The reliable, cost- and time-efficient performance of maintenance, service and repair is essential for a company's success. After all, these processes account for up to 40% of company costs - maintenance costs for property, plant and equipment, the housing industry, private households and motor vehicles alone amounted to around EUR 255 billion in Germany in 2009. According to a VDI study on "Maintenance expenditure in Germany", indirect maintenance costs are estimated to be three to five times higher.

Against this background, smart maintenance is more in demand than ever. To achieve this, intelligent technologies that are already available today must be implemented in the value creation process in a targeted manner - for example RFID technology. RFID transponders in the high frequency range of 13.56 MHz and in the ultra-high frequency range of 860 to 960 MHz are an essential component of intelligent maintenance processes.

The opportunities arising from the integration of RFID technology are clear and fast identification of machines and systems, consistent process support without media discontinuity, efficiency gains during the initial inspection and during follow-up inspections on site. The advantages also include the immediate availability of information on the previous inspection via the respective RFID transponder as well as the completeness of the data and automatic inventory. Other aspects include transparent and complete documentation of the inspection history and legal certainty in the verification of inspections. Potential sources of error are avoided by reducing manual data transfer processes. In addition, high cost and time savings can be achieved by minimizing paper documentation and its archiving.

Individually developed

One example of the use of RFID transponders in smart maintenance is provided by FAG Industrial Services (F'IS), a subsidiary of the Schaeffler Group, which is responsible for the global service business for its INA and FAG brands. F'IS offers manufacturer-independent services, service products and training in all aspects of maintenance and offers, among other things, a mobile monitoring device with RFID technology called 'FAG Detektor III'.

The mobile vibration measuring device is used for the early detection of faults in rotating components such as rolling bearings. As with online monitoring with permanently installed systems, measurements must also be taken regularly at exactly the same measuring point with mobile offline devices. This is the only way to ensure that the data is meaningful and possible damage can be detected at an early stage. As RFID technology enables measuring points to be identified quickly and unambiguously, F'IS has developed customized RFID transponders together with Smart-TEC, which are used to identify measuring points using mobile vibration measuring devices.

How RFID/NFC systems work.

© Smart-TEC

The decisive factor for the successful integration of RFID technology in companies is precise knowledge of the framework and operating conditions in order to be able to select the right RFID transponders in terms of frequency and RFID readers. For example, smartphones can be used as a reading unit as an alternative to robust and industrial RFID readers. For this purpose, the transponders are equipped with an NFC chip instead of an RFID chip, which reduces the entry costs and shortens the ROI period. When selecting the components, the environment in which the transponders are used and the required read ranges must also be taken into account; environmental influences also play an important role. When developing the special RFID transponder for F'IS, for example, resistance and the individual design required for the application were decisive factors. The result: neither mechanical stress nor high temperatures or the use of industrial cleaning agents impair the functionality of the RFID transponder used. The devices are resistant to dirt, oil and acids.

Drivers for an RFID-supported inspection system

A general overview of internal and external drivers for the implementation of RFID technology in inspection systems can be provided on the basis of a study by the Technical University of Munich. The first internal driver is the development of innovative services and products. Process efficiency is increased by optimizing the order sequence, providing sufficient information and avoiding mix-ups due to missing or damaged object identification. In addition, the seamless traceability and up-to-dateness of process statuses increases process transparency. Data quality can be improved by reducing missing or incorrect data on the object. The implementation of RFID technology also offers improved and traceable compliance with safety requirements and legal regulations (BetrSichV, BGV and others).

External drivers are the increase in customer satisfaction through secure processes, an increase in supply chain performance and the fulfillment of legal requirements.

Smart-TEC developed individual RFID transponders for mobile vibration measuring devices from F'IS.

© Smart-TeC

As far as the components are concerned, suitable RFID transponders, mobile RFID read/write devices and the software connection to the company's internal ERP system are required for efficient and paperless processing of the inspection processes. The requirements for RFID transponders are a high and freely programmable storage capacity, especially with decentralized data storage. Other important criteria for transponder selection are insensitivity to soiling, temperature resistance ideally up to 250 °C and an optimum mounting option, for example via a mounting hole or adhesive system. In addition, low sensitivity to metallic ambient conditions, robustness against mechanical loads, a long read range and a long service life play a decisive role. Individual printability - for example with a logo, a barcode or a serial number - are additional parameters that increase function and benefit.

Ideally, RFID read/write devices should be small in size and light in weight. Robustness against mechanical stress and high battery performance, including fast rechargeability, are essential. Data input using a keyboard or touchscreen - even with gloves if necessary - should be uncomplicated. Additional functions such as an integrated camera are also an advantage.

Paperless and contactless maintenance

Because complete proof of all processes is absolutely essential, maintenance, service and repair processes have to date usually been accompanied by time-consuming documentation and a lot of 'paperwork'. RFID technology provides a remedy here, as every product or device fitted with an RFID transponder can be clearly identified by the globally unique identification number (UID) of the RFID transponder. This ensures that the specific proof of relevant process steps is seamless. Another advantage over other identification systems is that RFID readers do not require mechanical contact or visual contact with the RFID transponder.

Author:
Klaus Dargahi is Managing Director at Smart-TEC in Oberhaching.