Schffler is a partner in the e-F@ctory Alliance from Mitsubishi Electric Europe

2014-08-21 | 000-005-219 DE-EN

SCHAEFFLER AG, SCHWEINFURT

The FAG SmartCheck on the path towards Industrie 4.0

Schaeffler is a partner in the e-F@ctory Alliance from Mitsubishi Electric Europe

By becoming a partner in the e-F@ctory Alliance from Mitsubishi Electric Europe, Schaeffler is taking a groundbreaking step in the direction of Industrie 4.0. The FAG SmartCheck is playing the leading role in this process. Since its product launch in 2011, the compact vibration sensor has proved its effectiveness and has been continuously further developed. Today, the FAG SmartCheck is one of the few solutions on the market that is both suitable for use as an individual monitoring device for smaller redundant units and for integrated concepts, such as comprehensive monitoring. With the e-F@ctory Alliance from Mitsubishi Electric Europe, Schaeffler has found a partner, who on the one hand makes it possible to access automation control units and process control systems, and on the other hand, pursues the same objectives for its customers as Schaeffler - that is, to reduce the overall costs of production and maintenance and to increase productivity. As part of the e-F@ctory Alliance, Mitsubishi Electric Europe joins forces with partner companies that are recognized technology and market leaders in their respective business areas. Together they ensure that their customers are always offered the best possible complete solution for their respective automation project.

Comprehensive condition monitoring of machines and systems

Increasing energy costs require the implementation of lean production and of maintenance measures that are based on proven findings. This is how, for example, combined condition and energy monitoring systems create the required transparency, from the production level to the control level. To ensure that this level of transparency is achieved, the joint solution provided by the e-F@ctory partnership, combines the Mitsubishi Electric control unit with the FAG SmartCheck to form a pre-configured overall solution for the customer. This facilitates an automated link from the manufacturing level through to the control level. In contrast to conventional monitoring concepts that often only measure conventional values, such as temperature, pressure, and operating hours, the FAG SmartCheck provides additional vibration-based parameters. In conjunction with the Mitsubishi control unit, it is therefore possible to develop a comprehensive solution for assessing the condition of a machine or system. The data can be sent via Ethernet (e.g. Ethernet TCP/IP protocols or web services) to other data receivers, such as the automation control units of other manufacturers or database supported receivers, such as SCADA or MES systems. Experts from Schaeffler and Mitsubishi Electric provide support during project planning, ranging from defining the measurement point through to ensuring connections to the customers own systems, such as SAP and Oracle. The scalable monitoring system provides high system availability and contributes towards ensuring trouble-free, continuous operation. The overall system efficiency and energy efficiency are also very closely linked. Furthermore, the solution allows predictive maintenance to be carried out. This not only reduces lifecycle costs but also plays a role in reducing energy consumption thanks to its ability to detect early signs of wear.

Successful use of the joint monitoring solution in a wastewater treatment plant

The sewage treatment plant in Rotenburg an der Fulda has treatment capacity for 34,000 residents (population equivalent) and serves approximately 20,000 people. At the secondary sedimentation tank, three Archimedes pumps are connected to the return activated sludge pumping station. Within the space of approximately one year, one of the three screw pumps failed due to a fault in the design. Due to bearing damage, the gear block was literally torn apart and had to be entirely replaced. This resulted in costly and time-consuming repair work. A condition monitoring system comprising a Mitsubishi control unit and three FAG SmartCheck devices was installed on the three pumps to help solve the problem. The FAG SmartCheck devices measure the vibrations and temperature of the gearbox. In the event of changes in vibration, the system provides data at an early stage about these deviations, which can be the initial signs of potential damage. In the event of irregularities, a detailed error message is sent to the customer's control system via the Mitsubishi control unit, which was integrated into the customers' process. This ensures that the problem can be rectified quickly and in a target-oriented manner.

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