Condition Monitoring for your KTS Tumbler Screeners
GKM Siebtechnik monitors the bearings of its KTS tumbler screeners with Schaeffler's Optime: wireless sensors track vibration and temperature, and the Optime C4 lubricator supplies all four lubrication points. GKM can also take over the monitoring.
Tumbler screening machines operate continuously and are subjected to high loads. For the operator, therefore, it is not only the actual screening performance that matters, but also how reliably the machine remains available over the long term. Bearings play a particularly important part in this regard: Changes in their condition can be detected early on – provided they are continuously monitored.
At GKM Siebtechnik, we therefore use Schaeffler’s Optime condition monitoring system on our KTS Tumbler Screeners. The aim is to provide transparency on bearing conditions and to detect potential anomalies at an early stage, before they lead to unplanned machine downtime.
From machine condition to specific action required
At the heart of the system are wireless Optime sensors, which are mounted directly on the relevant bearing points of the screening machine. They continuously monitor vibrations, shocks, and temperature, among other things. The data is transmitted via a mesh network to the Optime Gateway and forwarded from there to the cloud. Customers can access this information, whenever required, through the Optime app or the dashboard.
This changes the perspective on maintenance. Instead of performing inspections exclusively at fixed intervals or reacting only after a failure occurs, changes in the condition of a bearing can be monitored on an ongoing basis. Anomalies are automatically detected and analyzed. This provides the operator with an additional source of information for planning maintenance measures in a more targeted way.
At GKM Siebtechnik, this approach goes one step further: Upon request, the company monitors the installed systems on behalf of its customers. This means that the condition data is not simply transmitted to the operator, who must then decide for themselves what action needs to be taken. Instead, the operator receives support in the ongoing evaluation of the machine data. This allows anomalies to be detected early and maintenance measures to be planned in a targeted way.
For the user, this means one thing above all: less effort in daily condition monitoring and a better basis for planning maintenance and repairs.
Lubrication as a major part of the overall concept
In addition to condition monitoring, correct lubrication plays a key role for bearings. Insufficient or incorrect lubrication is a common cause of bearing failures. Manual lubrication of lubrication points, in particular, also requires regular monitoring and labor.
This is where the FAG Optime C4 comes into play. This intelligent multipoint lubricator can supply the four lubrication points on our KTS Tumbler Screener via four individually programmable outlets. With an outlet pressure of up to 70 bar, the lubricant can also be transported over longer distances. For our KTS Tumbler Screeners, cartridges containing 400 or 750 cm³ of our standard grease are available.
However, the benefits go beyond automatic lubricant dispensing. The Optime C4 also monitors its own operating status. Among other things, the system detects whether a cartridge is installed, determines the remaining amount of lubricant based on the number of strokes performed, and warns if the back pressure is too high. This makes it easier to plan maintenance without having to regularly check each lubrication point on-site.
When condition data and lubrication work together
Another benefit is the interaction between condition monitoring and lubrication. Based on the recorded vibration data, the Optime Ecosystem can detect signs of low lubricant levels. If an anomaly is detected, the user receives a warning via the app and, when using smart lubricators, can identify the specific lubrication point affected.
This creates a continuous information loop for your KTS Tumbler Screener: Sensors monitor the condition of the bearings, the data is automatically transmitted and analyzed, and if any anomalies are detected, the information is available for further maintenance. It is also possible to automate and monitor the lubrication system.
Digital support for availability
For us at GKM Siebtechnik, this development complements traditional and proven screening technology. The sensors provide data, the gateway establishes the connection to the digital platform, and the Optime C4 handles demand-based lubrication for applicable applications. Both the condition monitoring data and the lubrication information are displayed in the same app or on the dashboard – allowing the machine’s condition to be assessed at a glance. GKM also offers monitoring services for its customers upon request.
This means that condition monitoring does not become an additional task for the operator, but can instead be integrated into the machine’s routine maintenance. Especially in situations where production processes depend on the continuous availability of screening equipment, the continuous monitoring of the machine’s condition provides a basis for more predictable maintenance decisions.
Digitizing maintenance does not necessarily have to start with complex systems. For us at GKM, it is directly linked to a specific task:
Keeping track of the condition of bearings during operation and being able to respond in a timely way when necessary.
