Fit for the future with intelligent condition monitoring from Schffler

2015-11-04 | 000-006-398 DE-EN

SCHAEFFLER AG, SCHWEINFURT

Team of experts develops condition-oriented maintenance strategy for the production of special papers

Fit for the future with intelligent condition monitoring from Schaeffler

Whether its for receipts, bank statements or tickets of all kinds - thermal paper is all around us. The papers special properties are due to the use of a special coating, called the coat. Around 300 tons of thermal paper are coated in coating machine 3 at Mitsubishi HiTec Paper Europe GmbH in Bielefeld (MPEB) each day. 26 fan units ensure the coated paper can dry without being touched. 26 FAG SmartCheck systems from Schaeffler have been monitoring these fans for abnormal vibrations since 2014. They prevent unplanned machine downtimes and allow production to be optimized and reduce the total cost of ownership.

Bearing and process monitoring thanks to FAG SmartCheck

The 26 fan units on coating machine 3 at MPEB comprise supply air fans with a diameter of over one meter that weigh around 100 kg and smaller, lighter extraction fans. The fans speeds of 1500 rpm and mass of over 100 kg mean that, over time, they become subject to imbalance, which directly affects the bearing supports. Reduced production capacity and downtimes result if this imbalance is not detected and eliminated quickly.

This is what happened in mid 2013. One fan on coating machine 3 stopped working due to imbalance that had not been detected quickly enough. The bearing support and adjacent components were badly damaged. A sudden system standstill and a subsequent reduction in production speed occurred. The solution: Condition monitoring with FAG SmartCheck. The system shows warnings with a traffic light system on a status display at an early stage if limit values are exceeded to prevent bearing failures and the machine downtimes associated with them. An imbalance outside the normal limits has occurred if the status changes from green to yellow. However, the system can continue normal operation. A red warning means action must be taken immediately. An integrated web server means operating personnel can access each individual sensor and display detailed information.

The project was implemented in conjunction with Werthenbach who forward the information from the sensors to specialists at Schaeffler if necessary. These specialists not only say what the problem is, but also draw up a written recommendation for the action to be taken. Since the system provides an initial warning up to three months by displaying the yellow alarm, it allows enough time to plan system downtime and to order replacement parts. Sudden downtimes are therefore avoided. As an authorized distribution partner and with the assistance of bearing specialist Schaeffler and its service experts, Werthenbach has been implementing a range of projects for several decades, among others in the area of condition monitoring.

In addition to bearing monitoring, the solution also enables total process monitoring. One FAG SmartCheck monitors the vibrations in one fan unit. However, both plummer block housing units and the fan impeller each have their own vibration pattern. Trend curves can be created using the data history that are used as a basis for drawing conclusions about the condition of the machine and the processes. This often means it is possible to detect when and why a problem occurred for the first time so that it can be permanently eliminated. MPEB can track the behavior of the machines in the long term under constantly changing manufacturing conditions based on reliable data and then make specific improvements to the design.

Successful pilot project

Just a few months after being put into operation, the monitoring system demonstrated its abilities and identified irregularities in two of the exhaust air flotation dryers. Werthenbachs service team recorded the data and carried out an initial analysis. Schaefflers team of experts put the results and a recommendation for the action to be taken into a written report. The irregularities were caused by impermissible high imbalance and outer ring bearing damage. Both problems were resolved quickly during planned maintenance long before the imbalance was audible or noticeable and before damage to the adjacent components could have occurred. A complex and lengthy search for the problem with higher subsequent costs was therefore avoided.

On the strength of the good results delivered by the pilot project, Mitsubishi HiTec Paper Europe has decided to equip the coating machine at its Flensburg plant with the FAG SmartCheck as well. The 11 supply air and 11 extraction fans at this plant are now monitored by 22 systems.

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