Predictive Maintenance Reduces Driveshaft Failures

Description of Problem

At a large metal recycling facility, driveshaft coupling failures from transient torque overload events were causing unplanned shutdowns and lost production. nexpected shutdowns for the "mega shredder" machine cost $32,000 in lost production per driveshaft downtime event. The Shredder Manager sought insight to transient torque events within the driveshaft to optimize operations and reduce costly unscheduled downtime.

Description of Solution

The Perceptiv team prescribed a continuous torque monitoring system to trend peak torques, log data, and automatically send alerts in real-time when torque exceeded the configured thresholds. Additionally, the Perceptiv Reliability Engineering team provided weekly reports with actionable recommendations for inspections and proactive maintenance.

Benefits Seen by the Plants Included

• Eliminated lost production of over $32,000 per driveshaft failure event ($4,000 x 8hrs)
• Significantly reduced maintenance and parts replacement costs of ~ $250,000 per event
• Improved maintenance planning and scheduling
• More maintenance time for preventive inspections and repairs instead of reactive maintenance

The demand for reliable assets has never been greater, yet finding the resources and knowledge has never been harder

Everyday there are challenges in labor resources, supply chain, meeting production goals and unplanned downtime. The Perceptiv intelligence team applies decades of industry and application knowledge to diagnose and design outcomes based on your needs. The team uses advanced technologies to detect issues before they become your problem to help increase profitability, efficiency, and overall plant health.

Diagnostic Services

Technical tools are applied on-site for root cause analysis to assess equipment health. Receive easy to read reports on equipment performance along with prescriptive consultation to optimize your electromechanical powertrains.

Prescriptive Monitoring >

Manage assets with alerts, automatic trend detection and advanced condition monitoring tools. The Perceptiv condition monitoring services team can help with design and installation as well as regular reporting with prescriptive actions. Tie this system into your automation system or easily access information via the Perceptiv dashboard.

Maintenance, Repair, and Operations (MRO) Management>

Simplify MRO management for maintenance and procurement teams with the Tag-It Program. Reduce maintenance time, streamline procurement, and achieve inventory objectives by decreasing your MRO lifecycle up to 30%.

Perceptiv™ Solutions

Our diagnostic services team has developed a series of solutions for the various industries we serve. Browse our documented solutions to get a baseline for how you can achieve optimal performance.

Schedule a Time to Learn More About Perceptiv Solutions

Regal Rexnord manufactures components that span the complete powertrain, and we have decades of application and industry knowledge. It’s truly an extension of who we are to monitor applications, provide insights, and recommend appropriate actions before issues interrupt production.