A cool condition monitoring solution
Posted to News on 12th Jun 2023, 10:30

A cool condition monitoring solution

See Schaeffler at MachineBuilding.Live, 4 October 2023, on stand 69

A cool condition monitoring solution

Schaeffler has supplied a fruit processing company with its ProLink condition monitoring system to monitor the condition of trolley bearings on stacker cranes, which operate in cold and frozen storage areas.

Zentis, with its headquarters in Aachen, Germany, is one of Europe’s leading fruit processing companies, producing jams and fruit preparations for the baking, confectionery and dairy industries.

The Aachen site uses large stacker cranes for storage, transfer and retrieval. In order to monitor the large and difficult-to-access moving components in the cold and frozen storage areas and to avoid unplanned downtime, the logistics team at Zentis was looking for a predictive maintenance solution.

Zentis had previously implemented Schaeffler’s SmartCheck condition monitoring devices on gearboxes and cable reels to monitor the health of a critical pallet lifter. The devices have helped to prevent unplanned downtime and optimise production. If the pallet lifter fails, the first production stoppages occur around two hours later.

The SmartCheck devices measure the vibration, speed, temperature and imbalance of various rolling bearings in the gearbox, as well as the gear teeth/mesh. The CM solution has enabled an early warning period of several weeks which allows Zentis to carry out repairs and remedial action as part of planned maintenance work, thereby avoiding costly unplanned downtime.

A cold challenge

In the cold and frozen storage areas at Aachen, a different kind of CM solution was required. The stacker cranes constantly move around the 30-metre tall racks in different directions. The trolley bearings, in particular the non-driven bearings, are highly stressed. The fact that constant measuring conditions do not exist during regular operation posed an even greater challenge.

In addition, temperatures in the frozen storage area are as low as -20°C, which presented yet another challenge for the new measuring system, for example, how to attach the sensors to the measuring points.

Michael de Ben, head of internal logistics at the Aachen site, comments: “We were looking for a monitoring solution for our stacker cranes that could reliably take measurements despite inconsistent measuring conditions and ultra-low temperatures in order to protect us from unplanned downtimes.”

A smart solution

After approaching one of Schaeffler’s local authorised sales partners the Schaeffler ProLink condition monitoring system (CMS) was chosen. This intelligent measuring concept was adapted to suit Zentis’ unique requirements.

To monitor the stacker cranes, a Schaeffler ProLink CMS and five sensors (bearing guards) were installed on each stacker crane unit. In order to perform meaningful vibration monitoring, the original measurement concept had to be changed in the multi-channel CMS. Schaeffler achieved this by breaking down the short, slow travel times into many short measurements. Any extreme impacts could then be determined from these measurements.

To solve the temperature challenge in the cold storage area, the ProLink CMS was installed in the switch cabinet. In the frozen storage area, the ProLink system was placed in heated control cabinets that escort each stacker crane run. The sensors were attached to the measuring points using a special, cold-resistant adhesive compound.

Permanent benefits

The implementation of the ProLink CMS, has benefitted Zentis in several ways. With early warnings of any change in the condition of the stacker crane trolley bearings, the site has also seen an improvement in the planning of maintenance activities, as well as improved safety and transparency. The ProLink CMS is also fully integrated into the sites own control system.

As Michael de Ben states: “The ProLink CMS monitors heavily strained moving components on the stacker cranes that, due to their size or mounting position, cannot be repaired promptly in the event of an unplanned malfunction. By using bearing guards, the vibration pattern of this equipment can be permanently observed and any deviation can be detected at an early stage. In this way, the ProLink CMS makes a crucial contribution to safeguarding the production supply at Zentis.”

ProLink is part of the Schaeffler Lifetime Solutions portfolio, which offers a comprehensive range of products, services and solutions for industrial maintenance. It is designed to support maintenance engineers over the entire lifetime of a machine.


Schaeffler (UK) Ltd

Unit 308, Fort Dunlop
Fort Parkway
B24 9FD
UNITED KINGDOM

+44 (0)121 313 5830

Bosch Rexroth SICK (UK) LTD Procter Machine Safety Mechan Controls Ltd Pilz Automation Ltd ABSSAC Ltd Aerotech Ltd Leuze electronic Ltd PI (Physik Instrumente) Ltd Euchner (UK) Murrelektronik Ltd Kawasaki Robotics (UK) Ltd Phoenix Contact Ltd AutomateUK Machinesafe Compliance Ltd Dold Industries Ltd Heidenhain (GB) Ltd FATH Components Ltd M Buttkereit Ltd Micro Epsilon UK Limited Rittal Ltd AutomateUK STOBER Drives Ltd Spelsberg Els UK Ltd HARTING Ltd Servo Components & Systems Ltd Smartscan Ltd WEG (UK) Ltd