Sensors and software paired with know-how

The Schaeffler Optime ecosystem is a leading solution for machine condition monitoring and smart lubrication. Sensors and software, combined with the expertise of a world-leading bearing manufacturer, distinguish this offering from the motion technology company.

Now, with the FAG Optime E-CM (Electrical Condition Monitoring), Schaeffler is expanding its portfolio to include electrical condition monitoring of three-phase motors – such as those used in compressors, rotary pumps, fans, blowers, grinding machines, and in high volumes across all industrial sectors. Schaeffler is thus taking the next step toward trouble-free production processes.

A new perspective for condition monitoring

"Electrical condition monitoring adds a significant perspective to the existing Optime ecosystem and enables maintenance teams to detect electrical malfunctions early on, in addition to mechanical ones," says Dr. Philipp Jussen, Head of Schaeffler Industrial Lifetime Solutions Europe.

The existing Optime sensors are specialized in detecting vibrations that indicate premature wear and potential mechanical malfunctions. FAG Optime E-CM completes the product family by additionally monitoring and evaluating the electrical currents and voltages of the electric drives. "As a result, our customers can now prevent unplanned downtime in production environments even more effectively," explains Dr. Philipp Jussen.

FAG Optime E-CM enables the early detection of insulation faults and damage, cable defects, static and dynamic eccentricity, broken rotor bars, voltage fluctuations, and overcurrents. Customers benefit from improved system transparency, resulting in higher plant availability, earlier maintenance planning, and thus reduced costs and personnel requirements. This is particularly true for systems operating in hard-to-reach environments, as the sensors are mounted on the cables inside the control cabinet.

Easy Installation – AI-Supported Data Analysis in the Schaeffler Cloud

The technical installation is simple for electrical personnel. The system consists of a measuring unit and current sensors, which are attached to the live cables of the relevant equipment. Both are installed in control cabinets that are easily accessible for maintenance personnel.

The sensors used are either split-core current transformers or Rogowski coils (wound coils wrapped around a conductor that detect the change in current flow over time). The distance between the sensor and the measuring unit in the control cabinet can be up to ten meters and is bridged by cable. The central measuring unit also records the voltages of the three phases of the drive motor.

The data acquired by FAG Optime E-CM is transmitted directly and wirelessly via a secure LTE data connection to the Schaeffler Cloud for analysis. Here, Schaeffler—in addition to its decades of experience as a manufacturer and developer of rolling bearings—utilizes modern machine learning technologies and artificial intelligence to identify patterns in the data and derive recommendations for the maintenance teams.

Stand-alone installation or integration into an existing Optime ecosystem

Maintenance managers receive notifications via their PC dashboards or app when irregularities occur. The collected data can also be used to document and improve existing processes. FAG Optime E-CM can be integrated into an existing system or set up as an entry-level system for the Optime world.

With the now even more comprehensive Optime ecosystem, complex production environments with a wide variety of different equipment can be monitored and maintained easily, efficiently, cost-effectively, and reliably. FAG Optime E-CM will launch in Europe and selected Asian countries at the end of February 2026 and will gradually become available globally.