Schaeffler’s Optime condition monitoring solution has prevented unplanned downtime in the supply systems at the company’s own production plant in Schweinfurt, Germany, resulting in cost savings in the five-figure range.
At the Schaeffler industrial spherical roller bearings and ball bearing plant in Schweinfurt, rotating machines are used in a hardening shop around the clock, as well as various supply systems. The hardening shop, which produces bearing components such as ball elements, rings, and so on, comprises six separate hardening lines that process around 130 tonnes daily. Three of these lines are now monitored using Optime. 31 Optime sensors are installed on circulating air fans (2.2 to 10kW) that run at fi xed and regulated speeds of 950-1500rpm. The temperature can reach as high as 200ÅãC.
The hardening lines are supplied by 50 ventilation and media supply systems. Eight of these systems are monitored by Optime. Approximately 100 sensors are installed on motors, pumps, ventilators, plummer block housing units and belt drives.
The plant’s maintenance manager, Detlev Jacobi, was looking for a reliable and cost-effective addition to the existing condition monitoring system, because downtime of production systems caused by the failure of auxiliary units such as motors, pumps and fans are always associated with high costs. Consequently, the primary aim of the new monitoring scheme was to vastly reduce maintenance costs.
In addition, the solution was intended to provide better protection for personnel, as auxiliary units are generally difficult to access and therefore pose a safety risk. For this reason, the maintenance manager sought assistance from the Industry 4.0 experts in his own company.
The solution
Experts in the Schaeffler Industry 4.0 division recommended a comprehensive condition monitoring solution in the form of Optime. The solution comprises wireless sensors, a gateway, and digital service. The sensors monitor the machines and devices. The gateway receives the data from the sensors and transfers this to the Schaeffler Cloud. The data is analysed using the digital service and an error diagnosis is created on the basis of algorithms. The user receives clear statements about the condition of the machines via a mobile app.
Installation work, which involved fitting around 130 sensors, was completed in just a few hours. Hundreds of machines at the Schweinfurt plant are now monitored directly via the mobile app, with considerable success. After just six months, an outer ring defect on the exhaust air motor and the threat of damage to the supply air motor were detected in a supply system (see actual status message below).
Jacobi comments: “Since introducing Optime, we have had no unplanned downtime in the supply plant.” Potential cost savings at Schweinfurt are outlined below:
Other benefits include:
• Easy and rapid installation of components.
• Easy data reading with no expert knowledge required.
• Greater security for employees, as access to hard-to-reach machinery is no longer required with the digital service.
• Cost-effective solution for comprehensive and wireless monitoring of units.
• Long term planning is possible for maintenance measures, personnel requirements, and in the management of replacement parts.
• Unplanned downtime is no longer an issue for monitored machines.
Optime is now being installed throughout the Schweinfurt plant. Other Schaeffler plants across the world are also using the system to great effect, with downtime being saved in many key areas already.