Leading engineering solutions specialist BMG provides the engineering components and support services that, if coupled with a structured maintenance programme, will ensure high productivity, reduced energy consumption, minimal downtime and long service life of systems.
BMG is a complete process solutions provider to all industrial sectors, which means companies can access quality branded products and essential support services from a single, reliable supplier. This integrated approach guarantees lower production costs and higher efficiencies.
“We believe the introduction of a structured maintenance management programme, which can be implemented in-house or partially outsourced to a professional organisation, is critical to maximising production efficiencies in industry,” says Carlo Beukes, group sales development manager for BMG.
Maintenance of machinery can be a very expensive exercise, not only in terms of the cost of spare parts and labour, but also due to lost production because of plant stoppages. Careful consideration therefore needs to be given to disciplined inspections and planned maintenance of plant and production machinery.
Care in the initial designing and manufacturing stages of the plant, the selection of compatible quality branded mating components, professional installation – with particular attention to meticulous alignment of coupled components – will ensure reduced downtime, lower maintenance requirements and therefore lower operating costs.
“BMG’s proactive maintenance, which encompasses predictive maintenance services including condition monitoring and oil analysis, is enhanced by advanced technical and design support across all functional disciplines. Services include mobile breakdown, repair and maintenance support, which all help production plants to get up and running as quickly as possible following a breakdown,” says Beukes.
The importance of lubrication
The negative effects of friction and the resulting wear on moving components such as bearings, girth gears and industrial chain are significantly reduced by the selection and use of the correct lubrication. Although a general multipurpose grease or oil is sometimes adequate, more arduous operating conditions demand purpose specific lubricants. Factors that need to be considered include operating speed, ambient temperature, load, vibration and environmental conditions.
Through a wide range of energy efficient products, including synthetic oils, lubricants and bespoke lubrication systems, along with the support of a technically competent team, the company is able help plant operators to make these more difficult lubricant choices.
BMG’s specialist technical division also offers an oil analysis service, which includes laboratory-based sampling and analysis, as well as on site analysis, filtration and flushing. Other services include technical applications consulting, product and system design, product quality control and assurance, as well as condition monitoring services.
Condition monitoring identifies lubrication problems, misalignment and vibration issues and also helps in identifying the causes of damage, so that units can be fixed before further destruction occurs. The service more than pays for itself through reduced downtime, more efficient production and maintenance cost savings.
Filtration solutions
BMG Fluid Technology’s filtration solutions comprise a wide range of fluid power components and systems, which are supported by the team’s broad technical capabilities to ensure fluids, including oil, fuel and lubricant oil, operate within required cleanliness standards.
“Proficient filtration disciplines in all industries – especially in chemical and corrosive environments and for arduous mining conditions – are critical for dependable performance, high efficiency and extended service life of machinery, equipment and vehicles,” explains Willie Lamprecht, BMG’s business unit manager for Low Pressure Fluid Technology. “Without a structured control and contamination prevention programme, premature equipment failure is likely to occur, leading to unnecessary downtime and costly replacement of parts. “Optimum filtration performance, in conjunction with lower differential pressures (∆P) through the system, significantly reduce energy consumption and fuel efficiency. BMG’s fluid technology services include solutions for fuel and industrial filtration systems, hydraulics and pneumatics, lubrication, hydraulic hose and fittings, as well as instrumentation, pumps and industrial valves,” notes Lamprecht.
Predictive solutions for drives
BMG’s NORD predictive maintenance solutions offer fast, efficient and comprehensive evaluation of analogue and digital data to enhance the operational efficiency and safety of machines. “BMG specialists use predictive maintenance as a methodical extension of condition-based maintenance, with the prime objective of proactively maintaining machinery and equipment and the early detection of operational changes.
“Our NORD status-oriented maintenance system replaces traditional time-based maintenance to enhance the performance of the gear units, electric motors and frequency inverters, for increased efficiency of the entire plant as well as reduced downtime,” explains Deon Crous, national product specialist for NORD Drive Systems.
“Digitalisation boosts the added value our customers can derive from drive data, especially when used to monitor critical applications where a drive failure may cause severe damage,” says Crous.
BMG’s NORD drives for condition monitoring are based on intelligent algorithms and software in an Industrial Internet of Things (IIoT) environment, where networked drive units collect condition data in the inverter’s integrated Programmable Logic Controller (PLC) and pre-process it, together with data from connected sensors and actuators.
“An important advantage of this system is it offers our customers dependable data analysis, rather than raw data. Results of pre-processed or complete data can be optionally transmitted to an edge device, from which the data from all subsystems is managed and evaluated. This information is then available as pre-selected and edited smart data for further use and clear visualisation,” explains Crous.
A common application example is the sensorless determination of the optimum oil change period based on the oil temperature, which is the key indicator of oil ageing in gear units. This information is used in conjunction with gear unit parameters and specific operational parameters to precisely calculate the most appropriate oil change time, without the need for any additional sensors.
The company’s electromechanical specialists are able to extend and adjust NORD drive equipment for specific automation tasks, including drive monitoring, drive control and process control. The team is also able to advise customers about the correct PLC software architecture for any application.
Power transmission solutions
Stock availability and a wide range of standardised power transmission components, which are machined to accept taper-lock sleeves with bore sizes to suit a range of standard shafts, make for easy access and fitting of components to the shafts of machinery, such as motors and gearboxes. Components, such as vee belts, sprockets, couplings, slat top chain, belt systems, taper bushes, belt and chain tensioners and geared motors, accommodate broad power input and torque capacity requirements, as well as a wide speed range.
The accurate installation of correct power transmission equipment ensures long-term savings in equipment replacement costs, as well as reduced plant downtime and maintenance requirements. When alignment has been meticulously completed, it is critical that all components are securely located and doweled. This will ensure reduced wear, resulting in lower power losses, improved efficiency and the elimination of vibration. The net effect is an extended operating life for all drive components.
In belt and chain drives, the correct tensioning and accurate alignment of pulleys or sprockets also extends operating life and, as a result of reduced friction, lowers power consumption. Many chain drives also require correct lubrication to ensure trouble-free and efficient operation.
Tsubaki’s lube-free roller chain, however, is ideal for use in industries where clean environments are required and where product contamination cannot be tolerated, in food processing, pharmaceutical and electronics’ manufacturing, for example. Tsubaki’s Lambda chain is also suitable for environments where abrasive contamination is prominent, as is the case in wood processing and the paper and packaging industries.
Similarly, Timken Quick-Flex couplings require minimal maintenance and are able to be used in a wide range of critical applications, including hydraulic pumps, motors, industrial gearboxes, compressors, vibrating screens and ventilation fans. These couplings are designed to accommodate shaft misalignment within the drive and to also dampen vibration and torque fluctuations. “Quick-Flex drive couplings can directly replace virtually any similarly sized coupling. They require no lubrication and are also easy to install and maintain,” says Brandon Bouillon, product manager for BMG’s Power Transmission division.
Through its offering of a wide range of high-quality engineering components, along with associated structured maintenance and service programmes, BMG strives to keep plants free of the breakdowns and stoppages that unnecessarily affect efficiency and productivity.
“We are committed to ensuring every plant keeps operating by providing 24-hour customer process support for production efficiency and structured reliability-centred maintenance programmes,” concludes Carlo Beukes.
