Collini Wien has installed automatic lubrication systems on its electroplating robots, resulting in savings of around EUR45,000 through reduced downtime over the last three years.
Applied coatings specialist Collini Wien of Austria is making savings of around EUR15,000 (approximately £11,200) per year having installed FAG Motion Guard Champion automatic lubricators from FAG Industrial Services (F'IS), the condition monitoring and maintenance management organisation within the Schaeffler Group.
The electroplating plant at Collini Wien has been in operation with the automatic lubricators for more than three years, without any disruption caused by insufficient lubrication. The financial savings come from eliminating the cost of replacement parts, production downtime and labour associated with annual plant shutdowns.
Headquartered in Hohenems, Austria, Collini Wien specialises in finishing the surfaces of base materials by applying special coatings. These coatings protect the parts from corrosion and improve the aesthetics. The company employs around 900 staff across ten production sites.
Before installing the FAG Motion Guard Champion lubricators, Collini Wien frequently had to shut down its electroplating plant because of damage to bearings caused by insufficient lubrication. For example, worn linear bearing units and guideways on its electroplating handling robots had to be replaced every 12 months due to wear. This resulted in the complete plant having to be shut down for between three and seven days at a time. The company therefore wanted to simplify its relubrication process and prevent disruptions caused by insufficient lubrication.
The handling robots are six-axis KUKA robots with a repeatability accuracy of +/-0.3mm and a rated payload of 200kg. Arm length is 1000mm and the robots use INA linear ball bearings and 6m guideways, both supplied by the Schaeffler Group. In such a precise system, bearing lubrication is critical.
Experts from F'IS installed multiple FAG Motion Guard Champion lubricators – filled with FAG Arcanol Multitop grease – on the linear bearings. Each lubricator now ensures that bearings and shafts are continuously supplied with exactly the correct volume of lubricating grease, thereby increasing the service and maintenance intervals of the bearings significantly.
FAG Motion Guard Champion is a robust, electromechanically driven unit with replaceable batteries. The device is electronically controlled and has a back-geared motor that enables the unit to discharge lubricant at adjustable intervals of one, three, six or 12 months. A lubricant canister is screwed to the drive unit, holding 60, 120 or 250cm3 of grease. Pressure is automatically controlled at 5bar and the unit operates in temperatures from –10 to 50degC. The device is also protected against dust and splash water and is immune to electromagnetic interference from surrounding equipment.
By using Motion Guard Select Manager software, the user can select the discharge interval for the application, determine replenishment quantities and select greases. FAG Motion Guard Champion and Compact lubricators can be used on all types of plant, including pumps, compressors, fans, conveyors and vehicles.
For more information on F'IS products and services, visit www.schaeffler.co.uk.