Predictive Maintenance Reduces Driveshaft Failures
Description of Problem
At a large metal recycling facility, driveshaft coupling failures from transient torque overload events were causing unplanned shutdowns and lost production. Unexpected shutdowns for the "mega shredder" machine cost over $4,000 per hour in lost production, and repairs take ~ 8 hours when a driveshaft fails. The Shredder Manager required insight to the real torque occurring in the driveshaft to optimize operations.
Description of Solution
Perceptiv™ intelligence connected services team prescribed the Expert S7000 Shredder Torque Monitor, a continuous torque monitoring system to trend peak torques, log data, and automatically send alerts in real-time when torque exceeds the configured thresholds. In addition, the Perceptiv™ intelligence connected services team selected the Premium Analysis and Reporting package to provide a 24/7 view of torque data and weekly engineering reports with recommendations for inspections and maintenance.
Benefits Seen By The Manufacturer Included
- Eliminated lost production of over $32,000 per driveshaft failure event ($4,000 x 8hrs)
- Significantly reduced maintenance and parts replacement costs of ~ $250,000 per event
- Improved maintenance planning and scheduling
- More maintenance time for preventive inspections and repairs instead of reactive maintenance
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The demand for reliable assets has never been greater, yet finding the resources and knowledge has never been harder
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Regal Rexnord manufactures components that span the complete powertrain, and we have decades of application and industry knowledge. It’s truly an extension of who we are to monitor applications, provide insights, and recommend appropriate actions before issues interrupt production.