A análise de óleo como manutenção preditiva em máquinas agrícolas de uma usina sucroalcooleira visando economia em prevenção corretiva
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Data
2022-09-28
Autores
Iwasaki, Joshua Enrico Pereira
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Universidade Estadual Paulista (Unesp)
Resumo
No setor agrícola, a utilização de máquinas e equipamentos se torna cada dia mais indispensável para o aumento da produtividade, que aliada as boas práticas de manutenção, retorna um custo reduzido frente aos ganhos obtidos pela substituição de operações manuais por operações mecanizadas. Dentro da manutenção, um dos ensaios de maior recorrência e efetividade é a análise de óleo, que proporciona um controle de contaminação e desgaste dos componentes, tornando possível estimar o ponto adequado de troca de determinado componente sem comprometer outros sistemas e impactar a disponibilidade do ativo. A análise de óleo lubrificante identifica e contabiliza a quantidade de partículas de contaminação presente no óleo, permitindo, assim, não somente quantificar o desgaste, mas também indicar a provável peça desgastada através da contabilização das partículas de elementos de liga. Esse trabalho pretende analisar os dados obtidos de análises de óleo em máquinas agrícolas utilizadas na produção, avaliando os principais subsistemas afetados. Após a inspeção dos compartimentos e a realização da manutenção, foi feita uma comparação do custo de manutenção quando se aplica essa técnica e quando ocorre a manutenção corretiva não planejada. Observa-se um ganho de produtividade do equipamento devido ao menor tempo de parada e menor custo de manutenção. Na análise de custo, a situação real avaliada validou a teoria aplicada, uma vez que a estimativa do custo com a manutenção corretiva planejada foi 44,1% menor em relação a corretiva não planejada. Embora, analisou-se apenas um caso, para uma empresa com grande quantidade de ativos, o impacto no custo será bem maior, devido a economia com manutenção em todos os maquinários aplicando a análise de óleo como manutenção preditiva. As análises, associadas a inspeção dos compartimentos, proporcionaram a aplicabilidade da análise de fluido em maquinários agrícolas, se mostrando econômica para o produtor rural e usinas sucroalcooleiras.
In the agricultural sector, the use of machinery and equipment becomes increasingly indispensable for increased productivity, which combined with proper maintenance practices, returns a reduced cost compared to the gains obtained by replacing manual operations with mechanized operations. Within the maintenance, one of the tests of greater recurrence and effectiveness is the oil analysis, which provides a control of contamination and wear of the components, making it possible to estimate the appropriate point of exchange of a given component without compromising other systems and impacting asset availability. Lubricating oil analysis identifies and accounts for the amount of contamination particles present in the oil, thus allowing not only to quantify wear, but also to indicate the likely worn part by accounting for the particles of alloy elements. This work aims to analyze the data obtained from oil analysis on agricultural machinery used in production, evaluating the main affected subsystems. After inspection of the compartments and maintenance, a comparison of the maintenance cost was made when this technique is applied and when unplanned corrective maintenance occurs. There is a gain in equipment productivity due to shorter downtime and lower maintenance costs. In the cost analysis, the actual situation evaluated validated the theory applied, since the estimated cost of planned corrective maintenance was 44.1% lower compared to unplanned corrective maintenance. Although, only one case was analyzed, for a company with a large amount of assets, the impact on the cost will be much greater, due to maintenance savings on all machinery by applying oil analysis as predictive maintenance. The analyses, associated with the inspection of the compartments, provided the applicability of the fluid analysis in agricultural machinery, proving to be economical for the rural producer and sugar and alcohol plants.
In the agricultural sector, the use of machinery and equipment becomes increasingly indispensable for increased productivity, which combined with proper maintenance practices, returns a reduced cost compared to the gains obtained by replacing manual operations with mechanized operations. Within the maintenance, one of the tests of greater recurrence and effectiveness is the oil analysis, which provides a control of contamination and wear of the components, making it possible to estimate the appropriate point of exchange of a given component without compromising other systems and impacting asset availability. Lubricating oil analysis identifies and accounts for the amount of contamination particles present in the oil, thus allowing not only to quantify wear, but also to indicate the likely worn part by accounting for the particles of alloy elements. This work aims to analyze the data obtained from oil analysis on agricultural machinery used in production, evaluating the main affected subsystems. After inspection of the compartments and maintenance, a comparison of the maintenance cost was made when this technique is applied and when unplanned corrective maintenance occurs. There is a gain in equipment productivity due to shorter downtime and lower maintenance costs. In the cost analysis, the actual situation evaluated validated the theory applied, since the estimated cost of planned corrective maintenance was 44.1% lower compared to unplanned corrective maintenance. Although, only one case was analyzed, for a company with a large amount of assets, the impact on the cost will be much greater, due to maintenance savings on all machinery by applying oil analysis as predictive maintenance. The analyses, associated with the inspection of the compartments, provided the applicability of the fluid analysis in agricultural machinery, proving to be economical for the rural producer and sugar and alcohol plants.
Descrição
Palavras-chave
Manutenção, Análise de óleo, Máquinas agrícolas, Custos, Maintenance, Predictive maintenance, Oil analysis, Agricultural machinery, Costs, Manutenção preditiva