By installing the Schaeffler DuraSense lubrication monitoring solution on its vehicle handling systems, automotive machine maker Hager Sondermaschinenbau GmbH has seen a range of benefits, including the prevention of unplanned downtime due to insufficient lubrication, extended time intervals for general overhaul, and early detection of defective lubricators.
Hager is using the DuraSense lubrication monitoring solution on linear axes in large portal handling systems, which are being developed for car body production at major automotive manufacturers around the world. Hager intends to use this solution to reduce unplanned downtime for its customers on their production lines.
Challenge for Schaeffler
Hager produces portal handling systems that weigh up to 90 tonnes for renowned automotive manufacturers. The maintenance, general overhaul and assembly of the portal handling systems is undertaken by around 80 employees at its site in Möttingen, Germany.
In 2012, Hager designed a new type of clamping frame replacement system for car production. The KFG3 portal handling system, also known as a framer, moves vehicle clamping equipment (clamping frames) with the aid of linear axes. Up to 50 vehicles per hour can be produced using the KFG3. The monorail guidance systems used in the linear axes are counted among the system-critical components in the framer. If these fail, the entire production line is shut down. For this reason, Hager was searching for a monitoring solution that could not only be retrofitted to the linear axes, but which the company could also use to optimise the general overhaul intervals. As a result, Hager decided to seek assistance from Schaeffler.
Schaeffler Solution
Experts at Schaeffler recommended DuraSense as a monitoring solution for the linear axes. The system comprises carriages with sensors developed specifically for this task and a pre-processing unit for up to seven acceleration sensors. The pre-processing unit at the heart of DuraSense contains Schaeffler’s rolling bearing expertise, evaluates the sensor signals, and generates an authoritative lubrication parameter. The vibration energy that is emitted by the carriage is influenced by ageing lubricant or a decreasing lubricant volume, and DuraSense makes use of this effect. The determined lubrication parameter describes the current lubrication condition of the carriage and DuraSense sends a signal to the machine control system if the lubrication limit value is exceeded. DuraSense also detects the exact time for relubrication.
Customer Benefits
The DuraSense monitoring solution is an important tool for Hager in preventing unplanned downtime of portal handling systems.
Other advantages include:
· Early detection of defective lubricators and clogged/leaky lines.
· Predictable maintenance work and reduced workload for personnel.
· Longer term planning of replacement parts procurement and substitution.
· Extended time intervals for general overhaul.
· DuraSense can be retrofitted to existing systems.
· Unplanned downtime due to insufficient lubrication of linear axes is reduced.
Michael Hager, Executive Director at Hager Sondermaschinenbau GmbH and a qualified industrial engineer, summarises the benefits of the DuraSense solution: “With the monitoring system from Schaeffler, we have found a solution that is easy to integrate and will enable us to acquire knowledge about the wear behaviour of our plant with every system installed.”
Stefan Schneider, Technical Manager for Mechanical Systems at Hager Sondermaschinenbau GmbH commented: “DuraSense can unlock huge cost saving opportunities. With just one system, we can identify all sources of defects that lead to incorrect lubrication.”
