Success Story

Industry: Machine Tools

Application: Workhead Dresser

Cost Savings: € 13 080

Introduction

Within NSK's own plant in the UK, a grinding machine was experiencing raceway form errors. After numerous attempts to correct the error, the fault remains unidentified. Initial readings were taken by NSK Condition Monitoring Service prior to replacing the bearing and subsequent readings were taken within the following weeks. This helped to identify the root cause of the machine problem and saved time on unnecessary investigative maintenance and machine down time stripping down good components.

Machine Tool Application

Condition Monitoring Service (CMS)

Key Facts

The wheel spindle motor is rated at 10 Hp max rpm 3600
The wheel spindle speed is adjustable from 50 to 6000 rpm
The wheel spindle bearings are 1 pair front and rear
The work head motor is an AC servo rated at 2 kw
Fitted with 2 pairs of RHP bearings
The rpm is adjustable from 50 to 500 rpm
NSK Solution: Condition Monitoring Service (CMS) with bearing and motor details for the analysis
After the CMS Service the fault was identified and no further problems with the surface finish and the raceway form appeared

Value Proposals

An NSK expert performed an Condition Monitoring Service (CMS) on a grinding machine
The CMS Service indicated there were no issues of concern from either the spindle or the dresser
3 days to strip the spindle and investigate the potential bearing problem was avoided, along with the associated loss of production from that production cell
This now allows the maintenance engineers to focus their time in other areas
Performance improvements and operational cost savings

Product Features

Live assessment of a machine's condition and health while the machine is still in operation
Predicted life of the critical components inside a machine allowing the customer to plan maintenance more accurately
Early warning of problems occurring in machinery
Condition Monitoring is the most sensitive and long reaching methond of detecting the signs of machine wear
On-site support from NSK Engineers
Assurance that NSK as a full ragne supplier can help with the provision of critical bearing and linear motion spares

Product Sheet >>

Cost Saving Breakdown

Before		Cost p.a.	NSK Solution	Cost p.a.
	Engineering Costs: 2 x Maintenance engineers x 3 days investigation @ 84€ / hr	€ 4.680	Engineering Costs: No need to strip and investigate machine	€ 0
	Costs of lost production: 3.5 days machine downtime @ 2.400 € / day	€ 8.400	Costs of lost production
Total Costs		€ 13 080		€ 0

Reference:SS-E-2081

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