As part of a pilot project, two centrifugal pumps were fitted with two SmartQB sensors (for measuring vibration and temperature) and connected via one FAG SmartQB. In the event of any bearing defects, the FAG SmartLamp installed next to the FAG SmartQB illuminates red and the system generates an alarm message. With only two additional clicks on the touchscreen display, a maintenance technician can view more detailed information about the fault and is provided with specific recommended actions.

Both bearings in the 8-stage centrifugal pump were replaced in a short time, which prevented severe damage to the facility. Unplanned downtime of up to several weeks combined with damage amounting to several thousands of euros was prevented.

The pilot project was so successful that Perlenbach is considering fitting sensors to additional pumps and integrating the FAG SmartQB system into its internal maintenance alarm management system. In this way, all condition monitoring data can be centralised as well as viewed locally on the FAG SmartQB display.

Local data to cloud-based diagnosis

Vibration monitoring systems are one of the most reliable methods of monitoring the condition of rolling bearings. However, as the use of sensor technologies becomes more and more prevalent, the volume of measurement data available is increasing.

Schaeffler’s FAG SmartQB is a standalone system for monitoring the condition of rotating plant and equipment with fixed or variable speeds from 100 to 15,000 rpm. Due to its automatic fault assessment feature, the system can be operated by maintenance staff with little or no expertise in vibration monitoring technology.

The early warning system comprises a FAG SmartQB sensor unit, a cube-shaped housing with touchscreen display, and a cable for power and data transmission (Power-over-Ethernet).

The system was developed for detecting faults in electric motors, pumps, fans and other rotating plant and equipment supported by rolling bearings. It is supplied with ready-to-use, preset measurement configurations. Five causes of faults can be identified and displayed using the system: bearing damage, imbalance, friction/cavitation (for centrifugal pumps), temperature increases, and general changes in vibration patterns that cannot be clearly attributed to one of the causes already mentioned, and which may require additional analysis. The automatic fault assessment feature provides plain text messages, giving users clear instructions for action, enabling them to immediately undertake any corrective maintenance work and order replacement parts if required.

A 7-in touchscreen provides all relevant information, from assembly and set-up instructions to recommended actions if a fault occurs and contact details for technical support at Schaeffler.

When starting FAG SmartQB for the first time, the customer selects one of 16 languages provided and, if required, replaces the preset standard contact details of Schaeffler’s technical support with their own details. After selecting the component on which the FAG SmartQB sensor is mounted, the user specifies whether the machine operates at constant or variable speed, and enters the name of the drive system/assembly. FAG SmartQB then automatically selects the measurement configuration. The system is immediately ready for the automatic learning mode. This self-learning (Teach-In) mode enables the device to automatically adjust alarm thresholds. After set up and commissioning, FAG SmartQB operates autonomously. The relevant machine parameters are measured and saved continuously in the system, creating a substantial database of historical data over time.

A total of six sensors can be connected to one FAG SmartQB and allocated to multiple machines, individual machine components or sub-assemblies as required. Sensors can be added easily using the display – in a similar way to initial system installation. After initial operation, FAG SmartQB 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.