achieving energy and fuel savings, and helps to
reduce CO2 emissions as well.
COATING PERFORMS MEASURING
TASKS
With Sensotect, the actual measuring function
is performed by a thin PVD (physical vapour
deposition) coating that is sensitive to expansion.
After the component has been coated, this
layer is then created using a micromachining
process. The structures that are thus created
undergo the same degree of distortion as the
carrier component, which makes it possible for
the distortion to be measured. Schaeffler has
already successfully demonstrated the function
of this type of sensor system in its demonstration
vehicles.
One of the greatest challenges posed by this type
of sensor coating system is the manufacturing
process itself. By using very high-performance
coating sources and adhering to particularly high
requirements with regard to cleanliness in the
manufacturing process, Schaeffler can achieve
a level of quality previously only found on planar
substrates in semiconductor technology, even in
components with narrow radii.
Sensotect allows multi-functional surfaces that
are characterised in particular by their sensor
properties to be created without affecting the
design envelope – in other words, components
that are coated with it become sensors in their
own right.
Development of the technology for applications
in Australia and New Zealand is supported by
Schaeffler’s local manufacturing and research
facilities, backed by the extensive international
research facilities of the Schaeffer Group,
which employs more than 90,000 people at 170
locations in over 50 countries.
SENSOTECT BENEFITS
• Very precise measurement of force and
torque on functional components where the
possibilities associated with conventional
methods are limited
• Sensor layer is deposited directly on the
substrate surface
• Measurement possible on 2D and 3D
geometries
• Sensor technology with neutral effect on design
envelope
• No use of adhesives or transfer polymers
• Continuous measurement of force and torque
during operation
• High sensitivity with very little deviation in
hysteresis and linearity
• No temperature deviations
• No ageing effects
• Wireless transfer of data and energy (telemetry).
SCHAEFFLER’S DIGITALISATION
OFFENSIVE
Advantages such as Sensotect are integral to
Schaeffler’s global initiatives at the forefront
of Industry 4.0 automation and data exchange
technologies.
Smart technologies highly relevant in Australia
and New Zealand include the latest evolutions of
Schaeffler’s SmartQB and SmartCheck condition
monitoring systems, along with a host of
digitalisation and cloud-based technologies that
harness the advantages of Industry 4.0, such as
Schaeffler’s Bearinx software.
Schaeffler’s latest predictive maintenance
solutions enable machinery operators to look
ever more clearly into the future – they provide
machine operators with vital information about
the future condition of their machines.
Predictive maintenance allows not only the
capacity utilisation of factories, mines, utilities
and processing plants to be optimised, but also
makes it possible to plan maintenance intervals at
precisely the right time for optimised ‘total cost of
ownership’ calculations.
An important prerequisite for predictive
maintenance is automated rolling bearing
diagnostics, a function that is used in motor
gearbox units, for example. These units are
used not only in machine tools but also in belt
conveyors, presses, and steel mill rollers, for
example.
Schaeffler Bearinx software is one of the
leading programs for performing rolling bearing
calculations. It enables rolling bearing supports
to be analysed in detail – from single bearings to
complex gear systems and linear guide systems.
All calculations are performed in a consistent
calculation model. Even for complex gears, the
contact pressure on each rolling element is
considered in the calculation.
Because machine drives are operated virtually
without interruption, they require intensive
maintenance in order to prevent production
downtimes. This is why it is so important for
operators to know the condition of the drive
components at all times, and why the bearings
are becoming particularly important as a central
machine element.
The latest generation of the FAG SmartCheck
diagnostic system now represents a further step
forward for Schaeffler in these areas. In addition
to identifying the threat of bearing damage,
wear, and irregularities such as imbalance and
misalignments based on vibration pattern
changes, this system also features a cloud
connection. The system creates an automated
diagnosis in the cloud from the raw data supplied
by the FAG SmartCheck and from additional data,
e.g. from the machine control system.
Applications for which this technology applies
include bulk handling and conveyor applications,
mining and energy; building, construction and
access equipment installations, such as forklifts
and logistics; food and beverage and agribusiness
processes, including paper and packaging;
manufacturing, metals and process engineering,
transport and industrial motor and transmission
applications, including pumping and HVAC
installations and utilities including electricity,
water and waste water.
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