Flip-flop screening technology is increasingly widely used in waste management, mineral processing, and recycling in Australia and New Zealand, to separate materials that are sticky, clogging, wet, fine, or difficult to screen.
This flexible multiuse technology – employing a double-vibration principle and flexible polyurethane-type screen media – requires systematic and programmed lubrication to ensure smooth operation, while helping to prevent wear and curtail potential breakdowns and downtime.
The technology's particularly important need for systematic lubrication arises because the high stresses generated by the machines' core operating principle, as employed in municipal and industrial waste and waste recycling applications ranging from metals and mixed waste and compost, through to materials such as sand, cement, ash, fine minerals, and demolition waste, says global bearings and motion technology company, Schaeffler
"Flip flop technologies (and related flip flow screens) employ flexible media that undulate rapidly because of the machines' dual vibratory forces. These strong forces cause flip flop screening machinery's flexible mats to stretch and relax rapidly, which transfers energy to the material being screened, enhancing separation.
"This high-intensity, high-energy transfer at the heart of their operation also heightens their need for efficient maintenance and reinforces their particular suitability for automated digital predictive lubrication systems technologies such as the OPTIME Ecosystem. The highly adaptable and easily scaleable OPTIME system enables flip flop screen operators to get the best, most reliable, safest, and most sustainable resource recovery performance from these machines," says Schaeffler Australia, which operates throughout Australasia and Oceania, where its advantages include in-house technical expertise to achieve the best performance from the latest global technologies, such as the OPTIME Condition Monitoring and Smart Lubrication Solution. The OPTIME system was recently installed in a large Australian recycling facility.
The OPTIME Ecosystem is a family of real-time, 24/7 technologies that combine condition monitoring and smart lubrication. It includes components such as OPTIME 3, OPTIME 5, and OPTIME 5 Ex sensors for wireless condition monitoring, as well as OPTIME C1 lubricators for automated lubrication. The system also incorporates a mobile app and plug-and-play functionality for ease of use and setup. OPTIME Ecosystem has won numerous European and US awards, including IOT and Industry 4.0 categories, plus an international Red Dot Design Award.
The comprehensive suite of condition monitoring technology complements Schaeffler's long-standing expertise in bearing technology, vibration analysis, and lubrication, proven over more than 250 locations in 55 countries.
Primarily targeting rotating machinery – which covers a huge spectrum of industrial applications – OPTIME functions effortlessly across a diverse range of speeds, from 120 to 5000 rpm. Importantly, it is also suitable for hazardous environments, which can be found in applications where flip flop screening is prevalent.
"Recent OPTIME applications in Australasia, for example, include recycling, which is an area of increasing importance as sustainability grows even further as a corporate priority, along with the high levels of safety that OPTIME brings to the task."
Global OPTIME applications by Schaeffler include cranes, pulp and paper, cement, manufacturing, food and beverage, packaging, energy, resources, mining, and materials.
Key Advantages of Schaeffler OPTIME for Flip-Flop Vibrating Screens:
- Real-time Condition Monitoring: The OPTIME system uses wireless vibration sensors to detect abnormal vibrations, temperature, and lubricant conditions, allowing for early identification of potential issues before they escalate. This helps operators optimise maintenance schedules and minimise costly repairs. OPTIME sensors wirelessly monitor vibrations and temperature 24/7, providing continuous data on screens' operational status and health.
- Predictive Maintenance: By analysing vibration patterns and other parameters, OPTIME can predict potential failures and schedule maintenance before failures that dramatically increase downtime compared with prevention actions. The system can detect issues such as bearing damage, shaft damage, and lubricant problems before they become major failures.
- Improved Operational Efficiency: OPTIME provides continuous insight into machine performance, allowing for optimisation of operating parameters and increased efficiency. By minimising unplanned maintenance, OPTIME helps operators maintain consistent production flows while simultaneously reducing costly downtime.
- Remote Monitoring and Diagnosis: OPTIME facilitates remote monitoring and diagnosis of screens' conditions, enabling service providers to assist with troubleshooting and repair. The OPTIME app provides a user-friendly interface for accessing real-time data, managing alerts, and tracking maintenance activities.
- User-friendliness, featuring an intuitive mobile app that makes OPTIME easy to use by operators ranging from beginners to advanced personnel, a feature that helps to ease skills shortage pressures and costs. OPTIME's intuitive operation via mobile app ensures smooth operation extending from individual machines and to entire facilities. A distinguishing feature of the OPTIME Ecosystem is its user-centric design, which makes it accessible to a wide range of users, from beginners to maintenance experts. Its affordability further enhances its appeal, breaking traditional cost barriers associated with advanced monitoring systems.
- Cost-Effectiveness: OPTIME's wireless design, ease of installation and plug-and-play functionality make it highly cost-effective solution for condition monitoring compared with traditional methods, which may be more labourious, time-consuming and less precise. "The truly intelligent OPTIME system eliminates tasks such as lubricating by hand or having to manually check on many lubrication points," says Schaeffler Australia.
- Easy to scale. OPTIME Ecosystem's ease of use and affordability make it easy to scale up and expand the scope of particular applications in just a few steps. The ecosystem offers a complete overview of all machines and lubrication points. Easy-to-understand alarms and automatic analytics make it simple to know what to do next.
- Prompt return on investment. Because of its ease of learning, and by reducing the risk of unplanned downtime, OPTIME Ecosystem offers a quick return on investment. Its cost efficiency also makes comprehensive condition monitor and smart lubrication affordable.
"The OPTIME system's foundation lies in its wireless, battery-operated sensors that are remarkably easy to install. After the installation, the data collected by wireless OPTIME sensors is transmitted to a digital service via a gateway," says Schaeffler Australia. This setup enables continuous monitoring and early detection of potential machine issues, thereby preventing costly unplanned downtimes.
Importantly, it is also backed in Australasia by in-house technical expertise and guidance to get the best result from OPTIME technology. "Direct, in-house experience further extends the gains achieved by the system, which is based on Schaeffler's long-standing expertise in bearing technology, vibration analysis, and lubrication. Its product design is consistently geared towards the day-to-day tasks of maintenance teams."
About us:
About Schaeffler
Schaeffler Group – We pioneer motion
The Schaeffler Group has been driving forward groundbreaking inventions and developments in the field of motion technology for over 75 years. With innovative technologies, products, and services for electric mobility, CO₂-efficient drives, chassis solutions and renewable energies, the company is a reliable partner for making motion more efficient, intelligent, and sustainable – over the entire life cycle. Schaeffler describes its comprehensive range of products and services in the mobility ecosystem by means of eight product families: From bearing solutions and all types of linear guidance systems through to repair and monitoring services. Schaeffler is with around 120,000 employees and more than 250 locations in 55 countries, one of the world's largest family-owned companies and one of Germany's most innovative companies.
