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MDA Technologies 2/2016

MDA Technologies 2/2016

Predictive maintenance:

Predictive maintenance: a pivotal part of modern manufacturing Industry 4.0 focuses more and more on digital integration and interconnectedness, and predictive maintenance is steadily becoming a pivotal part of its landscape. Due to its inter-connectedness and seamless data exchange, the early warning signs of outages can be detected and necessary preventive measures can be triggered. MACHINE ELEMENTS Here, the in-service machinery condition data is acquired and combined with data from other systems, such as ERP and CRM software. In this way, early warning signs of outages can be detected and necessary preventive measures can be triggered. The benefits of predictive maintenance are twofold. First, it enables operators to detect and fix problems before they lead to costly production outages. And second, it does this on a just-in-time basis. By intelligently monitoring and analyzing machine condition data, it predicts the optimal time for intervention so that maintenance is performed only when necessary. It is therefore a cost-saving improvement on conventional maintenance strategies, not to mention a pivotal part of the Industry 4.0 landscape. At this year’s Hannover Messe, Schaeffler will be focusing on preventive maintenance and digital integration by presenting specific solutions for digitalized production and machine monitoring with its “Drive Train 4.0” technology. The spotlight will be on two new digital services for every drive train type: n The calculation of rolling bearings’ remaining useful life based on real load spectra n Automated rolling bearing diagnostics. Calculating the remaining useful life for rolling bearings By allowing the remaining useful life of rolling bearings to be calculated based on real load spectra that are recorded during operation, Schaeffler offers both machine manufacturers and operators an efficient solution for reducing total cost of ownership (TCO) as well as unit costs. Prerequisites for calculating the real load spectra during operation are machines equipped with sensor technology that matches the application, data from the machine control system, a “Bearinx” model of the machine, and a connection to the Schaeffler cloud. When the real load spectrum is available, an automatic cal- 01 Reducing the total cost of ownership by allowing the remaining useful life of rolling bearings to be calculated 02 The “automated rolling bearing diagnostics” service allows measurement data to be automatically and intelligently evaluated MDA Technologies 2/2016

03 The new generation of the FAG SmartCheck – compatible with cloud technology and analysis algorithms that are continuously updated are available for processing the data on Schaeffler’s software platform, which customers can access from their end devices without the need for additional software installation. “We have used our longterm experience to develop a system that is capable of automatically processing very high volumes of data. This means that our customers receive analyses and recommended actions that previously had to be carried out by experts for every individual case”, explains Dr. Hans-Willi Keßler, Vice President of Service Products at Schaeffler. Cloud compatible SmartCheck diagnostic system culation of the nominal rolling bearing rating life is made using Schaeffler’s “Bearinx” calculation tool via the cloud-based software platform. The respective nominal remaining useful life for each bearing in the machine or system is derived by subtracting the current runtime from this newly-calculated rating life. These complex calculations go unnoticed by the operator, however, as they are carried out cyclically and automatically during operation. The customer can then view the remaining useful life of every individual bearing position in the machine using an internet-capable end device. The continuous calculation of rolling bearings’ remaining useful life opens up the following possibilities: n Active control of machines’ capacity utilization with a view to predictive maintenance n Higher capacity utilization for individual axes and entire machines n Requirement-based maintenance intervals according to real load conditions n Utilization of real field data and load spectra for design optimization and re-engineering of machines by the manufacturer. Automated rolling bearing diagnostics Vibration monitoring systems are the most reliable method when it comes to monitoring rolling bearings and detecting incipient damage to bearings and other machine components. The quantity of measurement data available is constantly increasing as the use of sensor technology becomes more and more prevalent, and the “automated rolling bearing diagnostics” service allows this data to be automatically and intelligently evaluated. The results are then displayed to the customer in the form of recommended actions. This compact measuring system records the raw data from every assembly and transmits them to the cloud. Improved calculation The FAG SmartCheck diagnostic system detects bearing damage, wear, imbalance, misalignments and irregularities based on changes to the vibration patterns. Depending on the system type, defects can also be detected on very different components, such as rotor bar fractures and gearbox damage. The SmartCheck has thus far been predominantly used as a local system that includes both the analysis algorithms and a rolling bearing database. The FAG SmartCheck features a direct link to a cloud, to which the data from the SmartCheck will be transferred. The automated diagnosis signals are processed from the raw data transmitted by the FAG SmartCheck and any other data that are available (e.g. from the machine’s control system). This means that the vibration data are not only processed in the SmartCheck itself – they are also processed in the cloud, which offers greater processing power and more extensive analysis options thanks to the combination with other machine data. This increases the reliability of the diagnosis that the customer receives. For very critical applications, users also have the option of directly contacting the Schaeffler’s specialists, who are certified according to DIN ISO 18436-2, via the cloud. Photographs: Schaeffler AG www.schaeffler.com About Schaeffler The Schaeffler Group is a leading global integrated automotive and industrial supplier. The company stands for the highest quality, outstanding technology, and strong innovative ability. The Schaeffler Group makes a key contribution to “mobility for tomorrow” with highprecision components and systems in engine, transmission, and chassis applications as well as rolling and plain bearing solutions for a large number of industrial applications. The technology company generated sales of approximately EUR 13.2 billion in 2015. With around 84,000 employees, Schaeffler is one of the world’s largest family companies and, with approximately 170 locations in more than 50 countries, has a worldwide network of manufacturing locations, research and development facilities, and sales companies. MDA Technologies 2/2016

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