Schaeffler Introduces AI-Supported Electrical Condition Monitoring to Enhance Reliability of Industrial Drive Systems

FAG OPTIME E-CM: The system consists of a measuring unit and the sensors for current detection. (Image: Schaeffler)

(IN BRIEF) Schaeffler has introduced FAG OPTIME E-CM, expanding its OPTIME ecosystem to include electrical condition monitoring for three-phase motors commonly used across industrial applications. By analysing current and voltage in addition to mechanical vibration data, the solution enables earlier detection of both electrical and mechanical faults, improving plant availability and reducing unplanned downtime. The system features easy installation within control cabinets, secure wireless data transmission to the Schaeffler Cloud, and AI-supported analysis that delivers actionable maintenance insights. Available as a standalone solution or integrated into existing OPTIME systems, FAG OPTIME E-CM will launch in Europe and selected Asian markets in early 2026, with global availability to follow.

(PRESS RELEASE) HERZOGENAURACH, 27-Jan-2026 — /EuropaWire/ — Schaeffler has expanded its OPTIME condition monitoring portfolio with the introduction of FAG OPTIME E-CM, a new solution designed to monitor the electrical condition of three-phase motors used across a wide range of industrial applications. The addition strengthens the OPTIME ecosystem by providing deeper visibility into production systems and supporting more reliable, interruption-free operations.

The FAG OPTIME E-CM solution extends condition monitoring beyond mechanical indicators by analysing electrical parameters such as current and voltage in electric drives. Three-phase motors are widely deployed in compressors, rotary pumps, fans, blowers and grinding machines, making them a critical component in industrial production environments. By integrating electrical condition monitoring into the existing OPTIME ecosystem, Schaeffler enables maintenance teams to identify potential faults earlier and address issues before they lead to unplanned downtime.

While existing OPTIME sensors focus on vibration analysis to detect early signs of mechanical wear and damage, FAG OPTIME E-CM adds a complementary layer of insight by monitoring electrical behaviour. This dual perspective allows early detection of issues including insulation faults, cable damage, static and dynamic eccentricity, broken rotor bars, voltage fluctuations and overcurrent events. As a result, operators gain improved system transparency, higher plant availability and more proactive maintenance planning, reducing both operational costs and personnel requirements.

The FAG OPTIME E-CM measuring unit can be easily integrated into a control cabinet. (Image: Schaeffler (Craft Bildwerk))

The system is designed for straightforward installation by qualified electrical personnel. It consists of a central measuring unit and sensors for current detection that are mounted directly on live cables within the control cabinet. Depending on application requirements, either split-core current transformers or Rogowski coils can be used. The sensors and measuring unit can be installed up to ten metres apart and connected via cable, while three-phase voltage signals from the motor are also fed into the system.

Once collected, measurement data is transmitted wirelessly via a secure LTE connection to the Schaeffler Cloud. There, advanced data analytics, machine learning techniques and artificial intelligence are used to identify patterns and generate actionable insights for maintenance teams. Schaeffler combines this digital expertise with decades of experience in rolling bearing development and industrial applications to deliver practical, data-driven maintenance recommendations.

FAG OPTIME E-CM can be deployed either as a standalone solution or seamlessly integrated into an existing OPTIME setup. Maintenance managers receive alerts through desktop dashboards or mobile applications whenever irregularities are detected, while historical data supports continuous improvement of maintenance processes. With the expanded OPTIME ecosystem, even complex production environments with numerous assets can be monitored efficiently, reliably and cost-effectively.

The market launch of FAG OPTIME E-CM is scheduled for the end of February 2026 in Europe and selected Asian markets, with a phased global rollout to follow.

Schaeffler Group – We pioneer motion: The Schaeffler Group has been driving forward groundbreaking inventions and developments in the field of motion technology for over 75 years. With innovative technologies, products, and services for electric mobility, CO₂-efficient drives, chassis solutions and renewable energies, the company is a reliable partner for making motion more efficient, intelligent, and sustainable – over the entire life cycle. Schaeffler describes its comprehensive range of products and services by means of eight product families: From bearing solutions and all types of linear guidance systems through to repair and monitoring services. Schaeffler is with around 110,000 employees and more than 250 locations in 55 countries, one of the world’s largest family-owned companies and one of Germany’s most innovative companies.

Media contact:

Gregor le Claire
Head of Communications Bearings & Industrial Solutions
Tel.: +49 9721 91-3888
E-Mail: gregor.leclaire@schaeffler.com

Marco Bosch
Communications Bearings & Industrial Solutions
Tel.: +49 9721 91-1206
E-Mail: marco.bosch@schaeffler.com

SOURCE: Schaeffler AG