Induction Heating and Smart Monitoring at Maintenance Dortmund

Schaeffler will showcase technologies for industrial maintenance and plant availability at the Maintenance Dortmund trade show (25 – 26 February). The focus will be on medium-frequency induction systems for bearing handling, Arcanol lubricants for rolling bearings, and the OPTIME Ecosystem for smart condition monitoring of rotating equipment.

Medium-Frequency Induction Systems for Bearing Handling
Schaeffler’s medium-frequency induction systems are designed for controlled heating of bearings and other machine components during mounting and dismounting. Compared with conventional low-frequency heaters, medium-frequency technology allows both installation and removal of components through precise thermal expansion.

The systems operate in power ranges from 3.5 kW to 44 kW, enabling use across a wide spectrum of workpiece sizes. Applications range from small bearing rings to large components such as main bearings or wind turbine housings. Controlled inductive heating reduces mechanical stress during assembly and disassembly, minimizing the risk of surface damage and improving repeatability.

At Maintenance Dortmund, Schaeffler will demonstrate the mobile MF Generator 3.0, rated at 3.5 kW. The compact unit is intended for small to medium-sized workpieces and mobile on-site maintenance operations, where flexibility and fast setup are required.

Lubrication as a Service-Life Factor
Lubricant selection significantly influences the service life of rolling bearings. Schaeffler’s Arcanol lubricants are formulated to reduce friction and wear in rotary and linear bearing applications under varying temperature, load, and environmental conditions.

The portfolio includes multiple grease formulations tailored to specific operating profiles. According to Schaeffler, each production batch undergoes defined physical and chemical testing to ensure consistent quality and performance. Optimized lubrication can extend relubrication intervals, reduce energy losses due to friction, and support more sustainable maintenance strategies in manufacturing plants.

Electrical and Mechanical Condition Monitoring
The OPTIME Ecosystem addresses predictive maintenance through wireless condition monitoring. The recently introduced FAG OPTIME E-CM system expands the portfolio by adding electrical condition monitoring of three-phase motors, commonly used in compressors, rotary pumps, fans, and grinding machines.

Earlier OPTIME sensors focused primarily on mechanical vibration analysis for early detection of bearing and mechanical faults. FAG OPTIME E-CM supplements vibration monitoring with analysis of motor currents and voltages. By correlating electrical and mechanical parameters, the system improves fault detection in areas such as rotor imbalance, insulation degradation, and load anomalies.

Integrating electrical data with vibration diagnostics enhances failure prediction accuracy and supports earlier intervention, reducing the risk of unplanned downtime.

Application in Industrial Maintenance
The solutions presented at Maintenance Dortmund address key aspects of industrial maintenance: correct mechanical assembly, optimized lubrication, and continuous condition monitoring. Together, these technologies support higher manufacturing efficiency, improved plant availability, and data-driven maintenance planning across diverse industrial sectors.