SCHAEFFLER CREATES CUSTOMIZED INDUSTRY 4.0 PACKAGES FOR A WIDE RANGE OF APPLICATIONS

Schaeffler brought Industry 4.0 in real and specific applications to the Hannover Messe 2018 with reference projects that have already been implemented in selected sectors and for innovative business models. Everything is delivered with added value characterized by decades of systems and service expertise.

Schaeffler now offers OEMs, plant operators, and industrial service companies specific Industry 4.0 solution packages that are scalable and allow machine and equipment availability to be increased and processes to be optimized. Schaeffler’s Smart EcoSystem provides the IT infrastructure here for the integration of smart components, proven visualization and analysis tools, and digital services. At the Hannover Messe 2018, Schaeffler presented solution packages that are now available for selected sectors and business models in addition to new and advanced “enablers” for Industry 4.0 applications.

The broad range of possibilities on offer were illustrated by four reference projects that Schaeffler has implemented in practice and that demonstrate how the company’s rolling bearing and systems expertise can be utilized in the design and realization of intelligent maintenance systems and optimized processes.

Electric motors that report their condition to the cloud
A Dutch industrial service company equips its customers’ machines with SmartCheck units and thus optimizes the machine monitoring that it provides by transitioning from regular offline measurements to continuous online measurement. Connecting to the Schaeffler Cloud allows this service provider to take advantage of Schaeffler’s “ConditionAnalyzer” digital service, which delivers automated diagnoses of the machines’ condition in the form of clear text messages. “ConditionAnalyzer” offers in-depth analysis of the raw signals with true pattern detection, since the many years of bearing and vibration analysis expertise possessed by Schaeffler’s engineers have been integrated into the algorithms that it employs. Mechanical failure of the electric motors is thus reliably prevented. The transition to using the digital service with SmartCheck hardware means that the service company has to make fewer on-site visits to the customer and can plan maintenance work further in advance and thus increase the machines’ efficiency and availability.

Gearboxes with condition analysis via cloud-to-cloud communication
The partnership between Schaeffler and a major gearbox manufacturer has led to a 4.0 solution for the wind power sector. The expert models that were developed by the two partners deliver more precise analyses and predictions of the gearbox’s condition based on the real loads that occur during operation of the wind turbine, while cloud-to-cloud communication allows the gearbox manufacturer to integrate the bearing experts’ specialist knowledge into their system. Schaeffler's Smart EcoSystem is an open, digital system that allows joint cloud-to-cloud solutions to be implemented with customers and partners thanks to its standardized interfaces and encrypted communication via internet or VPN connection.

Drinking water supply pumps with autonomous monitoring and lubrication
Schaeffler ensures reliable and fault-free operation at a water supply association using a complete solution that comprises both monitoring and lubrication for the machines that are critical in ensuring a secure supply. To prevent centrifugal pump failures, the water supply association employs a complete solution from Schaeffler that includes a SmartQB condition monitoring system and Concept8 lubricator. The preconfigured SmartQB detects irregularities in the machines’ vibration behavior, identifies potential causes, and then reports on the findings in clear text. The Concept8 ensures optimum, requirement-based lubrication for the pump bearings. Thanks to Schaeffler’s complete solution, maintenance work can now be scheduled well ahead of time and maintenance processes can also be optimized.

Storage and distribution center with reliable material flows
For machinery at logistics centers operated by a major automotive and industrial supplier like Schaeffler, the dimensions are entirely different but the availability requirements remain the same. In collaboration with a logistics solution provider, Schaeffler has implemented an intelligent maintenance system for the operationally critical machinery at its newest logistics center: SmartCheck systems continuously monitor the lift and travel drives in the storage and retrieval systems, lifting stations, and spiral conveyors. Concept8 devices provide autonomous and requirement-based lubrication to the pallet conveyor and in-floor conveyor systems. The integration of the condition data and other central operating parameters into the visualization shown in the control room means that critical KPIs can be defined and regulated in a targeted manner. Autonomous subsystems reduce the outlay for manual maintenance tasks and the risk of maintenance measures being carried out incorrectly.

As these reference projects clearly demonstrate, Schaeffler’s Industry 4.0 solution packages are customized to suit their respective applications in drive technology, logistics, and communal infrastructure and are configured as modular systems that integrate sensor technology, mechatronics, and digital services.