FAG SmartCheck: The Time is Ripe - Vibration Sensors on Every Machine

HERZOGENRATH, March 10, 2011. FAG SmartCheck is a new and innovative measuring system for real time monitoring of machines and plants. Due to its very attractive price, online monitoring of small, redundant or non-redundant units becomes cost-efficient for the first time. Examples include electric motors, pumps, compressors, ventilators, fans and gearboxes. FAG SmartCheck uses novel technologies and trend-setting functions, making a valuable contribution to optimizing processes and thus reducing Life Cycle Cost (LCC) and Total Cost of Ownership (TCO). In spite of its wide range of functions and features, the FAG SmartCheck is very easy to operate, requiring no expert knowledge. The scope of delivery includes a number of parameter templates which make the system ready for use immediately. Fundamental operating functions can be carried out by pressing keys, and alarms are visualized by LEDs in the housing.

FAG SmartCheck – a different kind of sensor
At first glance, FAG SmartCheck resembles a classic vibration sensor. But FAG SmartCheck can do much more than conventional measuring devices. In spite of its small size of about 44 mm x 58 mm x 45 mm, the intelligent system records not only the standard parameters – vibration and temperature – but also other operating parameters such as pressure or flow rate. This provides a broad basis of information which permits experts to make a very accurate assessment of a machine’s condition that contribute to optimizing processes and reducing LCC. LCC include, apart from acquisition costs, the operating and maintenance costs throughout a machine’s entire service life. Customers increasingly demand that manufacturers guarantee the LCC to them. This is only possible if manufacturers know the LCC or can assess them as accurately as possible. This becomes feasible by the new FAG SmartCheck. It already offers numerous options that future machine monitoring schemes cannot be imagined without.

Fields of application and commissioning
Typical fields of application of the FAG SmartCheck include electric motors, pumps, compressors, ventilators, fans and gearboxes. The compact, cost-efficient system can be installed very easily at the machine to be monitored and is immediately operational. It comes with a set of parameters that permit a reliable general monitoring of machines. In addition, more than 20 predefined parameter templates for monitoring, for example, imbalance, alignment errors, rolling bearings, fans and gearings are available. Users who wish to use the parameter templates may access the integrated bearing database. The templates can be adapted easily to specific monitoring tasks with the help of assistants. At customers’ requests, the Schaeffler Group defines additional user specific parameter templates and makes them available to the user.

Data storage, visualization and analysis
The system’s alarm thresholds are adjusted automatically thanks to a patented selflearning mode. After commissioning, the FAG SmartCheck works autonomously. The relevant machine parameters are recorded and saved continuously in the system. In this way a substantial database of history data is created over time. Users can access the FAG SmartCheck’s web server via a standard Internet browser to configurate the system and visualize the latest data in real time. The recorded data can be retrieved directly and easily via the FAG SmartCheck’s Ethernet interface and analyzed using the analysis software that is included in the scope of delivery.

Flexible and expandable
The new FAG SmartCheck offers many different expansion options. Both the number of sensors and the level of system integration can be adapted, depending on customers’ specific requirements. If, for example, a user wishes to include additional parameters into the analysis, the recorded data can also – instead of being retrieved locally at the machine itself – be transmitted to a control unit or control station via TCP/IP or user specific RS 485 protocols. Moreover, users can retrieve and analyze data from other locations via remote link.

Unique service
The Schaeffler Group offers a unique range of services for FAG SmartCheck users – from initial training courses to expert support during the introduction stage and in diagnosis related questions to customized service contracts including remote monitoring. The various services were developed – like the product itself – on the basis of an exact knowledge of customers’ requirements. So they offer far more than the usual type of after sales service and always aim to optimize plants and processes while helping to minimize the LCC and TCO of machines and plants.

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Schaeffler Group Industrial Aftermarket
The Schaeffler Group's business unit Industrial Aftermarket (IAM) is responsible for the replacement parts and service business with end customers and distributors in all major industrial sectors.
With innovative solutions, products and services relating to rolling and plain bearings as well as by consistently applying the Total Cost of Ownership philosophy, the IAM reduces maintenance and operating costs, increases plant availability and thus the business success of the customers.
The Schaffler Group with approx. 65,000 employees at over 180 locations and sales of € 7.3 billion (FY 2009) is one of the world's leading manufacturers of rolling bearings and supplier to the automotive industry.

Contact

FAG Industrial Services GmbH

Sabine Drescher

Marketing & Communication

Tel. +49 (0)2407 9149-78

Fax +49 (0)2407 9149-59

E-mail: sabine.drescher@schaeffler.com

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