FEATURE u Automation The essentials of maintenance
When it comes to manufacturing, and automation, every second of production counts and any downtime can be extremely costly. To maintain optimum production and uptime, a predictive and preventative maintenance strategy is vital if facilities are to remain efficient and profitable.
A
maintenance strategy programme would not be complete without ensuring that production machinery
is correctly lubricated. This is essential to the correct functioning of any equipment with moving parts, yet all too often this subject isn’t given the attention it deserves and 80 per cent of premature rolling bearing failures could be prevented through the use of proper lubrication. The main reason to lubricate rolling bearings
is to prevent or reduce contact between rolling and sliding surfaces. Although lubricant separates the contact surfaces and prevents metal to metal contact, it also performs other important functions including anti-corrosion protection, heat dissipation, the flushing out of particles and contaminants, and support for the effectiveness of bearing seals. However, it is important to use the right type and quality of lubricant, in the right amounts, at the right place and at the right time. Under-lubrication can cause rolling bearings to wear out too quickly, whereas over-lubrication can lead to ineffective operation.
THE BENEFITS OF AUTOMATION Recognising that a reliance on human intervention is often the cause of ineffective and incorrect lubrication, Schaeffler has focused on developing its innovative range of CONCEPT automatic lubrication solutions that are designed to reduce maintenance outlay by up to 30 per cent compared to manual lubrication, ensuring problem free production in the long-term. Automatic lubrication means that roller bearings are supplied with the optimum quantity of lubricant and set to the correct lubrication intervals for the equipment. Lubricators in the CONCEPT range can be
pre-filled with Schaeffler’s Arcanol lubricating greases, which have superior characteristics in all areas compared to normal greases and are subjected to a thorough quality test when delivered. In Schaeffler’s analytical laboratory, Arcanol lubricating greases are checked for their chemical and physical properties to ensure extremely high product quality. It is also worth noting that CONCEPT devices can also be operated using third-party greases that are
14 April 2022 Irish Manufacturing
not part of the Arcanol range. Effective lubrication makes all the difference and Schaeffler’s solutions offer long-term savings potential of up to 25 per cent. They facilitate optimum machine availability and reduce total cost of ownership, with minimal maintenance and unplanned downtime – keeping production flowing as it should.
PREDICTIONS AND PREVENTIONS Another consideration of essential maintenance strategy is to look at predictive and preventative maintenance. Unplanned failure of auxiliary units such as motors, fans and pumps can quickly shut down an entire production line, but what if there was a way of monitoring these auxiliary units remotely that could prevent unplanned failures? Schaeffler’s OPTIME offers a unique solution
by providing a Plug > Play > Predict condition monitoring solution that enables automated data analysis of machines at an expert level. Moreover, with low installation outlay OPTIME allows the implementation of Condition Monitoring for a high number of machines simultaneously, whose condition previously could not be monitored cost effectively. The OPTIME system comprises wireless,
battery-operated sensor units, a gateway with SIM card, analysis software on an IoT hub and an app, or web-based dashboard. The installed sensors record vibrations and temperature data which is used to determine the relevant Key Performance Indicators (KPIs). They connect with one another automatically to form a mesh network. The data is transferred to Schaeffler’s IoT hub via the gateway. Continuous, automatic analyses are carried out in the IoT hub and recommendations for decisions and actions based on proven experience, and algorithms are sent to the user’s mobile phone or to the plant control room, directing them to the precise area where a repair is required.
This means that operators of process plants
have much more control because they can make decisions about what maintenance work needs to be performed on which machines, and when. The purchasing function can also be more efficient and cost effective, as parts and units no longer need to be held in stock for “just in case” scenarios.
Schaeffler
www.schaeffler.co.uk www.irish-manufacturing.com
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