AIQ Core gearbox condition monitoring
With AIQ monitoring & maintenance comes a flexible solution package that perfectly fits your demands. Avoid laborious maintenance and service measures and find out about upcoming maintenance tasks at an early stage. The deeply integrated sensor system helps find the ideal maintenance interval. Additionally, the implemented gear unit intelligence will even help you avoid unplanned shutdowns.
Profit from:
» optimized service intervals based on oil monitoring.
» early failure detection and alarming based on vibration measurement.
» storage and visualization of longtime data within our AIQ web portal.
» automated monthly reporting (gear unit health status).
» PLC integration of measured speed, temperature, vibration and status.
Make use of AIQ Monitoring & Maintenance in different setups (see picture below), coming from a simple sensor use case, ending in cloud-hosted data with 24/7 online availability. Flexible, optionally upgradeable.
For further information see
page 7 of the on-line catalogue
Predictive Maintenance not Preventative!
Optimized Service Intervals, not estimated!
AIQ Detect® helps determine the ideal maintenance intervals for mechanical power transmission couplings based on actual operating conditions & data, rather than fixed schedules.
Two world class mechanical power transmission couplings, the Flender N-Eupex® and Rupex® can be constantly analysed for wear of the elastomers whilst measuring the speed and the direction of rotation. Particularly suited to equipment systems that employ multiple mechanical power transmission couplings but provide peace of mind for any system using just single or multiple N-Eupex or Rupex couplings.
Switching from preventative to predictive maintenance allows for optimized service intervals by using the AIQ to determine the best time for maintenance based on actual operating conditions rather than fixed schedules. This approach can lead to reduced downtime, increased labour productivity, and lower maintenance costs.
A more detailed explanation:-
Preventative Maintenance: This involves performing maintenance tasks at predetermined intervals, regardless of the actual condition of the equipment. It's a proactive approach aimed at preventing failures, but it can lead to unnecessary maintenance and costs if the equipment is still in good condition.
Predictive Maintenance: This utilizes data from sensors and other sources to monitor equipment performance and predict potential failures. AIQ algorithms analyze this data to determine when maintenance is actually needed, optimizing service intervals and minimizing downtime.
Optimized Service Intervals: By using the AIQ to analyze real-time data, predictive maintenance can identify when a specific component is likely to fail, allowing for maintenance to be scheduled just before the failure occurs. This approach ensures that maintenance is only performed when necessary, maximizing uptime and minimizing waste.
Benefits of Predictive Maintenance:
Reduced Downtime: Maintenance is performed only when needed and covenient, reducing the likelihood of unexpected breakdowns and downtime.
Increased Productivity: Technicians can focus on tasks that are actually necessary, improving efficiency.
Lower Maintenance Costs: Unnecessary maintenance is avoided, leading to cost savings on parts and labour.
Improved Equipment Reliability: By addressing potential issues before they become critical, predictive maintenance can extend the lifespan of equipment and illiminate the chance of failure.
Better Inventory Management: By predicting failures, it becomes easier to plan for spare parts and materials, reducing the risk of an out-of-stock situation.
Two World Class Mechanical Power Transmission Couplings
N-EUPEX® couplings offer several advantages including operational reliability, dampening of vibrations and shocks, and flexibility in assembly and maintenance. They are designed to minimize downtime by reducing wear and tear on connected equipment and can be used in a wide range of industrial applications.
RUPEX® couplings offer several benefits, primarily due to their flexible design and robust construction. They excel at dampening vibrations and shocks, accommodating misalignment, and ensuring reliable torque transmission, even under demanding conditions. Their compact design and suitability for reversing operation also contribute to their popularity in various industrial applications.
AIQ Detect mechanical power transmission coupling condition monitoring
N-EUPEX as overload holding, fail-safe series
RUPEX for special safety and reliability requirements
Mechanical power transmission couplings will eventually begin to show signs of wear due to their purpose and the nature of the job they perform.
The widely patented AIQ Detect, the digital, coupling sensor, monitors the wear condition of the elastomers and measures rotation speed and direction. Minimize Downtime. Save Effort. Monitor Functions. Mechanical power transmission coupling condition monitoring.
Visual Feedback about coupling status
Green (OK)
Yellow (Warning / Change elastic elements)
Red (Critical warning)
*Please note diagrams exaggerated for illustrative purposes.
Life Cycle N-EUPEX / RUPEX (Failure Probability)
AIQ-Detect
Minimize Downtime
Continuous and permanent monitoring of the coupling with AIQ Detect prevents unplanned failures and increases operational reliability. It also forms the basis for condition-based maintenance. Instead of a regular exchange of elastomers, the replacement can now be targeted and done only when needed. This is not only cost-effective but also sustainable.
Save Effort
With AIQ Detect, the condition of your flexible coupling is always assessed in a consistent way based on valid measurements. Therefore, no training or adaptation of personnel is required for monitoring. Once the wear limit of the elastomers is reached, the sensor reports the change in condition. There is still enough time to plan for maintenance. Yearly routine maintenance can mean several hours of time and equipment shutdown. With AIQ Detect, you can save on this effort in the long term.
Monitor Functions
The sensor not only checks the wear of the elastomers but also records each rotation of the coupling. Based on this data, AIQ Detect can determine and provide rotation speed and direction. This ensures that the drive train is operating correctly at all times.
Hardware
Two small magnets + sensor.
By measuring the time difference between 2 points in a rotating system, the rotational speed and torsional angle can be determined.
Continuous Torsional Angle Monitoring As Enabler
» Detection of wear condition of the elastomers.
» Detection of operating faults (continuous very large torsional angle in the coupling).
Options
Sensor in combination with a new coupling
» Coupling equipped with magnets.
» Including Manual and AIQ Detect sensor.
Coupling prepaired / AIQ Detect ready
» Coupling equipped with magnets.
» W/O AIQ Detect sensor.
» Optional package RETROFIT completes the coupling monitoring.
Retrofit
» Includes magnets and AIQ detect sensor.
Installation tool
» Includes special drill and universal installation sticker.
Standard Connector - M12 / 8 Pin
General
» IP67 protection class.
» CE / EAC Certification.
» Wi-Fi (option for online mode).
» Bluetooth (option for local mode).
» Operating voltage 24 V DC.
» Dimensions 70 × 70 × 35 mm.
Wear Detection
» Hall sensors detect the wear of the elastic elements.
» Connection to PLC.
» Analog output / 4 to 20 mA signal.
» High resolution.
» Integrated intelligence.
Speed Measurement
» Hall sensors detect every rotation of the coupling.
» Connection to PLC.
» Digital output / pulse signal.
» High resolution.
Status Detection
» Sensor detects the status of the coupling continuously.
» Connection to PLC.
» Digital output.
» Integrated failure detection.
Functions
» Detects wear of elastomer elements.
» Measures speed.
» Maintenance forecast.
» Failure detection.
» Configurable output signals.
» Firmware upgrades via AIQ app.
Use and Connectivity Options
Option 1 Visual
Offline mode: visual status view LED light.
Option 2 Signal connection
Offline mode: signal connection to customer control (PLC).
Option 3 Bluetooth
Local mode: Bluetooth connection to smartphone via AIQ app.
Option 4 Online
Cloud connection via AIQ Core (Additional hardware required).
