ZSK Extruders in Focus: VibeTrack Condition Monitoring System Ensures Smooth Operation

ZSK twin screw extruders in sizes ZSK 40 to ZSK 140 can now be equipped with the VibeTrack condition monitoring system to detect initial irregularities in extruder operation. Using remote access or our C-BEYOND digital platform, we take over monitoring the system for you. In the event of an anomaly, we swiftly take necessary measures, provide prompt support and offer clear recommendations for the next steps. Early detection of issues allows for planned and proactive maintenance, minimizing any impact on the productivity of your ZSK extruder.

The key to the system is the sensors on the motor, gearbox and process section that monitor the extruder’s operation. Operational data is continuously captured and available in real time. Within the scope of your service agreement, our experts remotely access the results, issue all relevant reports and draw conclusions regarding necessary service measures. 

The VibeTrack condition monitoring system has already proven itself in practice on numerous pilot lines. The system can be both integrated into new extruders as well as retrofitted onto existing extruders. 

Operating principle: vibration and oil condition monitoring 

VibeTrack monitors two critical condition parameters of the extruder: vibration levels and oil condition within the gearbox. 

For vibration monitoring, multiple acceleration sensors are mounted at key points on the extruder to monitor vibration. These sensors measure the vibrations that occur and attribute them to components such as the gearbox, gear teeth engagement, and screw shafts. If vibration levels reach a critical threshold, a warning signal is triggered.

The condition of the oil within the gearbox is continuously assessed using a dedicated sensor that analyzes the oil’s quality parameters. As the operating hours increase, the oil quality generally declines. When the condition approaches a defined threshold, VibeTrack alerts operators so that maintenance actions, like oil changes or repairs, can be scheduled proactively.

Using the EpcNT and CSpro ZSK extruder controls, operators can access the data that VibeTrack captures at any time via web interface. Thus an immediate, comprehensive view of the extruder’s overall health and status is constantly available for the operator. 

Stefan Lachenmayer, Head of Service Sales, Global Service Compounding & Extrusion at Coperion, expressed pride in this comprehensive worry-free package: “The VibeTrack condition monitoring system is a key part of our commitment to customers to maximize the performance of a ZSK extruder throughout its entire lifecycle. With the VibeTrack service agreement, we monitor the operation of the ZSK and make data-driven, reliable decisions regarding necessary maintenance measures. This proactive approach helps prevent downstream damages caused by operational anomalies and ensures the long-term, smooth functioning of the equipment.”