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Diagnostic Services

Sensors, diagnostics, services

Ensuring process stability requires condition-based maintenance of the drive train. With DIAGNOSTEX®, sensors on our gear units measure deviations from the target state. These can be analyzed and evaluated for the purpose of maximizing plant availability.

DIAGNOSTEX marks an important step into the digital future of mechanical drive technology. With the help of DIAGNOSTEX, the gear unit identifies and communicates any deviations during operation, thereby initiating highly precise early damage detection by our experts. The “digital gear unit” opens up new possibilities for predictive maintenance: The necessary measures can be taken in good time and the planning of our services improved. In conjunction with optimized spare-part management, life cycle costs are significantly reduced and longer gear unit downtimes virtually eliminated.

Benefit from:

  • Globally available mobile measurement and diagnostic services from local service teams
  • Remote diagnostic services for standard and application-specific gear units
  • Highest reliability of results due to comprehensive technology and product knowledge as well as the industry expertise of the diagnostics engineers
  • Gear unit service direct from the manufacturer

 

Flyer: Gear units in focus. Processes under control.

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DX500 for predictive gear unit maintenance

Our entry-level product, DX500, already makes your mechanical drive components more digital. With DX500, we are the first gear unit manufacturer in the world to offer an independent monitoring solution for helical gear units in the low- to medium-torque range. The temperature and vibration sensor measures vibrations and heat buildup directly on the gear unit and, with its measured data, delivers important parameters for predictive gear unit maintenance.

DX500 reports any changes by means of LED and alarm signals in the DX Assist app on your smartphone or tablet. It makes your service planning easier before faults or unscheduled downtimes occur in the production process and thus increases the plant availability.

When you order the sensor, our technicians program it precisely to suit your gear unit configuration. You thus profit from our know-how in gear unit manufacturing and our many years of condition monitoring experience.
 
Due to the built-in analysis function, the sensor works independently. As a simple and independent monitoring and diagnostics solution, it is mainly intended for use with gear units in the low- to medium-torque range in all industrial applications. DX500 is ideally suited for helical gear units in applications such as bucket conveyors, water turbines, blowers/fans, cooling towers, agitators, aerators, dryers and many others.

Important: DX500 is not only used in new gear units, it can also be retrofitted to gear units during ongoing operation.

The installation is simple and uncomplicated. It is explained in a videocast which will be available on this web page as of June 2018.

Benefit from:

  • Cost-effective vibration and temperature measurement with app for gear units diagnostics
  • Optimized plant availability and avoidance of unplanned downtimes by means of predictive maintenance
  • Early fault message directly on the sensor or via the DX Assist app
  • Data evaluation and diagnosis by our competent team of experts

Remote Diagnostic Services (DX2000 & DX4000)

 

With online condition monitoring, we offer you a diagnostics instrument that is precisely tailored to your needs. Our remote diagnostic services allow condition-based maintenance of your standard and application-specific gear units. The diagnostics know-how of our gear unit experts, combined with the DIAGNOSTEX 2000 and DIAGNOSTEX 4000 hardware, represent a decisive step toward nonstop plant availability. Both remote service products offer you online data collection and recording as well as transmission of the measured data to our Remote Expert Center via secure data links.

DX2000 is the DIAGNOSTEX solution for complex gear units, e.g. for single- and double-screw extruders, pinion drives or ball mills.

Monitor up to ten gear units with only a single industrial PC and achieve cost savings up to 50%.

DX4000 is intended for gear units in demanding applications such as cranes, vertical mills and roller presses with planetary stages, and many others. DX4000 is also the right choice for monitoring of complex drive trains.

With both remote solutions, you benefit from:

  • Qualified data evaluation and diagnostics by competent experts
  • Specific recommendations for action as well as early warnings in the event of a fault
  • Ability to schedule repairs

 

Reference Flender CM

Technote Vibration Sensor Technology

Brochure Flender CM

Flyer Flender CM

Overview Flender CM

 DX Mobile

Increased plant availability and reliability ensured by condition monitoring

Mobile Services offer a flexible and cost-effective solution for Standard and Application-specific Gear Units. Measurements are carried out using hand-held devices on site by FLENDER service professionals at regular intervals or when required e.g. in troubleshooting cases. Data evaluation and diagnosis are carried out by our competent expert team.

Your benefits at a glance:

  • Plannable maintenance activities
  • Optimized spare parts management
  • Reduced maintenance costs through early detection of wear-related anomalies

 

Brochure Flender CM

Flyer Flender CM

Overview Flender CM

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DX Assist App

DX500 reports any changes by means of an LED on the equipment, and the alarm can also be displayed in the DX Assist app on your smartphone or tablet. This allows you to react at an early stage before faults or unscheduled downtimes occur in the production process.


The DX Assist app is a tool for holistic gear unit management. It knows your gear unit and displays all unusual behavior in the production process. You receive a digital and mobile service logbook of your gear unit in which alarms are recorded. On this basis, you can optimize your spare-part management and reduce maintenance costs and costs resulting from faults.


Request detailed gear unit analyses by Flender’s experts and benefit from the gear unit manufacturer’s comprehensive application know-how. Or simply order your spare parts. It takes just a few clicks to go from the DX Assist app to Flender’s online shop, where you can order suitable original spare parts.
 

Benefit from:

  • DX500 monitoring incl. condition and alarm monitoring, alarm messages with information about the potential location of the fault
  • DX500 data download and forwarding for the analysis by one of Flender’s experts
  • Gear unit management of your Flender gear units, display of gear unit-specific spare parts, log display (last alarm message)

Support and Consulting Services

 Technical Support

Our specialists offer support in resolving any issues relating to functionality or the operation of products

Technical queries about products can arise at any time. Our specialists will provide you with individual technical support via telephone or e-mail for all questions concerning the function, handling, application and troubleshooting of Mechanical Drives products.

Your benefits at a glance:

  • High planning reliability
  • Optimal engineering efforts
  • Improved availability of machinery

Spare Parts Services

 Spare parts on demand

Quick support when you need spare parts

To be able to supply you with spare parts at short notice, we keep numerous spare parts in stock – ready to dispatch anywhere in the world. We are offering express delivery of parts for urgent cases.

Your benefits at a glance:

  • Spare parts of original manufacturer quality
  • Supply of spare parts on demand for up to 10 years after product discontinuation

 Spare part and repair packages

Individually assembled spare parts packages ensure that defective components can be replaced quickly

FLENDER offers tailored spare part and repair packages for standard and application specific gear units. The packages are predefined and contain the right set of components - including the suitable mounting accessories - for the respective type of breakdown. Thus the plant operators can prepare, which will help to prevent particularly expensice machine downtimes.

Your benefits at a glance:

  • Plannable repair activities
  • Improved plant availability
  • Increased productivity thanks to reduced maintenance time
  • Reliable spare parts availability

 

Brochure spare part packages for large gear units

Info spare part Packages for large gear units

 Asset Optimization Service

Individual spare parts provisioning concepts based on a risk assessment conducted jointly with the customer

In order to help you achieve an optimum balance between plant availability and capital, we are offering you individual concepts on spares provisioning. Based on the analysis of plant inventory and available spares in stock we develop tailored recommendations for actions.

Your benefits at a glance:

  • An optimized inventory enables short reaction times and thus a maximized availability of the machinery
  • Reducing stocks of spare parts helps to cut costs

Repair Services

 Repair analysis

Greater transparency with repair analysis

With repair analysis service we are offering a complete product assessment including recommendation for action as well as a preliminary estimation of repair cost and duration.

Your benefits at a glance:

  • Transparency over the services carried out through reports
  • Greater degree of planning reliability

 Standard repair

Our service specialists are the right people to contact in case your product develops a defect

The standard repair service includes all necessary measures to investigate the condition of a product and restore its functionalities through either repair or replacement of the damaged parts or assembly groups.

Your benefits at a glance:

  • Repairs on the high-quality level of the manufacturer
  • Transparency over the services carried out and the parts used through repair reports
  • Worldwide network of certified workshops

 General overhaul

Enhanced productivity of machines and plants due to more efficient components

Within the general overhaul we assess the current condition of equipment, perform an oil change, replace all wearing and aging parts according to their specified lifetime and prepare a detailed report.

Your benefits at a glance:

  • Prevention of downtimes due replacement of consumable parts
  • Reduction of unscheduled plant down times
  • More reliable production
  • Improved plant availability
  • Reduction of lifecycle costs

Field and Maintenance Services

 Installation

Expert installation by FLENDER specialists for smooth operation of your equipment

Complex equipment needs to be expertly installed and commissioned to ensure its long lifetime. Our installation service includes gear units set up, fastening on the base plate, an establishment of the mechanical linkage with the neighbouring drive train components.

Your benefits at a glance:

  • Highly flexible service and an excellent cost-benefit ratio thanks to worldwide network of specially trained personnel
  • Extensive product know-how

 Commissioning

Expert commissioning by FLENDER specialists for smooth operation of your the equipment

Complex equipment needs to be expertly installed and commissioned to ensure its long lifetime. FLENDER is offering a worldwide network widely experienced commissioning personnel to provide you with this service which covers installation check, entire drive train alignment and connection to the power line, oil filling and a test run.

Your benefits at a glance:

  • Highly flexible service and an excellent cost-benefit ratio thanks to worldwide network of specially trained personnel
  • Extensive product know-how

 Inspection

Scheduled maintenance downtimes instead of unscheduled production stoppages

Inspection and preventive maintenance need to be carried out regularly, especially on machinery operating continuously in a harsh environment. The goal of inspection service is to identify and assess the actual equipment condition by either visual inspection or endoscopic inspection of the internals. A final report with action recommendations is included.

Your benefits at a glance:

  • Scheduled maintenance downtimes instead of unscheduled production outages
  • Planning of inspection and preventive maintenance intervals to suit operating conditions
  • Optimum plant and machine performance

 Preventive maintenance

Increase the lifetime of your equipment by having the core components checked out regularly

Maximize your equipment availability by choosing our preventive maintenance service. Regular maintenance measures defined based on the products' age and operating hours will help you keeping equipment in optimal operating condition.

Your benefits at a glance:

  • Scheduled maintenance downtimes instead of unscheduled production outages
  • Planning of inspection and preventive maintenance intervals to suit operating conditions
  • Optimum plant and machine performance

 Corrective maintenance

Corrective maintenance ensures optimum availability of industrial plants around the world

To resolve unplanned equipment downtimes as quickly as possible we are offering a fault correction service for your equipment worldwide – in the form of an emergency service if necessary. The scope of this service includes troubleshooting, error cause identification, repair or replacement of defective components and provision of a final report.

Your benefits at a glance:

  • Improved plant availability
  • Repairs on the high-quality level of the manufacturer
  • Transparency over the services carried out and the parts used through repair reports

 Special investigation

Our experts always get to the bottom of the problem

If you wish to receive information on the error cause which goes beyond the scope of a standard repair, there is an option of ordering a special investigation. The purpose of a special investigation is not only to identify the failure cause but also to determine sustainable countermeasures.

Your benefits at a glance:

  • Identification of fault causes
  • Reduction in the incidence of expensive consequential and repeat faults
  • Complete transparency when faults become costly

Retrofit and Modernization Services

 Replacement of a legacy product with a state-of-the-art product

Retrofit existing products and systems with state-of-the-art technology

Often it is possible to replace legacy equipment with state-of-the-art products from FLENDER. In this case, best suitable gear units are selected from our current product range. If any modifications are necessary, these can be carried out at the FLENDER factory or on site. We are offering an option of extending the liability for defects period beyond the normal period

Your benefits at a glance:

  • Optimal investment costs
  • Increased equipment availability
  • Improved spare parts availability for the actual product line
  • Less maintenance effort for advanced product lifecycle
  • Lower down time risks and reduced unplanned down time

 

Reference Aalborg

 One-to-one replacement of a state-of-the art product

Spare gear units to minimize unplanned down time

We are offering you spare gear units based on your demand, for example, to replace defective equipment or for stocking on site to have it at hand and immediately available when needed. We are offering an option of extending the liability for defects period beyond the normal period.

Your benefits at a glance:

  • Improved plant availability
  • Plug-and-play solution

 One-to-one replacement of a legacy product

Particularly ideal for old and tried-and-tested configurations

The option of retrofitting a one-to-one duplicate of the original gear unit can be attractive in special cases, particularly for drive trains that have already reached a very long lifetime. In this case, original gear units are replaced by an identical new ones. This option is available for example for product ranges REDUREX and DURUNORM.

Your benefits at a glance:

  • The core features of tried-and-tested drive trains remain unchanged
  • Increased equipment availability
  • Lower down time risks
  • Reduced unplanned standstill times

 Modification of parameters

Customized solution for greater efficiency

Modification of parameters is an optimal choice in case the existing gear unit has to be modified to fit with a new working machine. In this case, for example, a gear unit ratio, torque or shaft dimensions can be modified depending on the specific production and machine requirements.

Your benefits at a glance:

  • Increased equipment availability
  • Investment costs are lower compared to a new product

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