F’IS: Permanent Monitoring of Vibrating Screens Helps Save Costs

New Vibration Monitoring System for the Processing and Mining

Industries Avoids Unplanned Downtimes

SCHWEINFURT/HERZOGENRATH, September 28, 2004. The FAG Screen Saver monitoring system presented by FAG Industrial Services GmbH (F’IS) is a new, reliable systems solution for the monitoring of vibrating screens which are used, for instance, in the processing and mining industries. Permanent online vibration monitoring is considered to be one of the safest methods for detecting impending bearing failure at an early stage and thus being able to plan necessary repair and maintenance operations in good time. In this way, it is possible to avoid unplanned and costly downtimes as well as potential expensive consequential damage.

The Screen Saver monitoring system has been designed especially for use in harsh environments and reliably identifies the most important vibrating screen conditions that may incur unplanned machine downtime. These include bearing damage, loose parts and broken springs or situations when the screen becomes jammed. Up to four acceleration sensors, attached close to the shaft, record both radial and axial vibration. Damage-relevant signals are filtered out and typical damage patterns extracted. In addition, the system also examines the entire vibration condition of the machine. An alarm is triggered as soon as fixed threshold values or alarm limits are being exceeded. Data evaluation can take place directly at the actual monitoring unit or at the central machine control station. Optionally the data can be retrieved offline. In case of doubt, there is a possibility of transmitting the data to external vibration monitoring experts. A general remote condition monitoring including detailed depth analysis via the standard telephone network as well as cellular or satellite modems can also be carried out by the experts at the F’IS service center at any time.

Vibrating screens play a particularly important role in the processing of materials such as metals, ores, minerals and cement. The material is transported onto the vibrating screens by means of conveyor belts or trucks. Here it is sorted and cleaned through vibration generated with the help of large imbalance masses or directed to another production stage. As the screens are often found at the beginning of a fairly long production process, their unplanned downtime usually incurs considerable costs due to the resulting production losses. Depending on the plant, these costs can reach as much as 13,000 Euros per hour. Permanent online monitoring of the heavily stressed components helps not only to avoid unplanned downtimes, but also enables the operator to order the required spare parts and service engineers early on.

F’IS will present the new FAG Screen Saver monitoring system for the first time at the MINExpo INTERNATIONAL 2004 exhibition booth of FAG, INA and Barden (booth no. 1613). Recognized as the world’s largest and most comprehensive mining tradeshow, MINExpo will take place in Las Vegas (USA) from September 27 through 30.

FAG Industrial Services GmbH (F’IS)

Since the beginning of 2001, FAG Kugelfischer AG, a member of the Schaeffler Group, has been focusing its service business in FAG Industrial Services GmbH (F’IS), headquartered at Herzogenrath near Aachen. As an independent company, F’IS offers its maintenance services and service products on a manufacturer-neutral basis, so helping customers to save maintenance costs, optimize machine availability and avoid unexpected machine downtime.

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