Schaeffler: Plug-and-play machine and assembly monitoring with plain text display of the possible cause of a fault

Schaeffler presents an innovative stand-alone complete solution for monitoring the condition of machines and assemblies. With FAG SmartQB, a ready-to-use monitoring solution for electric motors, pumps, and fans that is very easy to install and does not require any specific knowledge about vibration diagnosis is available in the industrial sector for the first time. The automatically generated plain text messages on the 7-inch display are a genuine innovation on the condition monitoring market. The early warning system FAG SmartQB comprises an FAG SmartQB sensor unit (a variant of the existing FAG SmartCheck), a cubic housing with a touch panel, and a cable for power and data transmission. The system was specially developed for detecting irregularities in electric motors, pumps, fans, and their rolling bearings, and is supplied with a ready-to-use configuration. Five causes of faults can be identified and displayed using the condition monitoring system: bearing damage, imbalance, friction/cavitation (for centrifugal pumps), temperature increases, and all general changes in vibration patterns that cannot be clearly attributed to one of the aforementioned causes and require additional analyses. Due to this automatic fault assessment performed by FAG SmartQB, the system can be operated by maintenance personnel without any knowledge of vibration technology. The fault assessment enables users to immediately initiate maintenance work and order replacement parts if required. The system’s installation and initial operation are also remarkably simple. It can be installed and operated by any in-house electrician without additional knowledge of vibration technology. The touch display provides all the relevant information, ranging from assembly to recommended actions in case of a fault and the contact details of technical support. When starting the system for the first time, the customer selects one of the 16 languages and, if required, replaces the preset standard contact details of Schaeffler’s technical support with his details. After selecting the component on which the FAG SmartQB sensor is located (motor, pump, or fan), specifying whether the machine operates at constant or variable speed, and entering the individual name of the assembly, FAG SmartQB automatically selects the best measurement configuration. The system is immediately ready for the automatic learning mode. A total of six FAG SmartQB sensors can be located on a housing and allocated to individual assemblies as required. Further FAG SmartQB sensors can also be easily added using the display in the same way as during initial installation. After initial operation, the FAG SmartQB system displays relevant information, such as operating hours counter, fault frequency, maximum values, average values, trend curves, and the alarm status of each individual FAG SmartQB sensor. In case of an alarm due to a change in vibration signals that cannot be attributed, FAG Smart QB makes a recommendation to maintenance personnel via the display to send the measurement data to Schaeffler’s technical support, for instance, for a more indepth analysis. FAG SmartQB is used in the cement, paper, and steel sectors, in water management as well as in mechanical and plant engineering. The system is currently being validated in various customer projects in these sectors.