Germany-based manufacturer Schaeffler Group’s FAG brand SmartCheck measuring system, for the monitoring of machines and plants, makes a valuable contribution to optimising processes and ultimately reduces life-cycle cost (LCC) and the total cost of ownership (TCO), states bearings and power-transmission components distributor Bearings 2000 director Nick Stamatiadis.

“Owing to its highly competitive price-to-performance ratio, the system ensures that the online monitoring of small, redundant or nonredundant units – such as electric motors, pumps, compressors, ventilators, fans and gearboxes – becomes cost efficient for the first time,” he adds.

The system contains a 44 mm × 57 mm × 55 mm device, which has a key function of measuring the vibrations of machines, as well as record parameters such as temperature, pressure and flow rate, says Bearings 2000 marketing manager Michael Stamatiadis.

Other features of the system include preset component templates, which are stored in the device. These components can be selected for applications, such as fans or pumps, while addit- ional parameters, such as bearing type, the number of fan blades, gear teeth or belt lengths can be adjusted for monitoring, he adds.

Further, he notes that standard templates in the system can detect damages, such as rolling bearing damage, imbalance, misalignment and impacts at an early stage to prevent breakage.

In addition, the system includes an alarm indicated by a light-emitting diode on the device. This can be transmitted to the control station through an interface. He adds that an alarm receiver application can be downloaded to a plant production manager’s smartphone, through which the manager will be alerted to changes or damages, even if the person is not actively monitoring the machine.

“The system’s alarm thresholds are also adjusted automatically, owing to a patented self-learning mode,” he notes.

After it has been commissioned and installed, the system works autonomously, he says, adding that the relevant mach-ine parameters are recorded and saved continuously in the system, creating a substantial database of history data over time.

The latest data recorded from the system and its system configurations can be accessed on the FAG SmartCheck’s Web ser-ver through a standard Internet browser, while the recorded data can be retrieved directly through the FAG SmartCheck’s Ethernet interface. The data can also be analysed using the included analysis software.

In addition, companies can have several of the SmartCheck monitoring devices and all the recorded data linked to the same profile.

Expansion options of the system include adaptation of the number of sensors and the level of system integration, depending on the customer’s specific requirements, Michael Stamatiadis notes.

“If, for example, a user wishes to include additional parameters in the analysis, the recorded data can be transmitted to a control unit or control station through transmission control protocol, Internet protocol or user-specific RS 485 protocols, instead of being retrieved locally at the machine itself. In addition, users can retrieve and analyse data from other locations through a remote link.”

He points out that this provides a broad basis of information that enables experts to make a highly accurate assessment of a machine’s condition, thereby contributing to improving processes and reducing LCC, which includes the acquisition costs and the operating and maintenance costs throughout a machine’s entire service life.

Michael Stamatiadis adds that the system is user friendly, as no expert knowledge is required to use it.

As an authorised distributor of Schaeffler Group brands, such as FAG, Nick Stamatiadis points out that Bearings 2000 offers a unique range of services for local FAG SmartCheck users.

“Our function is to provide value-added services for clients,” Nick Stamatiadis points out, adding that these services range from initial training courses and expert support during the intro- duction stage to diagnosis- related questions on bearing failure or design, and customised service contracts.

“These services were developed on the basis of an exact know-ledge of customer requirements and ultimately aim to enhance plants and processes while helping to reduce the LCC and TCO of machines and plants,” he says.

Further, he comments that other condition-monitoring systems exist, but that these are cumbersome, complicated and expensive.

“This system, with its new technology, aids the bearing industry’s evolution, as it is currently quite a mature industry, with only a minor design change and few new innovations and no new bearing types being introduced to the market.”

The company does not foresee any key challenges in the distribution of the SmartCheck system. However, it notes that although other companies are forced to pay for machinery breakages, they are reluctant to pay for a device that will aid preventative measures, which is a key challenge.

“Companies are more reactive than proactive,” Michael Stamatiadis adds.

“Our product prices increased by 20% since last year June and the company was forced to absorb part of those effects, as customers are resistant to such high price increases,” he concludes.