We have a large staff of engineers with highly specialized expertise in machinery automobiles, aerospace, various household appliances, communication, optical devices, facilities and equipment, etc , electricity and electronics analog circuits, digital circuits, devices, semiconductors, microcomputers, etc. We practice strict compliance, and support our customers' operations by providing services ranging from dispatch of individual engineers to in-house outsourcing of numerous engineers, using its in-house contract system.
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The engineer group is capable of providing support in every field, from transport aircrafts, to general electric machineries, precision instruments, and various devices. All of our trainers are experts in their fields and they provide customers with training programs using 3D-CAD, measurement devices and 3D printer to meet their demands and skills. In addition, we also provide various e-Learning programs according to the growth levels of the engineers' individual skills. Highly skilled engineers under permanent employment are available to respond to increasingly diverse needs.
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We endeavor to enhance employee awareness to improve customer satisfaction. Industry-based past performance Automobiles, automobile parts, marine vessels, aircrafts, various mass-produced household appliances, optical devices, semiconductors, medical equipment, industrial machineries, and electric power facilities Plant equipment, infrastructure equipment, etc. You will need to carry many spares. You will suffer excessive downtime as equipment waits for the handover, the parts and the maintainer to arrive and correct the problem.
The maintenance will be done poorly and mistakes will be many because everyone is under time and production pressure. If we want high reliability you need to use your maintenance to reduce the risks of failure and not to fix failures.
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This requires that you initiate proactive maintenance and act to prevent all possible failures before the operational risk from an electromechanical item failing gets too great. For example, you establish a monitoring program of the failures of solenoid valves in size ranges 15mm to 40mm and 50mm to 80mm. You view the data each month and notice that where the 15mm to 40mm solenoids were failing at a rate of one every three years when the plant and equipment was younger, they have now reached a failure rate of one every two years. What do you do? Do you increase your spares holding and replace each item on failure that is reactive maintenance , or do you replace them all in a block of planned maintenance and renew all old 15mm to 40mm solenoids?
If you have of such solenoids in your plant you will have a major maintenance cost and a major production disruption If you had only 10 such solenoids you might justify a campaign to replace them one-by-one as each can be accessed on a planned outage. If you could do all ten at once you would. Fortunately we have yet to investigate the risk of solenoid valve failure.
Your solenoid valve failure monitoring program is also categorised by failure mode what you see when an item fails and by the plant area of the item that failed.
You can identify that the failures have historically been in a very damp part of the operation and the failure modes are mostly burnt coils due to moisture ingress e. It is clear that not all of the solenoids are at risk; only those in damp operational areas. You only need to campaign those solenoids in damp areas that are of the same design, Ingress Protection IP rating or below, and of similar operational age. That is a pragmatic approach to maintenance work selection. We can still do other pragmatic maintenance to maximise electromechanical system reliability. If we can control the environment immediately in contact with the solenoid valves and keep the moisture out of the coils we will have removed the scientific root cause of the failure.
We probably cannot address the latent root cause of the failures, which was why the company allowed such IP solenoid valves to be used in damp areas in the first place.
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We can only do what we can in the situation, and that will be to prevent moisture ingress. For our maintenance to be pragmatic in this situation we set-up a campaign to improve the sealing of all solenoids in damp areas against moisture ingress. To which we add a planned preventive maintenance route for valves at high risk of moisture ingress, in which their sealing is methodically inspected every six months and kept in good condition. These days I would also expect before and after photographs of each item as part of their historic maintenance record even thermographic images probably should be included.
I have not yet discussed the use of condition monitoring. It is because predictive maintenance strategy, which makes use of condition monitoring technologies and techniques, does not produce reliability improvement. Reliability requires ways to cause reduced rates of failure.
From a failure once every two years, to once every three years, to once every five years is reliability improvement. Predictive Maintenance does not increase the time between failure, it only finds the failure, hopefully well before it becomes a breakdown.
Condition monitoring used to increase reliability would be if it were used to identify the failure rate, and if was used to find the root cause of the failure. Once the failure rate is known we use the operating risk management options discussed above to renew components, install more robust assemblies, and even replace entire machines with more reliable ones.
Once condition monitoring helps us to find the root cause of failure we remove the cause. It is removal of the failure root cause that produces reliability, not the condition monitoring.
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All of the above depends on one other very pragmatic issue—is it going to make money for the business? All maintenance and reliability decisions need to be financially sound for the future well being of the business. If your plant is going to be decommissioned in six months you would not do most of what I suggested above. Only the additional sealing campaign might be justifiable. It bothers me greatly when maintenance decisions are made without a sound financial analysis of the available choices. The right maintenance to do is that which makes most money for the business.
That includes, if necessary, maintenance people training operators and engineers in better skills and practices. Electromechanical equipment is used everywhere, and increasingly so. The most beneficial pragmatic maintenance strategy to use for electromechanical systems is to keep their components safe from the risks that cause their failure.