Storage and retrieval machines safely monitored even at very low temperatures

Customer Success Story

Zentis GmbH & Co. KG in Aachen 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 and to avoid unplanned downtime, the logistics department was looking for a predictive maintenance solution. The company opted for the Schaeffler ProLink CMS monitoring system. Schaeffler experts and the local authorized distributor KSA Kubben + Steinemer GmbH & Co. KG (KSA) implemented an intelligent measuring concept to adapt to the customer's requirements.

“The ProLink CMS system monitors heavily strained moving components of 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. This way, the ProLink CMS system makes a crucial contribution to safeguarding the production supply at Zentis KG Aachen.“
Michael de Ben, Head of Internal Logistics, Aachen

Benefits
Challenge
Solution and What's special
Technical Information
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Benefits

Customer benefits

Early alert in case of change of condition
Plannable maintenance work
More safety and transparency
Integration into the customer´s own control system

Challenge

In the cold and frozen storage at Zentis, the stacker cranes constantly move around the approximately 30 meters tall high racks in different directions. The trolley bearings, in particular the non-driven bearing, are highly strained. The fact that constant measuring conditions do not exist during regular operation made things more difficult.

In addition, the temperatures of -20 degrees Celsius in the frozen storage posed a special challenge for the new measuring system, for instance, how to attach the sensors to the measuring point.

Michael de Ben, head of Internal Logistics at the Zentis plant, briefly summarizes the challenge:

“We are looking for a monitoring solution for our stacker cranes that can reliably take measurements despite inconsistent measuring conditions and ultra-low temperatures in order to protect us from unplanned downtimes.“

Technical information – Stacker cranes

Bearings
Channel bearings with satellite system

Capacity
Storage management of 18,500 pallet spaces

Height
Approximately 30 meters

Efficiency
Approx. 70 pallets per hour per device in storage, retrieval or transfer

Solution

To monitor the stacker cranes, one Schaeffler ProLink CMS and five sensors (bearing guards) were installed on each stacker crane unit.

In order to be able to perform meaningful vibration monitoring, the original measurement concept had to be changed in the multi-channel condition monitoring system. Schaeffler experts achieved this by breaking down the short, slow travel times into many short measurements. Extreme impacts could then be determined from these.

The temperature challenge was solved as follows: In the cold storage area, the ProLink CMS system was installed in the switch cabinet; in the frozen storage area, the system was placed in heated control cabinets that escort each run. The sensors could be attached to the measuring point using a cold-resistant adhesive compound.

What's Special

Zentis KG is absolutely satisfied with the monitoring solution that meets all their complex requirements. It was similar when Zentis was looking for a solution for their pallet lifters years ago. That challenge then was solved with the SmartCheck monitoring system and a SmartConnect Box.

Schaeffler ProLink CMS inside switch cabinet
Sensor (bearing guard)

Technical Information

Technical information on ProLink CMS

Data exchange with customer infrastructure, e.g. plant visualizations and cloud service	via OPC/UA
Interface to maintenance planning systems such as SAP/PM and IBM Maximo	via OPC/UA
Cyclic reporting or in case of alarm	e-Mail
Exchange of measurement data	via fieldbus In planning: Profinet and CC-Link IE Field

ProLink CMS 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.

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