Condition Monitoring to Enable Predictive Maintenance on a Six-Die Nut Manufacturing Machine through Force Data Analysis

Nut fasteners are produced by machines working around the clock. Companies generally operate with a run-to-failure or planned maintenance approach. Even with a planned maintenance schedule, however, undetected damage to the dies and non-die parts occurring between maintenance periods can cause considerable downtime and pervasive damage to the machine. To address this shortcoming, force data from the fourth and sixth dies of a six-die nut manufacturing machine were analysed using correlation to the best health condition on the force profile and on the force shock response spectrum profile. Fault features such as quality adjustments and damage to both die and non-die parts were detectable prior to required maintenance or machine failure. This detection was facilitated by the determination of health thresholds, whereby the force SRS profile generated a longer warning period prior to failure. The analytical approach could benefit the industry by identifying damage that would normally go undetected by operators, thereby reducing downtime, extending die life, enabling “as needed” maintenance, and optimising machine operation.