks match the
expected failure
Confidence near 100
mode signature
 Ranges from 0 (no
similarity) to 100
(perfect match)
Graphical status for specific component
 Multiple sensor signals are monitored with different
analyses and compared against known failure modes
 Analyses:
 Acceleration FFT
 High Frequency Enveloping (HFE) 10-20kHz
 High Frequency Enveloping (HFE) 20-40kHz
 Each analysis is displayed as a trend line
 The Confidence Analyses compiles all this within the Scatter
Plot
Individual Watch List (I)

 Keep track with those

components which
show already
indications of
impending failures
 Create your individual
and personal notebook
to follow your critical
signals
Individual Watch List (II)
User friendly handling of information (I)
Daily routine of a PROGNOST®-Predictor user:
 What’s going on?
 Check the alarm log for recent alarms
 Browse graphics or machine status tree for faulted
components
 Browse the system hardware tree for faulted sensors
 Move items of interest to the Watch List
 Analysis tuning

 Run data mining tools to check thresholds, find false passes

User friendly handling of information (II)

 Watch List
 Quickly check the
status of critical
machine components
 Create “morning
meeting” report
 Take corrective action
PROGNOST Customer Support Expertise
 Intense expert knowledge
on data analysis and
interpretation
 Engineers with 20+ years
monitoring experience
 Specific knowledge about
sensor mounting and setup
of analyses
Customer Support offering

 Remote online support

 Remote machine status
reports
 Remote system
optimization
 Remote software
upgrades
 On-site system checks
and support
Mobile services
 Receive email, text, or phone messages on alarms
 View basic status information over the web
Mobile services
 Provides important machinery status wherever you are
 Web site with summary status
 Watch list item status
 Machinery and hardware notification Log
 System health status
Mobile services
 Email notifications
 Selected new alarm status
 Regular update on selected components
 Spectrum and trend attachment for severity evaluation
 Text notifications and voice message
 Selected new alarm status
Key PROGNOST®-Predictor capabilities
 Confidence Factor technology gives clear and easy
understandable information about impeding failures
 Reliable monitoring of gearboxes and special capabilities
for planetary gearboxes
 Automated failure detection on roller bearings with
integrated fault frequency database
Key PROGNOST®-Predictor capabilities
 Watch list for user-friendly visualization of component
oriented health status
 Easy-to-use analysis and diagnosis software
 Time synchronous averaging for early failure detection of
gear tooth
Benefits
 Improving plant safety and efficiency by automated
monitoring of critical parameters
 Avoiding unplanned shutdowns by early detection of
machinery failures
 Extending MTBM (Mean Time between Maintenance) by
providing relevant information for maintenance decisions
 Avoidance of false alarms and missed detects by unique
monitoring tools (e.g. Confidence Factor)