Schaeffler's OPTIME ecosystem is a leading solution when it comes to condition monitoring and smart lubrication of machines. Sensors and software combined with the expertise of a leading global bearing manufacturer characterise this offering from the Motion Technology Company. Schaeffler is now adding FAG OPTIME E-CM (Electrical Condition Monitoring, E-CM) to its portfolio for the electrical condition monitoring of three-phase motors – such as those used in compressors, rotary pumps, fans, blowers, grinding machines and in large numbers in all industrial sectors. Schaeffler is thus taking the next step towards trouble-free production processes.

Further prospects for condition monitoring

‘Electrical condition monitoring adds a significant perspective to the existing OPTIME ecosystem and now enables maintenance teams to detect electrical malfunctions at an early stage in addition to mechanical ones,’ says Dr Philipp Jussen, Head of Schaeffler Industrial Lifetime Solutions Europe. The existing OPTIME sensors are specialised in detecting vibrations that indicate premature wear and possible mechanical malfunctions. FAG OPTIME E-CM rounds off the product family by additionally monitoring and evaluating the electrical currents and voltages of the electric drives. ‘As a result, our customers can now better prevent unplanned downtime in production environments,’ explains Dr. Philipp Jussen.

Higher plant availability

FAG OPTIME E-CM enables the early detection of insulation faults and damage, cable defects, static and dynamic eccentricity, broken rotor bars, voltage fluctuations and overcurrents, for example. Thanks to improved transparency regarding the condition of a system, customers benefit from higher plant availability, early maintenance planning and thus lower costs and personnel requirements. This is particularly true for plants that operate in hard-to-reach environments, as the sensors are attached to the cables in the control cabinet.

Easy installation

The technical installation is simple for electrical personnel. The system consists of a measuring unit and sensors for current detection, which are attached to the live cables of the relevant units. Both are installed in switch cabinets that are easily accessible to maintenance personnel. Either current transformers (split-core) or Rogowski coils (wound coils that are placed around a conductor and detect the change in current flow over time) are used as sensors. The distance between the sensor and the measuring unit in the control cabinet can be up to ten metres and is bridged by cable. In addition, the voltages of the three phases of the drive motor are recorded by the central measuring unit.

AI-supported data analysis in the Schaeffler Cloud

The measuring unit sends the data obtained by FAG OPTIME E-CM directly and wirelessly via a secure LTE data connection to the Schaeffler Cloud for analysis. In addition to its decades of experience as a manufacturer and developer of rolling bearings, Schaeffler uses modern machine learning technologies and artificial intelligence to find patterns in the data and derive recommendations for the maintenance teams.

Standalone installation or integration into existing OPTIME ecosystem

Maintenance managers receive notifications via their dashboards on their PC or via app when irregularities occur. In addition, the collected data can be used to document and improve existing processes. FAG OPTIME E-CM can be integrated into an existing system or set up as an entry-level system into the OPTIME world. With the now even more comprehensive OPTIME ecosystem, complex production environments with a large number of different units can be monitored and maintained easily, efficiently, cost-effectively and reliably. FAG OPTIME E-CM will be launched in Europe and some Asian countries at the end of February 2026 and will gradually become available globally.

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