Safety-relevant components in mechanical engineering: Schaeffler rolling bearings with digital twin and GS1 DataMatix for optimized maintenance and reliability

Rolling bearings play a central role in numerous industrial and everyday applications. Their importance ranges from ensuring passenger transport and the smooth operation of industrial plants to providing precision in aerospace. The modern world would be virtually inconceivable without them, as they make a crucial contribution to ensuring low-wear and low-friction movement.

Rolling bearings as safety-relevant components

In safety-critical applications – for example, in rail transport, aviation, or the oil and gas industry – the flawless functioning of rolling bearing components is essential. A defective rolling bearing can have serious consequences, including:

• Unforeseen maintenance costs: An unplanned replacement of components can tie up significant financial and time resources.
• Production losses: A plant shutdown can cause enormous costs and delivery delays.
• Personal injury and safety risks: In applications such as rail or aviation, sudden failures can cause accidents with fatal consequences.

Rolling bearings are found wherever there is movement. They are indispensable for:

• Trains and cars: They ensure smooth passenger transport.
• Industrial plants: They guarantee reliability and efficiency.
• High-tech applications: From wind turbines to aircraft engines, they enable precise and reliable movements.

Schaeffler: A world-leading manufacturer of rolling bearing technology

With over 40,000 standard rolling bearing products and numerous customer-specific solutions, Schaeffler one of the world's largest and most innovative suppliers in this field. The product range extends from miniature bearings just millimeters in size for dental drills to high-temperature bearings for the aerospace industry.

Each rolling bearing has specific properties tailored to its respective application. This makes it all the more important for customers to receive precise information about the specifications and condition of their deployed bearings. Schaeffler addresses this with digital technologies, creating a completely new level of transparency and maintenance efficiency.

Digitization through the GS1 DataMatrix code

A key component of Schaeffler's digital strategy is the use of the GS1 DataMatrix code. This code is engraved directly onto the inner and outer rings of the rolling bearings and provides access to a digital twin of the product. The digital twin links the physical bearing to a digital database that provides comprehensive information.

The GS1 DataMatrix code: structure and function

• Serialized GTIN: The code contains a serialized Global Trade Item Number (GTIN) that is encrypted and machine-readable.
• Individual identification: Every rolling bearing can be uniquely identified worldwide.
• Data access: Customers gain access to a wide range of product-related data via the code.

This technology creates complete transparency throughout the entire life cycle of a rolling bearing and enables numerous innovative applications.

Scope of the data provided

The GS1 DataMatrix code gives customers access to a wide range of information, including:

1. Manufacturing data

• Production site
• Date of manufacture
• Technical specifications

2. Operational data

• Mileage
• Vibration data
• Fat analysis

3. Maintenance data

• History of performed maintenance
• Recommendations for future maintenance intervals

4. Logistics data

• Location tracking
• Supply chain information

GS1 standards and IoT

The use of GS1 standards such as the DataMatrix Code is crucial for implementing IoT solutions:

• Uniform identification: GS1 identification numbers enable objects, machines and people to be clearly identified.
• Interoperability: GS1 standards act as a common language for data exchange between different systems and companies.
• Linking to digital twins: The GS1 Digital Link allows physical objects to be connected to their digital representations.

Advantages of the digital twin

Linking physical products to a digital twin offers numerous advantages for manufacturers, operators, and maintenance service providers. Key benefits include:

• Complete traceability: From the manufacturing process to the end of its life cycle, every rolling bearing can be seamlessly tracked.
• Predictive maintenance: Using the collected operational data, potential problems can be identified and resolved before failures occur.
• Optimized maintenance intervals: Based on the collected data, maintenance cycles can be precisely adapted to the actual usage.
• Cost reduction: Significant savings can be achieved by avoiding unplanned downtime and implementing more efficient maintenance processes.
• Increased reliability: Especially in rail transport and other safety-critical areas, improved monitoring capabilities contribute to safety.

Innovative service offerings

By using digital twins, Schaeffler has laid the foundation for a range of innovative services. One example is the so-called 100% Return Service. This service enables the professional reconditioning of rolling bearing components, which regain their full performance thanks to comprehensive data documentation.

Digitalization in the railway industry: A pioneer

A prime example of the application of these technologies is the rail industry. Here, Schaeffler is driving digitalization forward with great vigor, creating significant advantages for operators and manufacturers. "We are setting new standards for transparency and efficiency in the maintenance of rail vehicles," emphasizes a company spokesperson. By networking physical components with digital data, not only is operational safety increased, but also the reliability of the entire fleet.

Data Matrix Code (DMC): Sustainability and Efficiency

The integration of digital technologies such as the GS1 DataMatrix code and the digital twin also supports the industry's sustainability goals. Precise control of maintenance processes and the ability to remanufacture components extend product lifespans, conserving resources and reducing environmental impact.

Furthermore, the use of data-driven solutions is setting new industry standards. The continuous analysis of operational data makes it possible to optimize existing processes and drive innovation. In this way, Schaeffler not only creates added value for its customers but also positions itself as a pioneer in digital transformation.

Schaeffler impressively demonstrates how traditional technologies like rolling bearings can be redefined through the use of digital solutions. With the GS1 DataMatrix code and the digital twin, the company is setting new standards in reliability, efficiency, and sustainability. The connection between the physical and digital worlds not only creates advantages for manufacturers and operators but also increases safety and reliability in safety-critical applications.

Digitalization offers not only technological advantages, but is also an important step towards a more sustainable and efficient industry. With innovative approaches and a clear vision for the future, Schaeffler remains an indispensable partner for companies in all sectors where movement plays a role.

Suitable for:

• The GS1 DataMatrix code as the successor to the barcode used worldwide: It offers protection against manipulation and enables traceability

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The role of safety components and rolling bearings

Safety-relevant components play a crucial role in mechanical engineering, as their failure can have devastating consequences. Rolling bearings, in particular, are of great importance in almost all sectors of industry because they enable movement and are used in everything from small precision devices to powerful industrial plants. In this context, Schaeffler comes into focus, as it is one of the world's leading rolling bearing manufacturers. With its broad product range, the use of modern digitalization approaches, and the application of the GS1 DataMatrix code, Schaeffler offers a comprehensive solution for optimized maintenance strategies and increased reliability and availability of machines and systems. The following sections explain the relevance of rolling bearings in safety-critical applications, examine the digitalization approach using the so-called digital twin in more detail, and explain how the introduction of the GS1 DataMatrix code is revolutionizing maintenance.

Applications and relevance of rolling bearings

Rolling bearings – also known as ball bearings, cylindrical roller bearings, tapered roller bearings, or needle roller bearings – are found in a wide variety of applications. They serve to reduce friction on rotating or oscillating components while simultaneously absorbing high loads. These properties are essential for safe and smooth passenger transport: trains, cars, and airplanes are just a few examples of means of transport that rely on dependable rolling bearings. Bearings also play a crucial role in industrial plants, ensuring the uninterrupted operation of production lines, robots, and other machinery. Experts consistently emphasize: "A defective rolling bearing can have serious consequences." These include premature maintenance requirements, costly production downtime, and potential accidents if systems suddenly fail.

Rolling bearings in safety-critical applications

The use of rolling bearings is particularly critical in safety-critical environments such as the railway industry, the oil and gas sector, and the aerospace industry. These sectors often operate under extreme conditions that demand peak performance from the bearings: "In rail vehicles, the wheelset bearings are crucial for passenger safety," as is often stated. A failure could directly affect stability and maneuverability. The situation is similar in aircraft turbines, where continuous monitoring is essential to ensure they can withstand the enormous loads and speeds over the long term. Similarly, in oil and gas drilling platforms and production facilities, where pressures, temperatures, and corrosion are exceptionally high, maximum operational reliability is paramount. Only when all components, including the rolling bearings, function reliably can uninterrupted operation be guaranteed.

Advances and challenges in rolling bearing technology

Against this backdrop, it's no surprise that billions of rolling bearings are in operation worldwide, powering a wide variety of machines. At the same time, the demands on quality and efficiency have steadily increased. While advances in materials research, lubricants, and production logistics ensure constantly improving performance characteristics, Industry 4.0 is simultaneously placing greater emphasis on data acquisition and real-time monitoring. Therefore, one statement serves as a guiding principle for many engineers: "Without rolling bearings, no robot arm, no wind turbine, no aircraft engine, and no train would move today." Wherever there is movement, reliable and high-performance bearings are essential.

Schaeffler: A global market leader in rolling bearing production

Schaeffler has established itself as one of the world's largest rolling bearing manufacturers in this market segment. The company offers a diverse portfolio, ranging from tiny miniature bearings for dental drills to specialized designs for the mining industry. In addition, high-temperature bearings are developed for use in the aerospace sector, capable of withstanding extreme temperature fluctuations and harsh environmental conditions. According to internal figures, the standard product range comprises approximately 40,000 different rolling bearing types. But that's not all: "Every rolling bearing has its own unique characteristics," experts emphasize. Customer-specific solutions are often designed to precisely meet the requirements of individual industries or customers.

Data acquisition and sensor technology for rolling bearings

To ensure customers always know the specific specifications of their installed rolling bearings, Schaeffler provides comprehensive data. Since rolling bearings are always mounted in locations where movement occurs, they are particularly well-suited as measuring points for relevant operating parameters. Sensors and data recording allow bearing behavior to be analyzed under real-world conditions. This enables the collection of information from the fields of engineering, production, and logistics. Schaeffler has created a data interface through which customers can access data on mileage, vibration levels, and temperatures. The company emphasizes: "Rolling bearings are perfect data providers."

Digitization through the digital twin

In the course of digitalization, which is increasingly permeating all areas, Schaeffler has developed the digital twin approach. This involves linking the physical rolling bearing with a virtual counterpart in the cloud or on a data platform. The basis is the GS1 DataMatrix code, which is laser-engraved directly onto the inner and outer rings of the bearing. This code is a machine-readable marker that includes, among other things, the serialized Global Trade Item Number (GTIN). Each code is unique and enables the physical bearing to be uniquely identified. This creates the prerequisite for mapping all information about this bearing in a digital twin and tracking it throughout its entire lifecycle.

Advantages of the GS1 DataMatrix code and the digital twin

The advantages of this digital link are manifold. First, it offers seamless traceability. From the moment of production to disposal, it can be clearly determined when and where the bearing was manufactured, which materials were used, and what its specific characteristics are. This is a significant benefit, especially in safety-critical areas, because only a transparent and documented product lifecycle allows for rapid responses in the event of a recall or malfunction. Maintenance also benefits from this data collection, as maintenance intervals can no longer be based solely on statistical experience but can be individually tailored to the actual condition of the bearing. A phrase that operators repeatedly emphasize is: "Predictive maintenance reduces costs and increases availability."

The key role of predictive maintenance in industry

Predictive maintenance and digital diagnostics are key elements of modern maintenance. They are based on detailed real-time data and algorithms that detect irregularities in bearing stress. This technology-driven process makes it possible to identify wear early and initiate countermeasures in a timely manner, thus minimizing downtime. In industries with high production rates or safety-critical requirements, such as rail transport, preventive replacements can prevent damage before it has serious consequences. Furthermore, digital data forms the basis for application-specific services. Schaeffler, for example, offers a 100% return service for bearing reconditioning. This allows customers to rely on their bearings being professionally inspected, cleaned, and repaired if necessary. The process always involves examining which factors were particularly stressful during previous operation and how these must be taken into account during subsequent use.

Optimizations through the GS1 DataMatrix code

Thanks to the GS1 DataMatrix code, the company can consolidate production and logistics data in a central database and make it accessible to both customers and other authorized partners. This also leads to optimizations in the supply chain, as the unique identification enables end-to-end tracking in logistics and service. As one manager summarizes it: "The GS1 DataMatrix code is the bridge between the real and digital worlds."

Digital rolling bearings in the railway industry

In the rail industry, this approach is now considered a pioneering and exemplary model. Rail operators face the challenge of keeping their fleets available around the clock with minimal maintenance. The rail network in many regions of the world is already heavily utilized, meaning that breakdowns can significantly disrupt operations. The solution developed by Schaeffler, which digitally tracks rolling bearings throughout their entire lifecycle, makes a significant contribution to maintaining infrastructure stability. In addition to increasing safety, this approach reduces maintenance and spare parts costs, as planning is based on real-time data rather than purely time-based intervals. Future trains could report in real time when, for example, bearing damage is imminent, and a maintenance team could then provide the necessary components and personnel precisely when needed.

Sustainable maintenance and resource conservation

Another important topic is sustainability. With proper use, rolling bearings can last a very long time and can sometimes be remanufactured several times. Digitalization enables precise documentation of such processes and can promote resource-efficient circular economy models. Since all repair and maintenance steps are stored in the digital twin, the bearing's history is always traceable. This also simplifies decisions about whether a bearing should be remanufactured or replaced. Operators can see at a glance how many operating hours the bearing has already completed, what peak loads occurred, and what the results of lubricant analyses were. This transparency not only supports waste reduction but also leads to a more efficient use of personnel and materials.

New business models thanks to digital solutions

The integration of digital twins, sensors, and big data analytics is also opening up new business models. Some operators are already moving away from purchasing rolling bearings and instead sourcing their functionality as a service. In such a model, the manufacturer retains full responsibility for maintenance and replacement, ensuring that the bearings always deliver their target performance. This includes the continuous collection, evaluation, and use of data for planning. As one insider puts it: "We no longer just sell a bearing, but guaranteed availability."

The GS1 DataMatrix code as an identification anchor

The GS1 DataMatrix code serves as a secure identification anchor. It enables unique identification, minimizing errors in documentation and improving clarity. The transition from manual lists or error-prone barcode scans to laser-engraved, serialized GTINs also reduces the risk of installing the wrong bearing during maintenance. In highly automated facilities, robots can read the code and transfer the corresponding data directly into the systems. This reduces human error and further accelerates the bearing replenishment and assembly process.

The future of industry with Schaeffler

In summary, it is clear that Schaeffler, with its innovative rolling bearing solutions, is at the forefront of technological advancements and specifically addresses the requirements of modern industries. More and more companies are recognizing that selecting components solely based on mechanical criteria is no longer sufficient. Instead, information about origin, condition, and expected service life is an integral part of a holistic product lifecycle. This trend goes beyond traditional condition monitoring and culminates in comprehensive, networked solutions. This is precisely where the concept of the digital twin comes into play, which Schaeffler implements using the GS1 DataMatrix code. "We are rethinking rolling bearings – digitally," could be the motto.

Prospects for other industries

In the future, other industries will adopt this approach, be it in manufacturing, the energy sector, or construction. Wherever rotating or pivoting components subject to high stress are used, the principle of predictive maintenance can be profitably applied. Digitalization is the key element that increases both the safety and the efficiency of the systems. And it is companies like Schaeffler that are vigorously driving this path forward.

Rolling bearings: Data sources of modern industry

This makes it clear that rolling bearings are far more than mere mechanical components. They are both data carriers and data generators, forming the foundation for modern maintenance concepts. Thanks to their key position in moving systems and their openness to advanced technologies, they are ideally suited to enable the transition to a fully networked industry. This demonstrates that "where there is movement, Schaeffler is involved, and where Schaeffler is involved, there is a new quality and quantity of data." This applies to mechanical and plant engineering, the rail industry, aviation, and any other sector that prioritizes safety, reliability, and efficiency equally.

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