The optional equipment offers machine manufacturers lower manufacturing costs and operators lower operating costs as well as higher availability. For example, DuraSense can be used to monitor and evaluate manual relubrication. This means that an expensive central lubrication system can be dispensed with in favor of manual, monitored relubrication. If a lubrication system is installed, DuraSense detects any faults that could lead to a lack of lubricant at an early stage and prevents insufficient lubrication and over-lubrication. Shorter lubrication cycles are an indicator of signs of wear or the approaching end of service life.

Schaeffler DuraSense ensures needs-based lubrication and saves up to 30 percent lubricant in practice. This is particularly beneficial for machines that use cooling lubricants, for example, as the effort required for subsequent oil separation is significantly reduced.

In practice, it has also been shown that DuraSense reliably detects assembly errors and carriages damaged during assembly even before the system is commissioned. DuraSense thus saves the machine manufacturer any expensive repairs and delays in commissioning at the end customer. It is also planned to use the DuraSense data to detect damage to the linear guides, such as pitting or overrolling of foreign objects.

Interface to the raw data now available

In addition to the core functions of DuraSense described above, Schaeffler will in future provide its customers with an interface to the raw data from the vibration sensors. This functionality has been requested by customers who see DuraSense as a way of monitoring the condition of the machine. Paolo Matassoni, Head of Development at Andritz Kaiser, a leading manufacturer of stamping press machines, assesses the system as follows: "The position of the sensors is ideal for analyzing data on the machine status, as they are mounted exactly between the static and moving machine parts. We use DuraSense in our latest machine, the Top Line 2000. Now it's a matter of converting the recorded data into an understandable language."

DuraSense as a retrofit kit

As many machines and systems in the manufacturing industry are sometimes in use for decades, Schaeffler now also offers a retrofit kit for DuraSense. When the carriages need to be replaced at regular intervals, the customer receives new carriages with sensors. However, if the carriages are to be retained due to low mileage, the sensors can be fitted to the carriages using a new adapter kit. This is also ideal for carrying out initial tests with the system and getting to know how DuraSense works.