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Schaeffler Condition analyses and predictions for machine tool components

<p style="margin:0px 0px 10px;padding:0px;border:0px currentColor;border-image:none;color:#111111;text-transform:none;line-height:20.8px;text-indent:0px;letter-spacing:normal;font-family:"Helvetica Neue", HelveticaNeue, Helvetica, Arial, "Lucida Grande", sans-serif;font-size:16px;font-style:normal;font-weight:400;word-spacing:0px;vertical-align:baseline;white-space:normal;orphans:2;widows:2;font-stretch:inherit;background-color:#FFFFFF;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;font-variant-numeric:inherit;font-variant-east-asian:inherit;"> With a new multi-channel condition monitoring system (CMS) specifically designed for machine tools, <a style="font:inherit;margin:0px;padding:0px;outline:0px;border:0px currentColor;border-image:none;color:#1D4B7B;text-decoration:none;vertical-align:baseline;font-size-adjust:inherit;font-stretch:inherit;" href="https://www.schaeffler.co.uk/" target="_blank"><strong style="margin:0px;padding:0px;border:0px currentColor;border-image:none;line-height:inherit;font-family:inherit;font-size:inherit;font-style:inherit;font-variant:inherit;font-weight:bold;vertical-align:baseline;font-stretch:inherit;">Schaeffler</a> is pursuing two objectives: first, condition monitoring and condition predictions for key components in machine tools using a single CMS, and second, the flexible integration of sensors from different manufacturers into the CMS. <p style="margin:0px 0px 10px;padding:0px;border:0px currentColor;border-image:none;color:#111111;text-transform:none;line-height:20.8px;text-indent:0px;letter-spacing:normal;font-family:"Helvetica Neue", HelveticaNeue, Helvetica, Arial, "Lucida Grande", sans-serif;font-size:16px;font-style:normal;font-weight:400;word-spacing:0px;vertical-align:baseline;white-space:normal;orphans:2;widows:2;font-stretch:inherit;background-color:#FFFFFF;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;font-variant-numeric:inherit;font-variant-east-asian:inherit;"> <p align="center" style="margin:0px 0px 10px;padding:0px;border:0px currentColor;border-image:none;color:#111111;text-transform:none;line-height:20.8px;text-indent:0px;letter-spacing:normal;font-family:"Helvetica Neue", HelveticaNeue, Helvetica, Arial, "Lucida Grande", sans-serif;font-size:16px;font-style:normal;font-weight:400;word-spacing:0px;vertical-align:baseline;white-space:normal;orphans:2;widows:2;background-color:#FFFFFF;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;font-variant-numeric:inherit;font-variant-east-asian:inherit;"> <img alt="" src="http://www.bearing.com.cn/membcentre/editor/attached/image/20190104/20190104132355_72762.jpg" /> <p style="margin:0px 0px 10px;padding:0px;border:0px currentColor;border-image:none;color:#111111;text-transform:none;line-height:20.8px;text-indent:0px;letter-spacing:normal;font-family:"Helvetica Neue", HelveticaNeue, Helvetica, Arial, "Lucida Grande", sans-serif;font-size:16px;font-style:normal;font-weight:400;word-spacing:0px;vertical-align:baseline;white-space:normal;orphans:2;widows:2;font-stretch:inherit;background-color:#FFFFFF;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;font-variant-numeric:inherit;font-variant-east-asian:inherit;"> <p style="margin:0px 0px 10px;padding:0px;border:0px currentColor;border-image:none;color:#111111;text-transform:none;line-height:20.8px;text-indent:0px;letter-spacing:normal;font-family:"Helvetica Neue", HelveticaNeue, Helvetica, Arial, "Lucida Grande", sans-serif;font-size:16px;font-style:normal;font-weight:400;word-spacing:0px;vertical-align:baseline;white-space:normal;orphans:2;widows:2;font-stretch:inherit;background-color:#FFFFFF;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;font-variant-numeric:inherit;font-variant-east-asian:inherit;"> Condition monitoring systems for machine tools must fulfil complex requirements with regard to the available space and the number of drives components to be monitored. <p style="margin:0px 0px 10px;padding:0px;border:0px currentColor;border-image:none;color:#111111;text-transform:none;line-height:20.8px;text-indent:0px;letter-spacing:normal;font-family:"Helvetica Neue", HelveticaNeue, Helvetica, Arial, "Lucida Grande", sans-serif;font-size:16px;font-style:normal;font-weight:400;word-spacing:0px;vertical-align:baseline;white-space:normal;orphans:2;widows:2;font-stretch:inherit;background-color:#FFFFFF;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;font-variant-numeric:inherit;font-variant-east-asian:inherit;"> Not only axes, feed drives and spindles, but also ancillary equipment such as hydraulic motors are important subsystems that can cause total failure of a machine tool. <p style="margin:0px 0px 10px;padding:0px;border:0px currentColor;border-image:none;color:#111111;text-transform:none;line-height:20.8px;text-indent:0px;letter-spacing:normal;font-family:"Helvetica Neue", HelveticaNeue, Helvetica, Arial, "Lucida Grande", sans-serif;font-size:16px;font-style:normal;font-weight:400;word-spacing:0px;vertical-align:baseline;white-space:normal;orphans:2;widows:2;font-stretch:inherit;background-color:#FFFFFF;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;font-variant-numeric:inherit;font-variant-east-asian:inherit;"> In addition, manufacturers of subsystems and suppliers of ancillary equipment integrate their own measuring systems into machines. <p style="margin:0px 0px 10px;padding:0px;border:0px currentColor;border-image:none;color:#111111;text-transform:none;line-height:20.8px;text-indent:0px;letter-spacing:normal;font-family:"Helvetica Neue", HelveticaNeue, Helvetica, Arial, "Lucida Grande", sans-serif;font-size:16px;font-style:normal;font-weight:400;word-spacing:0px;vertical-align:baseline;white-space:normal;orphans:2;widows:2;font-stretch:inherit;background-color:#FFFFFF;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;font-variant-numeric:inherit;font-variant-east-asian:inherit;"> A CMS for machine tools must therefore enable sensors from different manufacturers to operate with the machine. <p style="margin:0px 0px 10px;padding:0px;border:0px currentColor;border-image:none;color:#111111;text-transform:none;line-height:20.8px;text-indent:0px;letter-spacing:normal;font-family:"Helvetica Neue", HelveticaNeue, Helvetica, Arial, "Lucida Grande", sans-serif;font-size:16px;font-style:normal;font-weight:400;word-spacing:0px;vertical-align:baseline;white-space:normal;orphans:2;widows:2;font-stretch:inherit;background-color:#FFFFFF;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;font-variant-numeric:inherit;font-variant-east-asian:inherit;"> <strong style="margin:0px;padding:0px;border:0px currentColor;border-image:none;line-height:inherit;font-family:inherit;font-size:inherit;font-style:inherit;font-variant:inherit;font-weight:bold;vertical-align:baseline;font-stretch:inherit;">Multi-channel CMS prototype for machine tools <p style="margin:0px 0px 10px;padding:0px;border:0px currentColor;border-image:none;color:#111111;text-transform:none;line-height:20.8px;text-indent:0px;letter-spacing:normal;font-family:"Helvetica Neue", HelveticaNeue, Helvetica, Arial, "Lucida Grande", sans-serif;font-size:16px;font-style:normal;font-weight:400;word-spacing:0px;vertical-align:baseline;white-space:normal;orphans:2;widows:2;font-stretch:inherit;background-color:#FFFFFF;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;font-variant-numeric:inherit;font-variant-east-asian:inherit;"> Schaeffler has presented a functional prototype of a multi-channel CMS for machine tools. <p style="margin:0px 0px 10px;padding:0px;border:0px currentColor;border-image:none;color:#111111;text-transform:none;line-height:20.8px;text-indent:0px;letter-spacing:normal;font-family:"Helvetica Neue", HelveticaNeue, Helvetica, Arial, "Lucida Grande", sans-serif;font-size:16px;font-style:normal;font-weight:400;word-spacing:0px;vertical-align:baseline;white-space:normal;orphans:2;widows:2;font-stretch:inherit;background-color:#FFFFFF;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;font-variant-numeric:inherit;font-variant-east-asian:inherit;"> In-house systems and sensors such as piezoelectric vibration sensors can be connected to the CMS. Piezoelectric vibration, force and pressure sensors from other manufacturers can also be integrated into the CMS via an IEPE interface. <p style="margin:0px 0px 10px;padding:0px;border:0px currentColor;border-image:none;color:#111111;text-transform:none;line-height:20.8px;text-indent:0px;letter-spacing:normal;font-family:"Helvetica Neue", HelveticaNeue, Helvetica, Arial, "Lucida Grande", sans-serif;font-size:16px;font-style:normal;font-weight:400;word-spacing:0px;vertical-align:baseline;white-space:normal;orphans:2;widows:2;font-stretch:inherit;background-color:#FFFFFF;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;font-variant-numeric:inherit;font-variant-east-asian:inherit;"> This offers a major advantage in that operators can use the sensors that are available and suitable for the individual measuring point and measurement task. <p style="margin:0px 0px 10px;padding:0px;border:0px currentColor;border-image:none;color:#111111;text-transform:none;line-height:20.8px;text-indent:0px;letter-spacing:normal;font-family:"Helvetica Neue", HelveticaNeue, Helvetica, Arial, "Lucida Grande", sans-serif;font-size:16px;font-style:normal;font-weight:400;word-spacing:0px;vertical-align:baseline;white-space:normal;orphans:2;widows:2;font-stretch:inherit;background-color:#FFFFFF;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;font-variant-numeric:inherit;font-variant-east-asian:inherit;"> The current prototype has six measurement channels. The system is designed so that, for example, the electronic monitoring of the lubrication conditions in linear recirculating roller bearing and guideway assemblies can also be integrated in the future. <p style="margin:0px 0px 10px;padding:0px;border:0px currentColor;border-image:none;color:#111111;text-transform:none;line-height:20.8px;text-indent:0px;letter-spacing:normal;font-family:"Helvetica Neue", HelveticaNeue, Helvetica, Arial, "Lucida Grande", sans-serif;font-size:16px;font-style:normal;font-weight:400;word-spacing:0px;vertical-align:baseline;white-space:normal;orphans:2;widows:2;font-stretch:inherit;background-color:#FFFFFF;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;font-variant-numeric:inherit;font-variant-east-asian:inherit;"> <strong style="margin:0px;padding:0px;border:0px currentColor;border-image:none;line-height:inherit;font-family:inherit;font-size:inherit;font-style:inherit;font-variant:inherit;font-weight:bold;vertical-align:baseline;font-stretch:inherit;">Software intelligence and cloud connection ported from other developments <p style="margin:0px 0px 10px;padding:0px;border:0px currentColor;border-image:none;color:#111111;text-transform:none;line-height:20.8px;text-indent:0px;letter-spacing:normal;font-family:"Helvetica Neue", HelveticaNeue, Helvetica, Arial, "Lucida Grande", sans-serif;font-size:16px;font-style:normal;font-weight:400;word-spacing:0px;vertical-align:baseline;white-space:normal;orphans:2;widows:2;font-stretch:inherit;background-color:#FFFFFF;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;font-variant-numeric:inherit;font-variant-east-asian:inherit;"> The software for the prototype is very sophisticated, as most functions, algorithms and the optional connection to the Schaeffler Cloud from other projects can be ported with only minimal outlay. <p style="margin:0px 0px 10px;padding:0px;border:0px currentColor;border-image:none;color:#111111;text-transform:none;line-height:20.8px;text-indent:0px;letter-spacing:normal;font-family:"Helvetica Neue", HelveticaNeue, Helvetica, Arial, "Lucida Grande", sans-serif;font-size:16px;font-style:normal;font-weight:400;word-spacing:0px;vertical-align:baseline;white-space:normal;orphans:2;widows:2;font-stretch:inherit;background-color:#FFFFFF;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;font-variant-numeric:inherit;font-variant-east-asian:inherit;"> Due to the connection to the Schaeffler Cloud, all digital services offered by Schaeffler for monitoring and detecting damage to rolling bearings are already available in the prototype CMS. <p style="margin:0px 0px 10px;padding:0px;border:0px currentColor;border-image:none;color:#111111;text-transform:none;line-height:20.8px;text-indent:0px;letter-spacing:normal;font-family:"Helvetica Neue", HelveticaNeue, Helvetica, Arial, "Lucida Grande", sans-serif;font-size:16px;font-style:normal;font-weight:400;word-spacing:0px;vertical-align:baseline;white-space:normal;orphans:2;widows:2;font-stretch:inherit;background-color:#FFFFFF;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;font-variant-numeric:inherit;font-variant-east-asian:inherit;"> As a local solution, the multi-channel CMS facilitates the monitoring of FAG rolling bearings based on the integrated bearing catalogue, as well as bearings from other manufacturers (after entering specific bearing data). <p style="margin:0px 0px 10px;padding:0px;border:0px currentColor;border-image:none;color:#111111;text-transform:none;line-height:20.8px;text-indent:0px;letter-spacing:normal;font-family:"Helvetica Neue", HelveticaNeue, Helvetica, Arial, "Lucida Grande", sans-serif;font-size:16px;font-style:normal;font-weight:400;word-spacing:0px;vertical-align:baseline;white-space:normal;orphans:2;widows:2;font-stretch:inherit;background-color:#FFFFFF;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;font-variant-numeric:inherit;font-variant-east-asian:inherit;"> A completely new development is the option to interpret vibration signals from ball screw drives. The beta version of the software module, which is currently in testing phase, will be available to customers shortly. <p style="margin:0px 0px 10px;padding:0px;border:0px currentColor;border-image:none;color:#111111;text-transform:none;line-height:20.8px;text-indent:0px;letter-spacing:normal;font-family:"Helvetica Neue", HelveticaNeue, Helvetica, Arial, "Lucida Grande", sans-serif;font-size:16px;font-style:normal;font-weight:400;word-spacing:0px;vertical-align:baseline;white-space:normal;orphans:2;widows:2;font-stretch:inherit;background-color:#FFFFFF;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;font-variant-numeric:inherit;font-variant-east-asian:inherit;"> <strong style="margin:0px;padding:0px;border:0px currentColor;border-image:none;line-height:inherit;font-family:inherit;font-size:inherit;font-style:inherit;font-variant:inherit;font-weight:bold;vertical-align:baseline;font-stretch:inherit;">Simple to configure and operate with a web browser <p style="margin:0px 0px 10px;padding:0px;border:0px currentColor;border-image:none;color:#111111;text-transform:none;line-height:20.8px;text-indent:0px;letter-spacing:normal;font-family:"Helvetica Neue", HelveticaNeue, Helvetica, Arial, "Lucida Grande", sans-serif;font-size:16px;font-style:normal;font-weight:400;word-spacing:0px;vertical-align:baseline;white-space:normal;orphans:2;widows:2;font-stretch:inherit;background-color:#FFFFFF;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;font-variant-numeric:inherit;font-variant-east-asian:inherit;"> Users can log on to the CMS and configure the system using a conventional web browser. The look and feel of the system and its operation are based on the FAG SmartCheck and its proven single-channel CMS. <p style="margin:0px 0px 10px;padding:0px;border:0px currentColor;border-image:none;color:#111111;text-transform:none;line-height:20.8px;text-indent:0px;letter-spacing:normal;font-family:"Helvetica Neue", HelveticaNeue, Helvetica, Arial, "Lucida Grande", sans-serif;font-size:16px;font-style:normal;font-weight:400;word-spacing:0px;vertical-align:baseline;white-space:normal;orphans:2;widows:2;font-stretch:inherit;background-color:#FFFFFF;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;font-variant-numeric:inherit;font-variant-east-asian:inherit;"> The prototype for machine tools is intended primarily to provide pilot customers with the CMS functions in a development stage close to volume production status. <p style="margin:0px 0px 10px;padding:0px;border:0px currentColor;border-image:none;color:#111111;text-transform:none;line-height:20.8px;text-indent:0px;letter-spacing:normal;font-family:"Helvetica Neue", HelveticaNeue, Helvetica, Arial, "Lucida Grande", sans-serif;font-size:16px;font-style:normal;font-weight:400;word-spacing:0px;vertical-align:baseline;white-space:normal;orphans:2;widows:2;font-stretch:inherit;background-color:#FFFFFF;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;font-variant-numeric:inherit;font-variant-east-asian:inherit;"> The design of the hardware is therefore of secondary importance. The prototype is currently being tested in initial pilot projects with various types of machine tools, including in-house production machines and selected partners. <p style="margin:0px 0px 10px;padding:0px;border:0px currentColor;border-image:none;color:#111111;text-transform:none;line-height:20.8px;text-indent:0px;letter-spacing:normal;font-family:"Helvetica Neue", HelveticaNeue, Helvetica, Arial, "Lucida Grande", sans-serif;font-size:16px;font-style:normal;font-weight:400;word-spacing:0px;vertical-align:baseline;white-space:normal;orphans:2;widows:2;font-stretch:inherit;background-color:#FFFFFF;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;font-variant-numeric:inherit;font-variant-east-asian:inherit;"> At the same time, the system is also being implemented in Machine Tool 4.0 at Schaeffler’s manufacturing location in Höchstadt. This machining centre serves as a technology platform and development project for digitalised products in the machine tool sector. <p style="margin:0px 0px 10px;padding:0px;border:0px currentColor;border-image:none;color:#111111;text-transform:none;line-height:20.8px;text-indent:0px;letter-spacing:normal;font-family:"Helvetica Neue", HelveticaNeue, Helvetica, Arial, "Lucida Grande", sans-serif;font-size:16px;font-style:normal;font-weight:400;word-spacing:0px;vertical-align:baseline;white-space:normal;orphans:2;widows:2;font-stretch:inherit;background-color:#FFFFFF;font-variant-ligatures:normal;font-variant-caps:normal;-webkit-text-stroke-width:0px;text-decoration-style:initial;text-decoration-color:initial;font-variant-numeric:inherit;font-variant-east-asian:inherit;"> Machine Tool 4.0 is used to develop and test the algorithms for the multi-channel CMS for monitoring and diagnosing the condition of rolling bearings and components in machine tools under real conditions.

04 Jan,2019