The Schaeffler Group has launched an ultra compact, online condition monitoring device for industrial plant and machinery. This new system can not only monitor vibration and temperature, but also a range of other machine and process-specific parameters such as pressure and flow rate. The device can also be used as a machine condition guard with safety switch-off
The FAG SmartCheck is suitable for the online monitoring of small, process critical and nonprocess critical plant and machinery, including machine tools, spindles, motors, drives, pumps, compressors, HVAC systems and gearboxes.
Despite its wide range of features and functions, FAG SmartCheck is said to be easy to operate and requires no special programming skills or knowledge. The scope of delivery includes a number of machine and process-specific parameter templates, which enable the system to be operational within minutes. Basic operating functions can be carried out via integrated push buttons, and visual alarms are indicated via LEDs located on the front of the device housing.
In spite of its compact design (44 x 58 x 45mm), the FAG SmartCheck’s intelligent system records not only standard parameters such as vibration and temperature, but also other operating parameters such as pressure and flow rate. By monitoring this type of data, users are provided with a broad basis of information in real time, which enables the accurate assessment of machine condition. By correlating process parameters with vibration data, users can optimise their processes and therefore reduce LCC (lifecycle cost). Aside from acquisition costs, LCC includes operating and maintenance costs throughout a machine’s entire service life.
Customers are increasingly asking machine manufacturers to guarantee LCC. This is only possible if manufacturers know the LCC or can assess these as accurately as possible. This is now feasible using FAG SmartCheck.
Applications and commissioning
Typical fields of application for FAG SmartCheck include electric motors, vacuum pumps, hydraulic pumps, compressors, ventilators, fans, separators, gearboxes and variable speed drives. The compact, cost-efficient system is easy to install and is typically mounted to the machine housing. The small, lightweight (210g) device requires less wiring and can fit into areas on a machine where space is restricted. The device is also supplied with a set of basic parameters that can be used to reliably monitor most general machinery and equipment. In addition, users can also choose from more than 20 pre-defined parameter templates for monitoring a range of other process and machine parameters such as imbalance, shaft alignment errors, rolling bearings, fans and gearings. Users who take advantage of these parameter templates are also given access to Schaeffler’s comprehensive, integrated bearing database.
With help from engineers at Schaeffler, these parameter templates can be adapted easily to specific monitoring tasks. At the customer’s request, Schaeffler can define additional userspecific parameter templates and make these available to the customer.
Storage, visualisation & analysis
Due to its patented self-learning or ‘Teach-In’ mode, FAG SmartCheck’s alarm thresholds are adjusted automatically. After set-up and commissioning, the device operates autonomously. The relevant machine parameters are measured and saved continuously in the system. In this way, a substantial database of historical data is created over time.
Users can also access the FAG SmartCheck web server via a standard Internet browser in order to configure the system and visualise the latest data in real time.
Flexible and expandable
FAG SmartCheck is a modular, scalable system that provides multiple expansion options. Both the number of sensors and the level of system integration can be adapted according to the customers’ specific requirements.
If, for example, the user wishes to include additional parameters into an analysis, the recorded data, rather than being retrieved locally at the machine itself, can be transmitted to a control unit or control station via TCP/IP or via user-specific RS485 protocols.
FAG SmartCheck is protected to IP67 and is ATEX-certified to Ex II 2 D/G mb IIB T4. The device can operate in temperatures from –20 to +70° C. There are three reverse polarity protected M12 plug-in connectors for power supply/RS485, inputs/outputs and 100Mb/s Ethernet interface. Power supply is 11-36V DC or Power over Ethernet (PoE). Current consumption is also low at less than 200mA at 24V.
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