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By installing online condition monitoring systems on its aluminium rolling mills, Aleris Aluminium is seeing annual cost savings of around 200,000 euros.
A manufacturer of rolled aluminium products is saving around 200,000 euros per year by monitoring the condition of critical machine components on its rolling mill machinery.
Aleris Aluminium, based in Koblenz, Germany has installed two FAG DTECT X1 condition monitoring systems from FAG Industrial Services (part of The Schaeffler Group). A total of 16 sensors and two, 8-channel DTECT X1 systems monitor the pedestal bearing on the bridle roller, 14 bearings on the deflector and flatness monitoring rollers, and 12 bearings and four gears in the mill pinion gears.
10 sensors are positioned on the bridal rollers to monitor the two pedestal bearings on each roller. Another sensor monitors the condition of the two bearings on the deflector roller input. A further sensor is used to monitor the condition of the two bearings on the flatness monitoring roller; and two sensors monitor the mill pinion gears.
On four separate occasions, DTECT X1 detected damage to machine critical components at the plant. This enabled Aleris Aluminium to take the appropriate maintenance measures and prevent any unplanned machine stoppages. After installing the DTECT X1 systems, Aleris Aluminium has calculated the annual cost savings to be around 200,000 euros, which comes from three main areas: faster repair times and material savings on roller bearings, which amount to some 30,000 euros per year; avoiding chatter marks was calculated to be worth a further 120,000 euros per year; and the elimination of stand fires due to overheated roller bearings amounts to around 50,000 euros per year.
In addition to this, F
| Product Model | Inside Diameter | Outside Diameter | Thickness |
| CSCA047 bearing | 120.65 | 133.35 | 6.35 |
| CSXD045 bearing | 114.3 | 139.7 | 12.7 |