www.bearing-news.com
2015
P918438 - 2015 / 03
SEPTEMBER ISSUE 04
BEARINGS FOR THE
MARINE APPLICATION
BEARING INDUSTRY MAGAZINE
Image: ALLSEAS
PREVENTING FAILURES AT EXTENDING
SEA
Interview
EPTDA
Interview
CBIA
BEARING LIFE BREAKING THE ICE WITH
SPLIT ROLLER BEARINGS
BEARING INSTALLATION
APPLICATION & LUBRICATION MYTHS BearingCLOUD.com
in 5 QUESTIONS
INNOVATIVE ASSEMBLY PROCESS PROVES ITS WORTH
LEGAL ISSUES FOR BEARING MANUFACTURERS
Hans Hanegreefs
?
Zhou Yu
THE LAST 6 MONTHS
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Bearings for the
MARINE APPLICATIONS! Bearings needs to provide the reliability and flexibility in extreme working conditions out at sea. Our main topic in this issue is ”Bearings for the Marine Applications”. There are today hundreds of applications where bearings are used at sea under extreme conditions, causing crucial problems who needs to be solved. There are meanwhile various methods developed by bearing manufacturers to find solutions which can eliminate these problems. We highlighted in this current issue some of these critical applications, how to extend the life of bearings and how to prevent failures at sea. Further in this issue, we have “a BearingNEWS classic” two exclusive interviews with the two leading organizations in the bearing industry. The first interview is made with mr. Hans Hanegreefs, the Executive Vice President of the EPTDA (Europe, Middle-East and Africa Power Transmission Distributors Association) and discussed the global transformation of the power transmission distribution industry.
What’s rolling in the bearing industry? A brief summary of what’s happened during the last six months in the bearing industry, the details of the ‘Bearing Reliability Conference and Expo 2016’, shaft and bearing analysis by using automatic parameter variations, why bearing manufacturers and suppliers should adopt compliance programs, bearing installation, application & lubrication myths, electrically insulated rolling bearings. Together with all these interesting topics, many other bearing industry related articles, insights and developments can be discovered in this September issue of the BearingNEWS magazine. 136 pages full of BearingNEWS.. We hope that you will enjoy it!
Kenan M. Özcan Editor in Chief BearingNEWS
Our second interview is with mr. Zhou Yu, the Secretary General of the CBIA (China Bearing Industry Association) which members represents 70% of the total Chinese bearing industry turnover. We took together with him a look at the latest developments in the Chinese bearing industry.
Page: 4
Bearing News • Issue 4
Game changer Introducing SKF EnCompass Building on more than 100 years of bearing leadership and application experience, SKF is changing the game again. By addressing more of the factors that impact bearing life in real-world applications, the SKF EnCompass Field Performance Programme will change the way bearings are designed, manufactured, evaluated and selected. All to give you a field advantage. For more details about the programme, including new bearing life models and calculation tools, visit skf.com/encompass.
The Power of Knowledge Engineering ® SKF is a registered trademark of the SKF Group | © SKF Group 2015 ™ SKF EnCompass is a trademark of the SKF Group
What’s Rolling What’s Rolling...
BREAKING THE ICE SPLIT ROLLER BEARINGS FROM COOPER KEEP ICEBREAKER GENERATORS RUNNING
CASE STUDY: EXTENDING BEARING LIFE
LARGE SPHERICAL PLAIN BEARINGS FOR THE PIETER SCHELTE MEGASHIP
CASE STUDY: PREVENTING FAILURES AT SEA
ELECTRICALLY INSULATED ROLLING BEARINGS PROTECTION AGAINST BEARING DAMAGE CAUSED BY THE PASSAGE OF ELECTRIC CURRENT
一攀眀 伀瀀瀀漀爀琀甀渀椀琀礀 昀漀爀 䈀攀愀爀椀渀最 ☀ 倀⼀吀 䐀椀猀琀爀椀戀甀琀漀爀猀 圀漀爀氀搀眀椀搀攀
CASE STUDY: CUSTOMIZED SOLUTION FOR GYROFIN STABILIZER SYSTEM
䈀爀愀渀搀 一攀眀Ⰰ 䄀氀氀ⴀ䤀渀挀氀甀猀椀瘀攀 䈀攀愀爀椀渀最 匀攀愀爀挀栀 倀氀愀琀昀漀爀洀 眀眀眀⸀䈀攀愀爀椀渀最䌀氀漀甀搀⸀挀漀洀 椀猀 伀瀀攀渀 昀漀爀 匀甀戀猀挀爀椀瀀琀椀漀渀℀
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甀琀漀爀猀 䐀椀猀琀爀椀戀 伀渀氀礀 昀漀爀
挀漀洀 匀攀愀爀挀栀
䐀漀渀ᤠ琀 洀椀猀猀 琀栀攀 挀栀愀渀挀攀 愀渀搀 刀攀最椀猀琀攀爀 琀漀搀愀礀 漀渀 眀眀眀⸀䈀攀愀爀椀渀最䌀䰀伀唀䐀⸀挀漀洀
䄀氀氀 猀甀戀猀挀爀椀戀攀爀猀 眀椀氀氀 爀攀挀攀椀瘀攀 琀栀攀 瀀爀椀渀琀攀搀 Page: 6 䈀攀愀爀椀渀最一䔀圀匀 洀愀最愀稀椀渀攀 昀漀爀 昀爀攀攀 愀琀 琀栀攀椀爀 挀漀洀瀀愀渀礀 愀搀搀爀攀猀猀⸀
BearingCLOUD.com in 5 Question
page
41 Bearing News • Issue 4
g... INTERVIEW WITH HANS HANEGREEFS: MEET EUROPE’S, THE MIDDLE-EAST AND AFRICA’S LEADING POWER TRANSMISSION DISTRIBUTORS ASSOCIATION
page
42
EPDTA EVENT: BEARING RELIABILITY CONFERENCE & EXPO 2016
page
51
What Happened
page
in the
Bearing Industry First Half of
58
2015
INTERVIEW WITH ZHOU YU: A LOOK INSIDE THE DEVELOPMENTS OF THE CHINESE BEARING INDUSTRY
CBIA
page
94 Page: 7
SHAFT & BEARING ANALYSIS Use of cases for automatic parameter variations
RESEARCH: ESTABLISHING FAILURE MODES FOR BEARINGS IN WIND TURBINES
RESEARCH: THE LARGEST CENTRAL EUROPEAN BEARINGS MANUFACTURER MODERNIZES ITS PRODUCTION
MEETING: INNOVATIVE ASSEMBLY PROCESS PROVES ITS WORTH
LEGAL ISSUES: WHY BEARING MANUFACTURERS AND SUPPLIERS SHOULD ADOPT COMPLIANCE PROGRAMS
KNOW-HOW: BEARING INSTALLATION, APPLICATION & LUBRICATION MYTHS
PRODUCT KS PERMAGLIDE® PLAIN BEARING
LOW-MAINTENANCE AND MAINTENANCE-FREE PLAIN BEARINGS
Page: 8
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Bearing News • Issue 4
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Camille Huysmanslaan 27/15 2020 Antwerpen – BELGIUM Phone: +32(0)489 32 85 21 Fax: +32 (0)3 303 52 82 Email: info@bearing-news.com Web: www.bearing-news.com EDITORIAL Editor-in-Chief Kenan M. Özcan kenan@bearing-news.com Managing Editor Jake Fisher fisher@bearing-news.com Art Director Alpay Bilgindil alpay@bearing-news.com Photography/Illustrations Ksenia Shamanaeva ksenia@bearing-news.com Marketing & Advertising Cengiz Kaplan info@bearing-news.com Web & IT Canbey Bilgili bilgili@bearing-news.com Birsen Kırgöz birsen@bearing-news.com Subscriptions info@bearing-news.com
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BREAKING
THE
ICE
Split roller bearings from Cooper keep icebreaker generators running
Split roller bearing specialists Cooper has supplied bearings for the generators of an icebreaker operated by the Canadian Coast Guard. The on-board generators’ existing sleeve bearings had a short operational life and their maintenance required too much time and effort. Cooper has developed a solution consisting of split cylindrical roller bearings, which eliminate these problems without the need to modify the generator itself and which Bearing unit with split bearing from Cooper
Page: 10
Bearing News • Issue 4
minimize downtimes. To keep seas and inland waterways navigable during Canada’s long, severe winters, the Canadian Coast Guard operates close to 20 icebreakers of various classes for light, medium and heavy-duty tasks. These icebreakers are designed and equipped to navigate frozen sea. They have engines that are much larger and more powerful than those of other vessels of comparable size to be able to plough through the ice and carve a sufficiently wide navigable channel for other ships. On-board electricity is supplied by generators. Recently, problems occurred with the friction bearings of the on-board generators of one of the icebreakers, and this was followed by the same problem on other ships of the fleet. Each of the two generators has two bearings that hold the generator shaft – one fixed and one floating to allow the shaft to expand as it heats up. The existing sleeve bearings had an unexpectedly short lifespan and required excessively complex maintenance work, partly owing to restricted access to the bearings. The need for oil lubrication also presented generic problems and replacement parts from the manufacturer had long lead times.
Cooper bearing installed on the shaft, with support plinth and standard pedestal base
Fully installed split bearing unit
These problems called for a solution that did not require alteration of the generator itself: The new bearing would have to be a direct, ‘drop-in’ replacement. Since the icebreakers have heavy work schedules, downtime must be kept to a minimum. The Cooper solution was to provide a high-quality split cylindrical roller bearing as a direct replacement for the existing sleeve bearings. The split bearing has a special cartridge that holds the shaft-end cover and is mounted on a standard pedestal. A support plinth and elevating pedestal
Page: 11
were built to customer specifications to provide dimensionally identical support for the shaft. The new solution allowed rapid replacement without modification of the generator. The roller bearings are fully split up to the shaft, and the labyrinth seal is also of a split design. They have clear advantages over the previous sleeve bearings: Their design allows easy-access inspection and maintenance, since no other components need to be removed. This significantly cuts standstill times and maintenance effort. The bearings have a long service life and do not need oil lubrication, eliminating the need for pumps and filters and the risk of oil leaks. The bearings run cooler and consume less power. There is no longer a risk of damage to the shaft from bearing failure. Cooper bearings have been tried and tested in marine environments for many decades, and Cooper supplies both OEMs and subsuppliers. From offshore support vessels to ferries, military vessels, fishing boats and tugs, Cooper split bearings provide the reliability and flexibility crucial in extreme working conditions out at sea. Beside marine propulsion, they can also be found in other shipboard, transport and loading activities. The split bearing was designed in 1907 by inventor and engineer Thomas Cooper. To this day, the company he established in King’s Lynn in Norfolk, UK is a world leader in the development of split bearings. All Cooper products are made in Norfolk and sold throughout the world. Cooper’s German subsidiary – Cooper Geteilte Rollenlager GmbH – has its headquarters in Krefeld. Cooper’s full
range of split roller bearings includes standard bearings such as cylindrical roller bearings and tapered roller bearings as well as special bearings including water-cooled bearings, flat thrust bearings, other solid bearings, high speed bearings, full row bearings and other special types, and large bearings over 600 mm bore size. In addition to maritime applications, Cooper bearings are used in industries including steel, mining, conventional power, cement and other building materials where operating conditions are beyond the average – including situations that are often dirty and feature extreme temperatures. Typical applications beside marine propulsion include conveyors, fans and blowers, cooling beds, continuous casters, stacker reclaimers, and many other applications, especially where bearings are in trapped positions and access is limited. Company information: Cooper Roller Bearings, an SKF Group company, is a manufacturer of split-to-the-shaft roller bearings, producing all standard bearing sizes and housings with fast turnaround on large, custom-built units. The company was established in 1894 by Thomas Cooper, a prolific inventor and brilliant engineer, in King’s Lynn, Norfolk, where the company is still based today. Thomas Cooper designed the split bearing in 1907, and since then the company continues to lead its development. Split roller bearings from Cooper are used in industries including steel, mining, marine, conventional power and cement. Cooper has service and distribution centres in the UK, USA, Germany, China, India, Brazil and Australia and representation around the world. In 1991 the Kaydon Corporation with headquarters in Muskegon, Michigan, USA became Cooper’s parent company. Since 2013 part of the SKF Group, Kaydon is a leading designer and manufacturer of custom-engineered, performance-critical products, supplying a broad and diverse group of alternative-energy, military, industrial, aerospace, medical and electronic equipment, and aftermarket customers. www.cooperbearings.com
What Happened in the
Bearing Industry First Half of
Page: 12
2015
Page
58
Bearing News • Issue 4
EXTENDING
BEARING LIFE
The reliability of most rotating equipment is almost inevitably linked directly to bearing life, and it is estimated bearing failure is responsible for almost 21% of these equipment failures (Bloch, 2011). Research into bearing failures shows that just over half of these are a result of contamination of the bearing oil (Fig 1). Clearly it is therefore essential to ensure that contamination of the bearing lubricant is minimised and if possible eliminated if optimum bearing life is to be achieved thereby improving the equipment reliability (MTBF). Prevention of bearing lubricant contamination can be provided by use of commercially available bearing isolators (or “bearing protectors”) however before applying such devices it is advisable that the user ensures that the protection device used does not itself adversely impact on the equipment reliability. Here, Dr Chris Carmody [Special Products Manager] at AESSEAL explains how through the use of labyrinth design bearing protection seals, that bearing oil contamination can be eliminated. This is further demonstrated through the use of statistical modelling and analysis of field data such that a properly designed device will last at least as long as the theoretical life of the bearing it is protecting.
Figure 1 Causes of Bearing Failure1 1
Bloch, Heinz; “Pump Users Handbook: Life Extension” 2011
Page: 14
Bearing News • Issue 4
One of the significant contributors to bearing oil contamination is the bearing enclosure breathing process required by rotating equipment. When equipment rotates the bearing housing heats up and the oil/air mixture inside expands and this is forced through the seal (Figure 2). The real problem arises when the equipment cools because the oil/ air mixture cools and contracts sucking air from the external atmosphere through the bearing seal back into the housing (Figure 3). If bearing seals are to work effectively they must facilitate this ‘breathing cycle’ in order to extend bearing life. Figure 5: Traditional lip seals cause damage to shafts
Early bearing protection design
Figure 2: When the equipment rotates the bearing housing heats up and the oil / aid mixture inside heats up forcing air through the seal.
Figure 3: As the equipment cools the oil / air mixture contracts sucking air from the atmosphere through the bearing seal into the housing.
Figure 4: Water contamination on a continuous digester prior to a LabTecta® 66 being installed.
Figure 4 below shows the effect of water contamination on a continuous digester that was originally fitted with inadequate bearing protection. The moisture contained in the atmosphere was able to penetrate into the bearing housing. This was enough to destroy the bearings. Independent research, has shown that water contamination as low as 0.002% (20ppm) in some oils can reduce bearing life by as much as 48%. The challenge for maintenance and engineering professionals is to reduce this contamination and provide an effective method of sealing the space between the bearing
Historically the most common way of protecting bearings was to use a lip seal. Today however it is generally accepted that lip seals have limitations (due to inexpensive initial cost they continue to be widely applied). They also rely on surface contact between the seal lip and the shaft to form the seal. This surface contact often results in costly damage to the shaft itself (Fig 5). In addition, lip seals can’t fully protect the bearing from moisture or particle ingress, which ultimately results in bearing failure. Other factors to consider are that they have short service life compared to labyrinth seal designs, they cannot be used in API applications and they don’t prevent the loss of bearing oil and hence gradual loss of lubrication resulting in premature equipment failure. An alternative to lips seals are bearing protector seals. The design of bearing protectors varies significantly. Typically some of these bridge the gap between rotating and stationary components with an ‘O’ ring or wedge ring (Fig 6). These components often wear or don’t adequately effectively seal the
housing and the drive shaft. 2
Schatzberg and Flsen 1983, “Effects of Water and Oxygen During Rolling Contact Lubrication”, Wear, Volume 12, 1968, pp. 331-342.
3
Cantley 1977 “The Effect of Water in Lubricating Oil on Bearing Fatigue Life”, ASLE Transactions, Volume 20, No. 3.
Figure 6
Page: 15
bearing housing. As a consequence of this many of these designs are now viewed as out dated and ineffective.
Labyrinth design In recognition of these shortcomings, more advanced labyrinth bearing protection seals have been developed, which can offer dust tight protection against both solids and liquids and are also non-contacting in operation. LabTecta®66 is one such labyrinth bearing protection seal that incorporates patented dynamic lift technology to protect against the ‘breathing’ issues that contribute to 52% of all bearing failures5. This dynamic lift technology uses the centrifugal force of rotating equipment to open a temporary micro gap allowing expansion of the oil air mixture in the bearing housing, which consequently allows the equipment to breathe (Figure 7).
Rated to IP66 of the ingress protection code, LabTecta®66 is capable of reducing water contamination of the bearing oil from as high as 83% to just 0.0003% compared to lip seals, even when exposed to high pressure water jets. The range is ATEX certified for use in explosive environments and a number of special designs make it suitable for a wide and varied range of applications. LabTecta®66 is also designed with a thinner cross section and seal length than competing devices, which means that it can be retrofitted on more equipment without having to carry out modifications. Furthermore the design of the LabTecta®66 enables it to be positioned differently on the shaft meaning shafts already damaged can be fitted with LabTecta®66 without replacing the shaft.
Life expectancy LabTecta®66 is a labyrinth bearing seal design that is non-contacting during operation. Once the seal starts to rotate centrifugal forces acting on the dynamic o ring forces it outwards creating a micro gap and hence no wear can take place during rotation. Therefore, a carefully specified, properly installed and operated non-contacting labyrinth bearing protector can have an infinite life expectancy.
Fig 7 Centrifugal force causes a temporary micro gap to be created allowing expansion of the oil air mixture in the bearing housing, allowing the equipment to breathe
When the equipment stops rotating the micro gap immediately closes forming a perfect seal (Figure 8). This prevents dust and moisture being sucked back into the bearing housing and eliminates bearing oil contamination.
Year
Quantity Supplied
Number of Returns
2006
5182
5
2007
11721
1
2008
17714
5
2009
14245
10
2010
16925
8
2011
20993
7
2012
20132
6
2013 (Aug)
13785
10
Note: All reported failures were attributed to installation errors. None of the instances were design or wear failures Table 1 details the recorded LabTecta® 66 returns between January 2006 and September 2013 (note that the first occurrence was in June 2006).
A recent research paper produced by AESSEAL® analysed the 120,000-plus LabTecta®66 products that had been supplied in the 8 years since the product was launched. During the period from January 2006 to September 2013 only fifty two of the 120,000 plus LabTecta®66 bearing protector seals were removed from service. After detailed
Fig 8 When the equipment stops the micro gap immediately closes 7
Heinz Bloch, “Rotating Seals or lip seals” Plant Engineering July/August 2014
8
Heinz Bloch and A. Budis. Pump Users Handbook: Life Extension 2nd Edition 2006
Page: 16
6
AESSEAL Internal Test Results
Bearing News • Issue 4
examination, it was concluded that any abnormality was found to be operator based (such as misinstallation and lubricant overfilling) and that the failures were not actually attributable to the design of the product. The research also conducted an accelerated life test with a stop start cycle of 4 times a day, which determined that the average LabTecta®66 life expectancy was over 10.5 years. The paper also showed that by using an established statistical (WeiBayes) technique, the average life expectancy was also in excess of 10.5 years. However, because such statistical data can only be modelled with failure data, and as no LabTecta®66 has ever failed, the results have to be viewed as conservative. With an average life expectancy of over 10.5 years a LabTecta®66 bearing protector seal has been proven to be the most effective way of protecting and extending the life of the bearing fluid and hence the bearing itself. The cost of this kind of protection is minute compared to equipment failures, machine downtime, lost production and more onerous maintenance requirements that are caused by premature bearing failure. The real life examples of LabTecta®66 in service today show that such upgrades can have payback periods of as little as 1 month. Even in the arduous moisture laden environments frequently found in pulp paper manufacture, LabTecta®66 has the longevity that both experimental and statistical data suggests. The following are examples of some of the many LabTecta®66success stories we have to date.
Case Study 1 A leading paint manufacturer was experiencing unacceptable reliability levels on a badly aligned bottom entry paint mixer. Leaking paint was entering the motor bearing through the OEM lip seal, causing the motor to fail on average every 2 months, costing over £6,000 a year. The cost of replacing the lip seal with the LabTecta®66 was repaid within 1 month of fitting and has currently increased the MTBF of this application by over 500%. The LabTecta®66 upgrade is saving the customer over £6,000 per annum in reduced maintenance costs and an expected 9.5 days per year of lost production.
Case Study 2 7
A paper mill in Maine, USA was having issues with water and stock getting into their Hydropulper gearbox. This was shortening the life of the gearbox and was costing the mill up to $50,000 per outage. The Hydropulper gearbox has a vertical shaft that is sealed with packing and leaks excessive amounts of stock and water down into the gearbox which was sealed with a lip seal. AESSEAL® installed a LabTecta®66TE (top entry) bearing protector seal in August 2006, and over 8 years later is still giving the paper mill uninterrupted service.
Case Study 3 A coal fired power plant in the USA, was having 3 - 4 bearing failures a year on their primary air fan. For safety reasons the customer would inert the fan duct with steam to reduce the risk of a flash fire from the coal dust in the system. This safety procedure was causing water to get into the pillow block bearings, leading to premature bearing failure, and a $10,000 to $12,000 bearing replacement cost. AESSEAL® installed a LabTecta®66RDS (Radially Divided Seal) on the drive end to ensure no heavy equipment needed moving or shaft realignment was necessary, and a standard LabTecta®66 on the non drive end. The LabTecta®66 bearing protectors have been installed and running trouble free for over 2 years, saving the customer over $80,000 in bearing replacement costs. For more information on LabTecta®66 from AESSEAL®, visit: www.labtecta.com, or call: 44 (0) 1709 369966. About the author Dr. Chris Carmody PhD, MSc BEng (Honours) started his career as a maintenance engineer in the chemical and process industry and joined AESSEAL as the companies first full time seal designer and development engineer. Chris went on to academia for a bachelors degree, a master of science in structural integrity and doctoral degree on the fluid structure interaction of bioprosthetic heart valves. He re-joined industry as a Consulting engineer and worked on many prestigious projects such as the A380 Airbus, the award winning Falkirk wheel and the new Wembley s tadium. Chris returned to AESSEAL and took up the position of special products manager where he is responsible for development of high integrity sealing projects including dry gas seals. He now has 25 years of experience in the design of mechanical seals and is a named inventor on many of AESSEAL product designs. In addition to his responsibilities at AESSEAL he also sits on several different bodies including the API692 Compressor Dry Gas Seal Committee Bloch, Heinz; “Pump Users Handbook: Life Extension” 2011.
C. Carmody and C Rea. “Predicting product life expectancy of the LabTecta bearing protector” Sealing Technology, August 2014
Page: 17
LARGE
Spherical Plain Bearings
for the Pieter Schelte
MEGASHIP Page: 18
Bearing News • Issue 4
The Pieter Schelte, built by offshore contractor Allseas, is the world’s largest working ship. (Image source: Allseas). Page: 19
for the Pieter Schelte
LARGE
Spherical Plain Bearings
MEGASHIP
Maintenance-Free with a High Load Carrying Capacity Plain Bearings in X-life Quality Plain bearings can fully demonstrate their advantages in crane and water power applications, as they are perfectly suited to the slow rotary, swiveling, and tilting motions that occur there under very high loads. Schaeffler has systematically expanded its range of plain bearing solutions and offers a wide range of maintenance-free plain bearing materials. In addition to the maintenancefree plain bearings with ELGOGLIDE that have proven themselves for many years, the product range also includes metal-polymer composite plain bearings and plain bearings with ELGOTEX. Schaeffler has been able to obtain its largest order for ELGES spherical plain bearings to date for the “Pieter Schelte” working ship. Schaeffler is supplying a total of more than 240 bearings with outside diameters ranging from 400 to 1060 mm for the “topsides lift system”, which is used for oil platform installations.
ELGOGLIDE – proven quality with the highest requirements The advantages of bearings with ELGOGLIDE are their total freedom from maintenance and very high load carrying capacity, especially in the case of very high unilateral loads and swiveling
motion. ELGOGLIDE stands for a sliding layer that primarily comprises a technical woven material made from support fibers, PTFE fibers, and a synthetic resin matrix. Our special ELGOGLIDE W11 variant allows minimal friction values even at low pressures.
Metal-polymer composite plain bearings – cost-effective within the smallest space The special characteristics of metal-polymer composite plain bearings are down to the combination of plastic and metal materials. This material compound enables low-wear sliding characteristics combined with a high load carrying capacity and thermal conductivity. The resistance of the metal-polymer composite plain bearings has been tested for a wide range of media. The optional design with bronze backing allows the bearings to be used in water. The metalpolymer composite plain bearings are a costeffective alternative for applications with minimum available space and a comparatively high sliding speed.
ELGOTEX – maintenance-free, wearresistant, and waterproof Bearing positions subjected to high loads, such as those found in construction and agricultural machinery, conveying equipment, and transport vehicles, are conventionally equipped with solid plain bearings lubricated with grease or oil. Plain bearings with ELGOTEX are an ideal replacement for existing solutions requiring maintenance that uses environmentally friendly and maintenancefree technology. These bearings are maintenancefree throughout their operating life due to the material combination used, and are perfectly suited
As soon as the ship moves around a drilling platform that is firmly anchored to the seabed, the enormous loads caused by the waves and acting on the ship have to be compensated. The TLS levers allow for these wave motions. The hydraulic cylinders of the TLS in turn ensure that the platform topsides can be elevated and lifted off safely.
Page: 20
Bearing News • Issue 4
pipelines, it is equipped with a “topsides lift system” (TLS) that has a capacity of up to 48,000 tons and enables the installation of even the heaviest platform topsides, while its “jacket lift system” (JLS) can remove and install steel platform substructures weighing up to 25,000 tons in one piece. Schaeffler supplies maintenance-free large spherical plain bearings with an ELGOGLIDE sliding layer to Allseas for the TLS levers and to Bosch Rexroth for the TLS hydraulic cylinders. Schaeffler supplies maintenance-free large spherical plain bearings with an ELGOGLIDE sliding layer to Allseas for the TLS levers.
to use in tough environmental conditions. INA plain bearings with ELGOTEX WA were specially developed for use as rudder bearings and in stabilizers for marine applications. Germanischer Lloyd has certified ELGOTEX WA for loads of up to 15 N/mm² in marine applications. The salt water-resistant ELGOTEX WA material comprises two layers. The internal sliding layer, which is embedded in a resin matrix with fillers and solid lubricants, is made of continuous synthetic and PTFE fibers. The external layer also comprises continuous glass fibers in epoxy resin. This combination of materials allows a consistently low friction value and a low level of wear to be achieved in addition to absolute freedom from maintenance.
ELGES large spherical plain bearings in X-life quality – the “Pieter Schelte” working ship The Pieter Schelte, built by offshore contractor Allseas, is the world’s largest working ship. In addition to installing oil platforms and laying
As soon as the ship moves around a drilling platform that is firmly anchored to the seabed, the enormous loads caused by the waves and acting on the ship have to be compensated. The TLS levers allow for these wave motions. The hydraulic cylinders of the TLS in turn ensure that the platform topsides can be elevated and lifted off safely without any damage occurring. The bearings must have a very high load carrying capacity, both for load compensation and to allow for the motion of the hydraulic cylinders. Our spherical plain bearings in X-life quality are equipped with extremely robust and maintenancefree ELGOGLIDE material. Offshore use of the bearings requires very high corrosion resistance, high moisture resistance for the sliding material, and freedom from maintenance over an operating life of at least 25 years. The bearings have been certified by Lloyd’s Register to meet the safety requirements of the marine industry. The screw connection of the axially split outer ring was optimized as part of the introduction of X-life for ELGES large spherical plain bearings. The fabric additionally undergoes special treatment before the hardening process in order to improve its adhesive properties and optimize moisture resistance. Overall, X-life optimization has resulted in 15% higher load ratings and a 15% increase in rating and operating life. This also means additional benefits for the customer, including downsizing opportunities and a higher power density, longer service intervals, and an increase in overall costeffectiveness (TCO).
ELGES large spherical plain bearings in X-life quality feature an outer ring equipped with an ELGOGLIDE fabric sliding layer and allow low-friction sliding motion with a very high load carrying capacity.
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Bearing News • Issue 4
PREVENTING FAILURES at
SEA
By Adrian Messer, CMRP, UE Systems Inc.
Page: 23
PREVENTING FAILURES at
SEA
Imagine this: you’ve worked hard all of your life, you’ve raised your children, put them through school, and provided a good life for you and your family. Now, you’ve decided to take the vacation that you’ve always dreamed about. You book a cruise for you and your spouse. It’s what you’ve always wanted to do. You set sail, and you’re having a great time. You’re hundreds of miles out at sea and having the time of your life, along with thousands of other people who are also onboard. All of a sudden, there’s a loss of power while you’re having dinner. It’s dark, and the staff begins to reassure everyone that power will be restored momentarily. Hours go by, and still no power. Temperatures inside the cruise liner begin to rise. There’s no fresh water, and food begins to spoil. All of a sudden, that trip of a lifetime quickly becomes a trip that you wouldn’t wish on your worst enemy. Too often in recent news, we have seen headlines with similar stories of stranded ocean going vessels. Vessels that have become stranded due to failures that could have possibly been detected much earlier through the use of condition monitoring tools such as ultrasound, infrared cameras, vibration analysis, or even oil analysis. The necessary repairs could have then been planned for accordingly, and the repairs made with little to no interruption to passengers or shipping. Condition monitoring tools are widely used throughout various manufacturing plants and facilities world-wide to routinely monitor the health of the assets that are making products, providing utility services, as well as other vital services that many of us take for granted on a daily basis. Cruise ships and other ocean going vessels should be no different,
Page: 24
How ultrasound technology can be used on off shore vessels to prevent catastrophic failures especially when thousands of people’s lives are at risk while hundreds of miles out to sea. Cruise ships aren’t the only ones at risk though. There are literally thousands of vessels crossing our waterways on a daily basis, including off shore oil rigs. When it comes to condition monitoring tools, one of the most versatile tools available is airborne & structure-borne ultrasound. These handheld, portable instruments are typically used for applications such as compressed air & gas leak detection, bearing & motor condition monitoring, pumps, gearboxes, and electrical inspection by detecting corona, tracking, and arcing of energized electrical equipment. Other applications that are specific to marine and off shore vessels include diesel engines, steam traps, valves, and hatch/ tightness testing. Ultrasound technology can easily be deployed on ships and other ocean going vessels and can be used while at port or at sea.
How Ultrasound Works Ultrasonic instruments are listening devices that sense and detect high frequency sound that is normally inaudible to human hearing. The threshold of normal human hearing, that is to say, the maximum frequency at which humans are capable of receiving sounds is around 16kHz to 17kHz. The frequency range of the ultrasonic instrument begins at 20kHz and can be adjusted to 100kHz. So, the instruments are “listening” for sound that is above the range of normal human hearing. Once the instrument detects the ultrasound, it heterodyned or translated by the instrument to an audible sound that is heard
Bearing News • Issue 4
through the headset by the person performing the inspection. The sound is also measured by the ultrasonic instrument as a decibel level (dB) which is also displayed onboard the instrument. The high frequency sound travels via a solid or a gas; therefore, there are airborne ultrasounds and structure-borne or contact ultrasounds. Examples of airborne ultrasounds are compressed air/gas leaks, steam leaks to atmosphere, and electrical inspection of energized electrical equipment. Structure-borne or contact ultrasound inspections would include bearings, gearboxes, pumps, valves, and steam traps. There are also three main sources of ultrasound. First is turbulence, such as a compressed air/ gas leak. Internal turbulence can also be detected by using the contact approach. For example, turbulence is created when a valve is leaking by. The inspector would make contact on the outlet or discharge side of the valve and would be able to hear the valve leak by. Second is friction. An example of friction producing ultrasound would be a bearing that has a lack of lubrication. Third is ionization. Ionization is produced by electrical discharges such as corona, tracking, and arcing.
the motor and shows a very distinct fault harmonic. It was determined that the motor with the fault harmonic had an inner race bearing fault.
Figure 1: Outboard bearings on a 60hp motor
Figure 2: Outboard bearings on an identical 60hp motor showing an inner race bearing fault
The instrument that was used to collect this data also had onboard spectrum analysis capability. The inspector was able to see the FFT and Time Wave Form on the display as the data was collected. Figure 3 is a screen shot from the display of the ultrasonic instrument that also shows the inner race harmonic.
Mechanical Inspection with Ultrasound Ultrasound is rapidly becoming the first line of defense tool to inspect and monitor bearings. Ultrasound technology has proven to be very good at finding incipient, or early stage bearing wear and fatigue, thus giving an earlier indication of failure. Even before bearing temperature increases and particle debris discovered during analysis of oil samples. Ultrasound can be used on gearboxes to find faulty gear teeth, pump cavitation, and is very effective on slow speed bearings. For bearings, an indication of bearing failure is noted by an increase in amplitude or decibel level. A bearing that is in a “good� condition will have a much lower decibel level than one that is in a failure mode, such as an inner race or outer race fault. To further aid in diagnosing mechanical problems with ultrasound, instruments with onboard sound recording can be used. Recording the sound of the bearing allows for further diagnosis of the bearing condition through FFT & Time Wave Form analysis. The FFT examples below are a comparison between two identical 60hp motors. Figure 1 is a recording of the bearings on the outboard end of the motor. Figure 2 is recording of the bearings on the outboard end of
Figure 2: Outboard bearings on an identical 60hp motor showing an inner race bearing fault
Further comparison can also be done by using the FFT Overlay feature in a spectrum analysis software, such as the Spectralyzer software from UE Systems. The FFT Overlay feature allows the user to have up to four FFT’s displayed on the screen at the same time (Figure 4). This is a great way to compare up to four identical points on four identical machines. Or, to compare a baseline sound file to a recorded ultrasound of when the same point reaches a critical failure mode. Marine type diesel engines (Figure 5) can also be inspected using ultrasound. Both airborne & contact methods can be utilized. Airborne ultrasound inspections on marine engines include compression leaks, leaks on the air intake system such as loose or cracked hoses, small leaks around fittings, and any orifice where turbulence is created by the vacuum created when the engine is in operation. Structure-borne or contact applications for which ultrasound can be used include valves, Page: 25
pistons, cylinders, and solenoids.
a more diagnostic inspection should be performed to determine why the dB did not change. It could be that the bearing is in a failure mode that is beyond a lack of lubrication.
Figure 6: Recorded ultrasound of a bearing in the process of being lubricated. Note the before and after lubrication
Figure 4: FFT Overlay showing four identical points on four identical machines. One has an obvious fault harmonic
Figure 5: Caterpillar C280-12 Source: www.marine.cat.com
Lubrication issues can also cause failures as well. Studies show that the majority of premature bearing failures can be attributed the lubrication. Whether it’s a lack of lubrication, over lubrication, using the wrong grease for the wrong application, or contaminated/dirty lubricant, all of these are related to lubrication. Ultrasound instruments can be used to listen to bearings while applying lubricant. The source of the ultrasound is friction. When a bearing is in need of lubrication, there is an increase in friction; therefore, an increase in dB. If the inspector is listening and watching the dB while greasing, there will be a gradual drop in dB as grease is applied. Once the dB has dropped back down to a normal level the inspector would stop greasing (Figure 6). In some cases, after the dB has dropped, if another pump of grease is added, the dB may actually start to slowly increase. If this is noted while greasing, the bearing has been sufficiently lubricated. An increase in dB will also be noted if grease is applied to a bearing that is already has enough grease (Figure 7). If grease has been applied, and there is no change in the dB, then Page: 26
Figure 7: Recorded ultrasound of a bearing that has been over lubricated. Note the increase in amplitude once the bearing has reached over lubrication
Electrical Inspection with Ultrasound When it comes to electrical inspection, ultrasound instrumentation can be used on almost any energized electrical equipment including metalclad switchgear, transformers, substations, relays, and motor control centers just to name a few. Ultrasound can be used on low, medium, and high voltage systems. Traditional inspection of energized electrical equipment has been performed by noncontact infrared cameras. However, in recent years, ultrasound has been deployed as an added means of safety. When ultrasound is used, the inspection can be done without opening energized electrical equipment. Since the test is noninvasive, there is a decreased risk of arc flash. If there is a condition such as corona, tracking, or arcing taking place inside of the equipment that is to be inspected, the airborne method is used (Figure 8) to scan any openings on the equipment such as vent opening, louvers, or even the seal around the cabinet door. The ultrasound created from the electrical anaomaly inside the equipment will be heard via those Figure 8: Airborne electrical inspection being done on electrical equipment openings. Making use of recorded ultrasounds of electrical anaomalies is also very useful, and is the only way to diagnose what is being heard by the inspector. Corona, tracking,
Bearing News • Issue 4
and arcing each have distinct characteristics that can be identified in both the FFT and Time Wave Form view in the spectrum analysis software. Figure 9: Arcing as seen in the Time Wave Form The example below (Figure 9) is from a recorded sound file of arcing which can be described as erratic sudden bursts of electrical energy that is searching for a pathway to ground.
for instance will have a very distinct cycling sound when the trap opens to release steam. A float & thermostatic trap will have more of a continous flow sound since the trap is not designed to cycle like an inverted bucket trap. The inspector will hear more of a continuous modulating sound as the float inside the trap rises and falls on the condensate inside the trap.
Leak Detection with Ultrasound The most widely used application for ultrasound is for compressed air/gas leak detection (Figure 10). It is by far the easiest application for the technology, and there are many benefits associated with using ultrasound for compressed air/gas leak detection. One advantage for using ultrasound for compressed air/ga leak detection is that the inspection can be performed in areas where it is noisy. Since the ultrasound instruments are only listening for the high frequency sound that humans can’t hear, it makes it very easy to locate leaks in areas of high background noise such as engine rooms or mechanical rooms. Leaks as small as 10-2 standard cubic centimeters per second at 5psi can be found using ultrasound. Marine hatch testing would also be an airborne ultrasound application. With this method, ultrasonic tone generators that emmit ultrasonic signals are placed in strategic areas inside of the bulkhead. The inspector closes and seals the hatch and begins to scan around the seal of the hatch. Anywhere there is a potential for leakage around the seal, the sound from the ultrasonic tone generators that were placed in the bulkhead area will be heard in the headset by the inspector. This is an easy and repeatable test to perform and may even be required by some marine insurance companies. Leak detection applications aren’t just limited to airborne inspections. Structure-borne leak detection includes valves and steam traps as well (Figure 11). When making contact with the outlet or discharge side of a steam trap, the inspector will be able to hear if the steam trap is working properly. When testing steam traps, trap identification is a must. Depending on the type of trap, will determine what the trap is supposed to sound like. A disc trap or an inverted bucket trap
Figure 10: Checking for compressed airleaks
Figure 11: Steam Trap testing
Valve leak detection can also be done with ultrasound. When valves leak or fail, the consequences can be severe in some cases. Especially when safety and energy loss are at risk. Similar to a steam trap, the source of the ultrasound in valve leakage is turbulence. As a fluid or gas moves from the high pressure side of the valve to the low pressure side, turbulence is produced. To inspect a valve, an A,B,C,&D method is recommended. Contact is made at the A point Page: 27
which is slightly upstream of the valve, Point B closer to the inlet side of the valve, Point C close to the outlet side of the valve, and Point D slightly downstream of the valve. The dB values are noted at each of the four points. If the valve is in a leak by condition, there will be a higher dB reading at Point C due to the turbulence created by the high pressure fluid/gas leaking across the valve seat (Figure 12). Point A and Point D readings are taken to ensure that the ultrasound is not coming from either further upstream or downstream of the valve. Time wave form analysis of recorded ultrasounds can also aid in diagnosis.
Figure 12: A,B,C,&D Valve testing showing C having the higher dB reading indicating valve leakage
Conclusion Airborne & structure-borne ultrasound is a versatile technology that can be used for many marine and offshore applications. Due to its versatility, it is complementary to other technologies that are currently in use on vessels and other marine applications such as vibration analysis and infrared thermography. For areas with little to no accessibility due to safety issues or areas that are just out of reach, remote monitoring can also be done. Remote sensors can be used to connect directly to the hand-held ultrasound instrument, or wired into the ship’s monitoring system. Ultrasound is another tool that can be used to find failures early before they become catastrophic. Additionally, operational impact can also be observed in more efficient planning and scheduling of repairs and in spare parts inventories. When safety and human lives are at risk, finding failures early and making necessary repairs can help to avoid loss of life and the negative press that comes along when things go wrong at sea.
STOP KILLING YOUR BEARINGS! DEFEND THEM WITH ULTRASOUND
The majority of premature bearing failures are lubrication related. Start using ultrasound assisted lubrication to reduce bearing failures. Simultaneously lubricate and monitor ultrasound levels on the display of the Ultraprobe® 401 Digital Grease Caddy Pro to prevent over-lubrication.
Prevent over-lubrication > Prolong equipment life
Monitor and trend
> Improve maintenance efficiencies
Analyze and report
> Decrease operating costs
Windmolen 22 • 7609 NN Almelo • The Netherlands • +31 (0)548 659 011
www.uesystems.eu
NKE SQ77E deep groove ball bearing with insulation on the inner ring.
Electrically Insulated
Rolling Bearings Protection against bearing damage caused by the passage of electric current Electrically insulated rolling bearings feature electrical insulation that is built into the bearing, providing reliable protection against current passage and electrical corrosion. Typical applications are electric motors, generators and other electrical machines. The Austrian manufacturer NKE Austria GmbH offers electrically insulated rolling bearings in several versions. In this article, Klaus Grissenberger, Application Engineer with NKE, explains the causes of passage of electrical current through rolling bearings, damage symptoms and countermeasures, properties and production processes of electrically insulated bearings. A difference in electrical potential between the outer and inner ring of a rolling bearing can lead to a damaging electric current that permanently damages the bearing’s raceways and impairs its running characteristics. A current flow results in electrical discharge in the contact zone between the rolling elements and the inner or outer ring. This, in turn, causes local melting of the surfaces. The result: pitting, material transfer and local microstructural damage through thermal stress. At least a very thin layer of the eroded surface is re-hardened, making it extremely hard and prone to cracking. This process is called electrical corrosion and often affects bearings in electromechanical applications, such as generators and electric motors, but also machines that are powered by electric motors, such as pumps and gearboxes. In addition, the electric discharge renders the lubricant useless. The base oil and additives contained in the lubricant oxidise, resulting in the characteristic black colour of the lubricant. Premature ageing permanently impairs the lubricant’s ability to form a separating layer between the metal surfaces. The bearing’s damaged Page: 30
functional surfaces and the loss of lubrication action result in a rapid loss of the bearing’s functionality.
Possible causes of undesirable passage of electrical current through rolling bearings The main reasons for current discharge are known. Asymmetries in the magnetic flux of an electrical machine give rise to a low-frequency voltage
Fig.. 1.a
Bearing News • Issue 4
an oxide ceramic insulation layer. An overview of the various design variants of the insulation layer is given in the table. Electrically insulated rolling bearings from NKE offer exactly the same outer dimensions and technical characteristics as the corresponding uninsulated types.
Fig.. 1.a
between the shaft and the housing, which results in a flow of current through the rolling bearings. Such a passage of current can also result from the use of unshielded asymmetrical electric cables if the earth connection of the machine is ineffective. Another cause is the use of frequency converters: The operating principle of many frequency converters is based on pulse width modulation (PWM) and generates high-frequency common mode voltage, which also results in a passage of current through the rolling bearings. Lastly, electrostatic charging of the shaft and housing followed by discharge through the rolling bearings is also a possible cause.
The most important advantages of these bearings are higher operating reliability, which is assured by optimal protection against electrical corrosion. Electrically insulated bearings are less expensive than, for example, applying insulation to housings or shafts. They are interchangeable with conventional bearings because they have the same key dimensions and technical characteristics. They also offer a reduced risk of damage and thus also longer operating life than conventional bearings when used in electrical machines. When electrically insulated bearings are handled properly, there is no risk of damage to the coating. The main range of electrically insulated bearings consists of cylindrical roller bearings and deep groove ball bearings, but all other bearing types can also be electrically isolated. Application areas include traction motors of railway vehicles, electric motors and generators, particularly in conjunction with fast-switching frequency converters.
Damage symptoms and possible countermeasures
Production process and operating principle of electrically insulated rolling bearings
Typical signs of electrical corrosion include grey, tarnished tracks in the raceways and on the rolling element surfaces. Melt craters (Figs. 1a and 1b) or fluting is also discernible, mainly on the raceway surfaces. Damage due to current discharge usually manifests itself in increased running noise.
For electrically insulated bearings from NKE, the insulating layer is applied to the outer ring (SQ77 or SQ77C – Fig. 2a) or the inner ring (SQ77E or SQ77H – Fig. 2b) by plasma-spraying, a thin-film technology. During plasma- spraying, an electric arc is created between two electrodes with a suitable gas supply. The plasma jet serves as a carrier medium for applying the aluminium oxide powder (Al2O3) either to the outer or inner ring at high velocity. In order to obtain optimum protection the oxide layer also covers the side faces of the sprayed rings. In the next process step, the layer is then sealed to prevent any penetration by moisture.
In order to prevent damage of this kind, it is advisable to insulate the bearing seat in the housing or on the shaft. However, this entails additional design measures of the surrounding parts. A simple, economical solution in this case is to use electrically insulated rolling bearings from NKE. Since the key dimensions and performance data of the insulated bearings is identical with those of the corresponding uninsulated models, no changes to the overall design are required.
Electrically insulated bearings – properties and application Electrically insulated bearings from NKE, designated with the suffix SQ77, are provided with
The physical effect of the insulation layer depends on the frequency of the voltage that causes the harmful currents in the bearings. In the case of DC voltage, the insulated bearing has Ohmic resistance. The higher this resistance is, the lower the electrical current. The resistance value of the insulated bearings is greater than 50 MΩ, thus limiting the electrical current to a level that cannot cause damage to the bearing. Page: 31
high as possible in order to reduce the current to a level that is incapable of damaging the bearing.
Figs. 2a and 2b: For electrically insulated bearings from NKE, the insulating layer is applied to the outer ring (SQ77 or SQ77C – Fig. 2a) or the inner ring (SQ77E or SQ77H – Fig. 2b) by plasma-spraying, a thin-film technology.
In the case of AC voltage the capacitive nature of the insulated bearing is advantageous. The bearing then behaves in approximately the same way as a parallel circuit consisting of a resistor and a capacitor with a frequency-dependent resistance, called impedance. The impedance determines the magnitude of the alternating current that flows through the bearing for given values of voltage and frequency. Here too, the impedance should be as
To achieve high impedance values, the resistance of the insulating layer must be high and its capacitance must be low. This can be achieved by making the insulating layer as thick as possible and by reducing the overall insulation surface area. When transferred to the bearings, this means that this layer should preferably be applied to the bore of the inner ring. However, the coating is usually applied to the outer diameter for reasons of cost and due to the constraints of the manufacturing process. In most cases, this still results in more than adequate protection against damage from electrical corrosion. Another important property of the coating is its dielectric strength. Depending on their version, the bearings from NKE have a dielectric strength of at least 1000 V or 2000 V.
Table: Overview of the design variants of electrically insulated NKE rolling bearings:
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Bearing News • Issue 4
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Customized Solution for Gyrofin Stabilizer System Stefano Cugno - RKB Europe SA “Gyrofin Stabilizer System” is a special project developed by RKB in cooperation with a prestigious European shipbuilding corporation. The main scope of this project was to design some customized roller bearings for a stabilizer fin system of a ship. The ideal solution was found by RKB Technical Team Unit in two large size spherical roller bearings with bore diameter up to 950 mm. This engineering solution was supported synergic ally by design process (sophisticated calculations, 2D-3D CAD, and FEM analysis), and manufacturing technology (suitable bearing steels and advanced machining processes).
Introduction The operating economics of a cargo or cruise ship are affected by the motions and forces due to rolling, which can cause ship damage and discomfort to the crew and passengers. To solve these problems a variety of roll stabilization systems has been developed. Anti-rolling tanks and fin stabilizers are typical examples of roll stabilizing devices. Of all stabilization systems, the fin stabilizer is particularly effective when a ship has relatively high speed, due to its active control. Fin stabilizers are widely used for cargo and cruise ships requiring high seakeeping performance in waves. The fin stabilizer system is a hull stability equipment that reduces ship rolling up to 90% by using the generating lift of the fins extended to both sides of a ship. Active control stabilizer fins are usually mounted on rotatable stocks at the turn of the bilge near the middle of the ship. The fin angle of incidence is continually adjusted by a control system (gyroscope) that is sensitive to the rolling motion of the ship. The stabilizer system that uses a gyroscope, as a control unit, is called gyrofin
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stabilizer system. The gyrofin stabilizer develops lift forces that generate roll moments about ship’s center of gravity. In this way, the roll moments are arranged to oppose the moment applied by the waves and the roll motion is reduced. Usually, at speeds above 10-15 knots, stabilizer fins are the most effective solution to stabilize a ship. However, as fins usually are not designed for ships operating at low speed, their effectiveness decreases as ship speed Fig. 1 - Retractable gyrofin reduces. Retractable fins are often required for cargo and cruise ships. The active fins can be withdrawninto the hull when the ship operates in calm weather conditions to eliminate their small resistance with the water (figure 1).
Technical specifications Gyrofin stabilizer system is designed as a complete system consisting of a hydraulic driven fin, fin drive unit, electro-hydraulic power unit, electric power controls and gyroscope control unit (figure
Bearing News • Issue 4
2).
RKB engineering solution
Gyrofin stabilizer is an active system designed to reduce the rolling when the ship is in the water. Every ship has two stabilizer fin systems, one for port side and one for starboard side. The arrangement being such that, the gyroscope senses the ship rolling movement and commands the electro-hydraulic power unit to correct that movement by inclining the fins to the oncoming flow by fin drive unit, and a net upward lift force is developed on the descending side of the ship.
From container carriers to cruise ships, the engineering solutions supplied by RKB enable vessels to operate more efficiently. Considering the technical requirements imposed by all shipbuilding companies, the ideal solution for this project was found by RKB Technical Team Unit in two large size application-optimized spherical roller bearings with bore diameter up to 950 mm, for support of both sides of the fin shaft (figure 3). Both bearings have tapered bore and are mounted on the shaft by using adapter sleeves. RKB solution was supported by Fig. 3 - RKB spherical roller bearing and sleeve during mounting on the fin shaft design process, which involves high-level calculations, 2D-3D CAD and FEM analysis, and by manufacturing technology, which means top quality materials, advanced machining processes and leading-edge heat treatments.
The fin drive unit contains Fig. 2 - Gyrofin stabilizer system: 1) driven fin; 2) fin drive unit; 3) ship hull; 4) the shafting, ship side; 5-6) electro-hydraulic power unit bearings, seals, drive components locking device and all other mechanisms to produce the driving forces and support the reactive forces produced by the fin. The determination of the stress levels for all these components and mechanisms at specific conditions includes cyclic load factors, because the stabilizer fin movement is cyclic and repetitive. The design stress cannot exceed 35% of the material yield stress at specific operating conditions or 70% of the material yield stress at maximum overload conditions. Generally, for the fin shaft large spherical roller bearings and tapered roller bearings (TDO and TDI configuration) are used with grease lubrication. Design of gyrofin stabilizer systems has to take into account a number of important parameters, environmental and technical:
DESIGN PROCESS Technical calculations Mainly based on the data supplied by the customer (loads and rotating speeds), the RKB Technical Team Unit started studying the case by means of two software packages (figure 4) purposely developed by RKB Advanced Calculations and Optimization Department headed by Prof. Lucian Tudose. Taking into account the requirements of service life, reliability and safety index, these software tools provided consistent data and information for the selection of bearing type and size.
• seawater temperature: –2 °C ~ +35 °C; • inner temperature: +5 °C ~ +55 °C; • sea state: Beaufort 5; • maximum ship roll: 25° for port and starboard. In addition, crucial issues related to expected bearing life (more than 10.000 hours) should be always considered: bearing loading and work velocity should not exceed the recommended characteristics provided by the manufacturing company and the lubrication process should be carried out in a proper way. Fig. 4 - RKB software tools for advanced calculations
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In order to evaluate the life of bearings, several factors were uploaded in RKB proprietary software system: pitch diameter, basic dynamic radial load rating, basic static radial load rating, applied axial load, applied radial load, speed, grease temperature and grease quality, etc. For the stabilizer fin application, the results concerning bearing life were as expected: more than 11.000 hours in extreme operating conditions. The software system developed by RKB offers a statistically predicted primary representation of suitability. Naturally, the calculation of bearing life only applies if the service life of the adjacent mechanisms of the fin drive unit is at least as long as the bearing life. This method of calculating bearing life is associated with 90% reliability, high quality materials, and good manufacturing quality and operating conditions.
2D and 3D computer-aided design
Fig. 5 - 3D model of the fin drive unit studied by RKB
In today’s competitive market, customer demand is extremely diverse and changes rapidly. For this reason, companies need to answer a lot quicker to satisfy customer needs. Being specialized in a large range of bearings, each with many constructive dimensional variants, RKB uses CAD systems to improve working efficiency. In addition, the rich panel of tools embedded in CATIA V5 and SolidWorks allowed RKB Technical Team Unit to productively manipulate and modify the single parts and assemblies of the fin drive unit, also performing collision and clearance checks (figure 5).
FEM analysis The 3D model of the stabilizer fin shaft was then used to check how the bearings would behave under the loads acting on the customer’s application. For the calculation of the reaction forces inside the bearings, the finite element method or FEM was used (figure 6).
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Fig. 6 - Equivalent von-Mises stress of the fin drive unit
A major improvement in the application reliability, where misalignments and shaft deflections are more than likely, was reached by means of a special internal geometry and optimal contact conditions. The analysis, performed in ANSYS, of the contact areas between the rollers and the inner and outer raceways Fig. 7 - Optimal contacts between rollers and inner ring raceway, achieved through special internal geometry (figure 7) was of vital importance to guarantee high levels of performance of the bearings in real life conditions. It is a matter of general knowledge, in fact, that such contacts have a major influence on the distribution of stress and generation of stress peaks, friction and heat, that ultimately lead to wear and determine the service life of a bearing.
RKB MANUFACTURING PROCESS High quality materials and leading-edge heat treatment Materials play a crucial role in the functionality of a bearing. For example, fatigue cracking, due to the non-metallic impurities present in the raw material, represents one of the main causes of bearing failure. By drawing on extremely clean steels, the bearings fatigue life can be extraordinarily extended. For this reason, RKB uses only premium quality steels, that have low content of oxygen and non-metallic inclusions. In addition, due to the great width of the bearings for the fin drive unit, in order to reach homogenous core hardness after heat treatment, the production plan required the use of a special steel grade for proper hardenability. In spite of the extremely heavy and repetitive stress produced by the stabilizer fin movement, the bearings have to maintain high precision and Bearing News • Issue 4
rotational accuracy. For this very reason, RKB accurately selected the most appropriate raw materials and heat treatment techniques to reach the best possible level of hardness and resistance to deformation, fatigue and wear.
Advanced machine tools and techniques All RKB manufacturing plants feature the most advanced machine tools and production techniques to obtain reliable bearings, suitable also for critical applications. By way of example, Tough Rollers®, optimized surface finishing and roller sorting in tighter precision classes are just some of the factors that contribute to the superior performance of RKB rolling bearings. In more detail, Tough Rollers® are the perfect solution to give bearings higher load capacity and longer life expectancy. With regard to the stabilizer fin application, the working conditions of both spherical roller bearings are quasi-static, as a result of very high radial loads and low speeds of rotation. This way, the most heavily loaded rolling elements and raceways are subjected to extremely high stresses, that over time can lead to bearing failure. Therefore, both bearings of the stabilizer fin were equipped with Tough Rollers®, whose working principle is easy but extremely effective. In fact, after a special forging process, the rollers, due to the stretching of the crystals or dendrites in the direction of the metal flow, become much tougher
and, as a consequence, can attain much higher load rating capacities. Cutting-edge machining processes, which can be performed only by skilled personnel on last generation machines (figure 8), are the basis of the possibility to produce bearings with top performance. In particular, optimized surface finishing maximizes hydrodynamic lubricant film formation, improves rolling motion by reducing friction, and lowers operating temperatures. The aim of this operation is also to obtain improved topography with reduced surface roughness. Finally, tighter tolerances in roller sorting ensures uniform load distribution, influencing also the bearing radial internal clearance. Moreover, the roller controlled contour helps reallocate the end stress concentration. In order to guide the fin shaft correctly and obtain a proper contact between raceways and rollers, the RKB spherical roller bearings of the fin stabilizer system were designed with an extremely accurate C2 radial clearance. All the above procedures and techniques are of paramount importance to the final quality of the bearings, but they are nothing if production repeatability cannot be guaranteed over time. And that’s why RKB carefully and continuously tracks all manufacturing and quality control data in its central traceability system.
Conclusions Thanks to the high-profile work of its technical department, the long-standing experience of its production men, and the top quality technologies used in every stage of the manufacturing process, RKB bearings proved to be the right choice for the gyrofin stabilizer system. In a very competitive market, where the quality of bearings is necessary, but not sufficient to mark the difference, the proposal of a true technological partnership, combined with strong reactivity in production and short time to market, plays an important role to gain customers’ loyalty.
Fig. 8 - CNC vertical lathe for hard-turning in RKB T3 Plant
RKB is not only the Swiss bearing manufacturer, but also, and most of all, a qualified supplier of innovative technical solutions. Page: 39
The most economic, user-friendly and efficient bearing and P/T stocks search engine www.BearingCLOUD.com is launched in May 2015 and aims to deliver an unseen service for distributors worldwide. We tried to explain you the details of this revolutionary project with 5 questions.
What is BearingCLOUD? BearingCLOUD is a search engine which provides easy access to bearing and power transmission distributor stock-lists worldwide. This revolutionary search engine is extended with an inquiry system that connects international and national players of bearing and power transmission distributors worldwide. The system can be used on all PC’s, and compatible with SMART Phones (iOS / Android) and Notebooks.
Who can become member of BearingCLOUD? All global and local distributors of bearings and other power transmission products can join the BearingCLOUD platform.
How many companies are already member of BearingCLOUD? BearingCLOUD has reached 350 members during the first 3 months after launch. The amount of members is increasing every day
5
and is expected to reach +1000 members in 2016.
What are the benefits of BearingCLOUD?
QUESTIONS
in
1. BearingCLOUD enables users to search bearings, pulleys, chains, sprockets, belts and seals according to the brand name and part number in requested quantity amongst approved distributor’s stock lists worldwide. 2. All pages on BearingCLOUD are simple, widescreen and without flashy turning jumping advertisements. 3. All members will be subscribed automatically to the printed and digital BearingNEWS magazine, the only bearing industry magazine in the world; and will receive it for FREE at their company address. 4. The system will be FREE for a while and at a small charge in the future. 5. First year subscribers will have the second year subscription for FREE.
Which products can be searched on BearingCLOUD? There are 6 products which can be searched on BearingCLOUD.com: BEARINGS
PULLEYS
SPROCKETS
SEALS
CHAINS
BELTS
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Hans Hanegreefs Executive Vice President, EPTDA Page: 42
MEET EMEA’S LEADING POWER TRANSMISSION DISTRIBUTORS ASSOCIATION
Page: 43
Global Transformation of Power Transmission Distribution Industry
The global power transmission industry is undergoing a period of fast and dynamic transformation. The impacts of ongoing industrial globalization and consolidation, and the rise of ‘Industry 4.0’ is clearly changing the landscape of the industry. EPTDA (EMEA Power Transmission Distributors Association) is playing a critical role in this transformation, as the leading organization for the power transmission industry in Europe, the Middle-East and Africa. Through a meticulously selected membership base of world-leading distributors and manufacturers, and a footprint expanding across 33 countries, EPTDA is driving a robust growth strategy to advance industrial distribution. BearingNews sat down with EPTDA’s Executive Vice President, Hans Hanegreefs, to get insights into the association’s strategy, outlook and strengths.
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Bearing News • Issue 4
Hans Hanegreefs Executive Vice President, EPTDA
What is EPTDA’s Mission? EPTDA exists and thrives to strengthen its member companies, distributors and manufacturers of PT/ MC products in the EMEA region, to help them be successful, profitable and competitive in serving customers according to the highest standards. Our vision is to be the leading pan-EMEA community within industrial distribution, as recognized by customers. Our aim is to bring qualified distributors and manufacturers of EMEA PT/MC industry on one global platform to address business issues and industry growth prospects, highlight and set trends, develop leaders of the future and promote ethical business practices.
How did it all start? EPTDA was founded in 1998 in Marbella (Spain)
– initiated by executive directors and members of PTDA (EPTDA’s sister organization in the USA) and other local PT companies operating in Europe. These companies recognized the need of creating a dedicated European community of trusted global leaders of the distributors and manufacturers companies, to drive the industry forward. We started as a legal entity in the USA (State of Delaware) then and in 2003, EPTDA became an independent non-profit organization, registered in Belgium. We started with 38 members back then and within a decade we grew rapidly across Europe with a highly prestigious membership base. In 2013, we took the bold step to expand our horizons in the Middle-East & Africa. Today, we represent 257 member companies across EMEA. Our growth isn’t at all about numbers; it’s about bringing the worldclass leaders together. Page: 45
“EPTDA started with 38 members in Europe in 1998 and within a short span, we have grown to 257 member companies across EMEA – such is the power of an executive network like ours.” What are some of the biggest challenges EPTDA have faced and how have you dealt with them? Facing the worldwide economic downturn in 2008 was not an easy feat for our members, nor for the association – or in fact any business in the world. With huge restrictions on budgets and emphasis on cost control, several companies tighten their belt, putting an enormous pressure on the membership growth. When some saw this as a threat, we saw the downturn as an opportunity. We worked with our members and volunteers to truly showcase the value EPTDA adds to a business’ success, especially in testing times. With a comparatively smaller investment, our members could still benefit from the opportunity to meet key decision makers of the industry, from around the world in one place, at one time, and focus on driving business. Our annual convention served, not just a feelgood social networking platform, but as a trusted, secured, ethical and genuine business development arena for the executives and movers and shakers of the industry. We brought forward members from emerging markets with massive growth potential to our meetings, so our members could look beyond their usual comfort zones of operations. We invited leading economic forecasters and gurus from our own and other related industries to show us Page: 46
the way, and highlight the paths/markets to be avoided… when to pull and when to push. This was when, and where, we all rolled up our sleeves and join forces to define the mutual success of our members and member companies. We are very proud in the high member retention rate and loyalty we have earned over the years.
“At our 2015 Annual Convention in Barcelona, we will excel ahead with our commitment to attracting NexGen to our industry by hosting a series of seminars and workshops on issues of the future, addressed by the leaders of the future.” How many members do you have today? 257 member companies, 350 executives represented on an average at our annual conventions, with a representation from across 33 countries from Europe, the Middle-East and Africa
How many bearing manufacturers and distributors are member of the EPTDA? Out of the 257 member companies, 147 are producing or distributing bearings. EPTDA has 112 distributors of bearings in the EMEA region as member.
Can you share some statistics of your bearing industry members? EPTDA represents the highest-quality distributors or manufacturers, who are the trusted providers for end-users. The stamp of quality that EPTDA stands for, serves as a guarantee on its own that when you do business with EPTDA members, you are doing business with highly ethical and responsible Bearing News • Issue 4
A glimpse of EPTDA’s MD-IDEX meeting sessions in Istanbul 2014.
corporations and individuals. I am happy to share, with BearingsNews readers, our top five countries in terms of number of membership, who are active in the Bearing industry: • 23 members in Germany • 16 members in the UK • 15 members in Italy • 11 members in Turkey • 9 members in The Netherlands In addition, we have bearing distributors and manufacturers in all corners of Europe and the rest of the world including Belgium, Canada, Denmark, Egypt, Estonia, Finland, France, Greece, Hungary, Iceland, Ireland, Nigeria, Norway, Poland, Portugal, Romania, Russia, Scotland, Slovenia, South Africa, Spain, Sweden, Switzerland, UAE and USA.
“Market research and business intelligence is one of the most significant benefits to EPTDA members; and we will continue to invest in bringing business critical insights to our member companies, on time, so they can make informed business decisions and stay ahead of the curve.” Can you tell us more about the EPTDA Annual Convention? EPTDA Annual Conventions are the leading events in industrial distribution and they take place every year. The EPTDA conventions offer an executive level forum for discussion and business development. It’s one of its kind in the whole
industry – there is no other event or platform where you meet all decision makers under one roof, at one given time. Our Annual Conventions are also renowned to bring the world’s most coveted speakers who shed light on industry trends, economic growth and personal development. The Convention’s most successful highlight is the MD-IDEX (Manufacturers Distributors Idea Exchange) sessions – our very unique speed meetings where distributors and manufacturers meet for 14 pre-allocated meeting slots of 25 minutes, spread out over two days. I am exceptionally proud to celebrate 60 of our members are with EPTDA for more than 15 years. Our Annual Conventions give us that fantastic personal space to celebrate these successes and reward these members for their commitment and loyalty. Every year, we put our heart and soul in crafting a business focused, and socially entertaining annual convention program for our members who attend with their spouses and partners to celebrate the past achievements and focus on future successes. Each year, we select a special destination – based on the business importance, membership and leadership representation, and the social appeal. From Prague to Istanbul, Lisbon to Venice, Paris to Dublin, Marbella to Athens, our Annual Conventions have become a legend in their own right. After a fabulous celebration in Istanbul, we are heading to Barcelona, one of Europe’s best kept treasures and world’s fantasy destination. This year, in addition to hosting our powerful MDIDEX sessions, we will be introducing a dedicated IDEX session for Distributors only, the so called D2D informal meeting sessions. We will also be excelling ahead with our Page: 47
commitment to attracting NexGen to our industry by hosting a series of seminars and workshops on issues of the future, addressed by the leaders of the future.
“This year, EPTDA is also launching bespoke Online Product Trainings focused on building skillsets of Sales Managers, NexGen, University Graduates and executive leaders of our industry.” Which other EPTDA tools, services and channels do you offer your members? EPTDA is continuously developing new tools and intelligence points to better serve the evergrowing need of its members and the industry. The association offers several reports on market trends, big data, economic forecast of related industries, emerging markets and players, social revolution impacting the PT/MC industry and much more. We are also investing an incredible amount of efforts in developing personal training and product training for existing professionals of our industry. These also serve as our mighty vehicle to attract young generation to select our industry as a preferred employer. At Barcelona Annual Convention, we will be launching bespoke Online Product Trainings – relevant to the European markets – focused on building skillsets of Sales Managers, NexGen, University Graduates and executive leaders of our industry. Market research and business intelligence is one of the most significant benefits to EPTDA members; and we will continue to invest in bringing business critical insights to our member companies, on time, so they can make informed business decisions and stay ahead of the curve. These reports will be provided by a specialized consultancy firm and will focus on economic analysis. Currently, we provide our members bi-monthly economic outlooks for Europe, quarterly market forecasts and we also monitor EU legislation for legislative developments that might have an impact on the day to day businesses of our members. Page: 48
Another important benefit for our members is the fact that EPTDA has solid partnerships with the leading industrial fair organizers in the EMEA region, like Deutsche Messe, and members can co-exhibit under EPTDA pavilion and benefit from special member prices and conditions.
“As the PT/MC industry goes through a global transformation, EPTDA and PTDA will continue to drive the global agenda on ethical business practices, and setting highest standards of operations and service.” How do you see the future for the bearing and power transmission industry? As the PT/MC industry goes through a global transformation, EPTDA and PTDA will continue to drive the global agenda on ethical business practices, and setting highest standards of operations and service. Quality comes at a price; but with that price comes a great sense of comfort, satisfaction and confidence – that end users have collaborated with companies of highest operational and service standards, and the products are of the best quality. Customer loyalty in itself is going through a transformation, as competition heats up. That’s where members of EPTDA can play a critical, valueadding role by being more than just a supplier – an advisor and a real partner in success by sharing know-how, by following up, by investing in solution and evidence based relationships. Our mission is to strengthen our members and making sure they deliver the best quality to their end customers. I strongly believe that the future of industrial distribution is bright. With the ongoing developments in technology to produce and distribute, highly skilled labor entering the global workforce, strategic consolidations across the globe driven to serve the customers faster and in a more personalized manner, and a genuine desire to succeed, our members and our association is going to play an even more important role in EMEA’s PT/ MC industry and beyond. Bearing News • Issue 4
Made in Germany
A new standard for production of balls and rollers
BR Manufacturer WAFIOS Umformtechnik GmbH Im Rehsiepen 35 42369 Wuppertal Phone +49 (202) 46 68-0
WAFIOS Umformtechnik at the Korea Metal week from 28th – 31st October 2015 WAFIOS Umformtechnik at the WIRE South America Sao Paulo, Brazil from 6th – 8th October 2015
sales@wafios-umformtechnik.de www.wafios-umformtechnik.com
Cold Former BR 220 Hydraulic driven push-out aid for change overs System to process the residual wire at the end of the coil Ejecting stroke infinitely adjustable (motorized – option) Very precise working linear material feeding system for volume consistency of less than 0,3 %
WAFIOS (Shanghai) Machinery Co.,Ltd 威夫斯(上海)机械有限公司 No. 99-1, Hongjian Road, Minghang District, Shanghai China, 200336 威夫斯(上海)机械有限公司上海 市闵行区虹建路99号1幢1楼 200336 tony_wafios@163.com Mobile Phone: 0086 13814861671 Precision Parts Forming Machinery
Page: 51
1
VENUE! RESULT!
LEARN ABOUT!
Bearing Reliability • The Best Strategies • Reduced Downtime • Maximized Production Output • Lowest Maintenance Costs
BEARING RELIABILITY CONFERENCE & EXPO BRCE is the meeting place where both the global bearing players meet the established global equipment Reliability strategies and brings them both together as one message – Bearing Reliability! For two days you will experience powerful Key Note speakers from both competencies, listen to selected experts present their strategies to make the bearing more reliable, join workshops designed to help you implement the best strategies and visit the key industrial players at the Exhibition center.
WHY JOIN THIS EVENT? The Bearing is the rotating heart of all machines and if it fails or malfunctions, then so does the machine or equipment, simply put DOWNTIME and LOST PRODUCTION prevail.
By making the bearing last longer -more reliable, equipment uptime will increase and maintenance costs will subside. This Conference, Workshop and Exhibition structure, will give you the knowledge to help improve your companies business result.
BEARING RELIABILITY
EQUIPMENT RELIABILITY
• Bearing Quality and Capacity • Availability • Lubrication Management • Care and Maintenance • RCFA (Root Cause Failure Analysis) • Training (Handling, Care, Maintenance)
• Reliability Strategies • Predictive Maintenance • Lubrication Management • RCA (Root Cause Analysis) • Training (Strategies, Work Processes etc.) • Management Techniques
OUR PROGRAM KEY NOTE SPEAKERS
THE INDUSTRY LEADERS
DAY 1 The Opening Presentation
DAY 2 The Opening Presentation
Our 4 keynote speakers have been selected as the Industry leaders who have helped shape and influence the industrial world as it is today.
The Bearing Industry responsibilities, in making their products last longer and become more reliable. 1 hour
The Bearing Condition and Prediction. Past present and the Future.
Lunch Session
Lunch Session
They will share with you their insight into the past, present and the future of Industrial Bearing reliability.
Bearing Reliability and Maintenance Understood. Simple in concept –difficult to understand.
Bearing Lubrication -getting it right, the hidden pot of gold.
INDUSTRY PRESENTATIONS
DAY 1 Presentation Program
DAY 2 Presentation Program
Morning Session • Understanding Equipment Reliability. • Bearing Quality and Capacity. • Bearing Reliability –Is it different?
Morning Session • The role of Oil Analysis. • Vibration Monitoring developments. • Thermography in the Prediction Strategy?
THE CONCEPTS IN DETAIL Our presentation topics cover a wide variety of subjects and have all been chosen for their uniqueness in the concepts of achieving improved bearing reliability. Conference delegates can select the subjects of their choice and also attend our workshops.
PRACTICAL WORKSHOPS
THE CONCEPTS IN PRACTICE Our workshop topics cover 1.5 hours of hands on Learning. They are broken up into 3 half hour slots and are repeated in the aſternoon, enabling participants to see to also view the presentations of their choice.
Aſternoon Session • New bearing development. • Bearing Tools and Maintenance. • Bearing Training –do we need it? Main Presentation • The Role of The Manager in Reliability.
Aſternoon Session • The use of Ultra Sound. • Lean Manufacturing Trends and Concepts. • The Bearing of the Future.
DAY 1
DAY 2
Presentation Program
Presentation Program
Morning Session • Bearing Failures and their Causes. • Bearing Lubrication. • RCM, Reliability Centered Maintenance
Morning Session • Lubrication Reliability • Industrial Reliability Made Easy. • Bearing Prediction and Analysis.
Aſternoon Session • The above are repeated in the aſternoon.
Aſternoon Session • The above are repeated in the aſternoon.
KEYNOTE SPEAKERS DAN BRADLEY Dan Bradley is a graduate Mechanical Engineer from The Ohio State University and has over 30 years of experience in Service & Reliability field. He has assisted over 500 people in the areas of vibration analysis, predictive maintenance programs and balancing. He has worked in Product Development creating several Condition Monitoring Software applications, Data Collection Devices and Wireless sensing devices. Notably he has worked for IRD Mechanalysis, Inc. and SKF in a variety of management positions including responsibility for Global Reliability Systems while at SKF AB. Dan has been a publisher and speaker at numerous Reliability forums around the world. Background • Consulting expertise in a range of technology and general management areas. • Director Traditional Energy Business Unit SKF: Global business leader for SKF focused on Energy Segments including Oil & Gas, Chemical Processing, Power Generation (Fossil and Nuclear). • Director SKF Reliability Systems: Corporate management of global business units providing consulting, instrumentation and software to industrial customer base. • SKF Condition Monitoring, Inc.: In charge of unit designing, developing and marketing industrial instrumentation and software. • Product Manager IRD Mechanalysis: Managed all software lines for condition monitoring and decision support. Project leader on first generation of Windows software developed for PM marketplace. • Field Engineer Schlumberger: Wireline Field Engineer for Open Hole, deep, hostile environment logging in South Texas
IAN KNIGHT
Australia.
Ian Knight is widely experienced in the fields of Bearing and Industrial Maintenance and Reliability. He has over 35 years experience working in bearing Industry starting with Timken and then 31 years with the SKF Group. He started his career with Timken in the Australian manufacturing plant, where he transitioned into field sales and support in Victoria and Western
Background He joined SKF in the early 80’s as State Manager Western Australia and transferred to Europe in 1989 to joined the newly created SKF Condition Monitoring group. In Europe he held global positions in the spheres of Product Marketing, Sales and Support and Training. He started his own company Enluse BV, in the The Netherlands and today he is still very active as the CEO and Owner. Enluse BV specialise in the discipline of Lubrication Reliability and Ian is actively involved in facets of the company activities.
PER ARNOLD ELGQVIST Per Arnold Elgqvist is a Mechanical Engineer, having graduated at the University of Gothenburg in 1970. He is a regular speaker at industrial maintenance seminars and his is work covers the areas of Mexico, Venezuela and Brazil. Per Arnold is a fluent communicator in English, Swedish and Spanish. Background He worked for SKF for 33 years and held many positions in both Sweden and Mexico, which included positions in Product Control and Product Engineering Manager. In the period of 1990 to 2003, he held the position of Technical Services Manager for SKF Mexico, where he was responsible for Service and Reliability Support and Training. In February 2003 he started his own company Servicios Tecnologicos Corporativos. SA de C.V. which continues today, with the main activities of Training and Consulting in Lubrication, Lubricants and Reliability of Rolling Element Bearings in different industrial applications. He is referred to in Latin America as the Doctor of Bearing Reliability.
JAN BRONS Jan Brons is an Organization and Strategic Business consultant living in the Greater San Diego Area. Before starting his own consultancy organization, he had an extensive career with SKF that spans 30 years in Finance, Management, Marketing, Industrial Reliability and Sales. His career positions included. Senior Business Consultant for SKF develop markets and portfolio to address the Oil and Gas industry. Director and responsible to develop product platforms in (Seals, Lubrication Systems, Maintenance products, Mechatronics) for the Service (aftermarket) division. One of 3 business divisions in the SKF Group Background • Responsible for SKF Business in Middle-East and Africa • President SKF Reliability System: responsible for establishing and developing the Service platform (Reliability Systems) in SKF. • President SKF Condition Monitoring: Global management of this business unit • President SKF Singapore & SEA: Responsible for Area logistics operations and management of a number of SKF Markets in region. • President SKF Philippines: Responsible to establish a SKF company and manage SKF business in Philippines. • State manager SKF NSW: Responsible for SKF business in NSW
FABRICE BRION Fabrice Brion is a Qualified Reliability Engineer with over 15 years experience in all facets of Reliability Based Maintenance. He is currently the CEO and Owner of I-Care SRL, based out of Mons Belgium and operating his Predictive Maintenance, Product Development, Training, Service and Customer Support organization across the European continent. Background Prior to starting his own company I-Care he worked with Emerson Process Management in a wide scope of functions including, implementation of Reliability based maintenance strategies, Training and Supporting customers with condition monitoring instrument sales and implementation and developing their Oil Analysis capabilities.
HOTEL / ACCOMODATION The BRCE event will take place in Dortmund, the largest city in the German Ruhr area. The accommodation will be at the 4-star Mercure Dortmund Messe & Kongress Hotel, next to the Westfalenhallen exhibition center @ Strobelallee 41, 44139 Dortmund / Germany.
VISIT THE STANDS OF OUR EXHIBITORS, COVERING BEARINGS, SERVICES, TOOLS, EQUIPMENT AND RELIABILITY CONSULTANTS.
Registiration On
www.bearingreliabilityconference.com
Contact Us
info@bearing-news.com
The Managing Partners
RELIABILITY INDUSTRIAL RELIABILITY GUIDE
LINK
COM
What Happened in the
Bearing Industry First Half of
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2015
Bearing News • Issue 4
January
13
Frisa Express Stainless Steel Forgings Stainless steels are widely used in applications where resistance to heat and corrosion are required, commonly in markets such as oil & gas, power generation, autoclaves, medical equipment, water resources and many more. Recently, Frisa Express has developed complex forging projects that required the use of two of these corrosion resistant materials: the challenging Nitronic® 60 and 304 stainless steel used for heavy
January
15
forgings. The projects consisted in the production of several forged rings for the hydro power generation industry, where we forged a couple of 304 stainless steel rolled rings, with a combined weight of 40,000 lb., in only 2.5 weeks.
NN, INC. Announces Organizational Changes To Metal BEARING COMPONENTS Group NN, Inc., a diversified industrial company, announced today that the Metal Bearing Components Group has reorganized its portfolio into two distinct business units – Global Rollers Division and Global Ball Division. The Company also announced four newly created positions to the Group: • Rob Heinrich named Vice President/General Manager of the Global Rollers Division • Dario Galetti named Vice President/General Manager of the Global Ball Division • Jeff Hodge named Vice President of Business Development • Trevor Lynch named Group Controller Leading our global rollers division will be Rob Heinrich. Prior to this appointment Mr. Heinrich served as general manager of NN’s roller and stamped parts operation in the Netherlands. Dario Galetti has been appointed to lead our global ball division. Previously, he led the Company’s European ball division. Jeff Manzagol, Senior Vice President and General Manager of the Metal Bearing Components Group, stated, “Rob and
Dario have contributed greatly to NN over the past years; their expertise and proven leadership will be invaluable as we continue to expand our portfolio within these newly formed divisions.” Supporting the newly organized divisions is Trevor Lynch who has been appointed Metal Bearing Components Group Controller and Jeff Hodge who has been named Vice President of Business Development. Mr. Manzagol concluded, “These appointments highlight our continued focus on strategically organizing our businesses to deliver world class precision, quality and service to our customers and end markets.” NN, Inc., a diversified industrial company, manufactures and supplies high precision metal bearing components, industrial plastic and rubber products and precision metal components to a variety of markets on a global basis. Headquartered in Johnson City, Tennessee, NN has 25 manufacturing plants in the United States, Western Europe, Eastern Europe, South America and China. Page: 59
What Happened in the
Bearing Industry First Half of
January
24
2015
NSK Develops New BNEQARTET™ Long Life Bearing for Front-Loading Washers NSK Ltd. announced that it has developed BNEQARTET, a new long life bearing for front-loading washers. This new product achieves more than twice the rolling fatigue life of that of the standard product used for drum support in frontloading washers, delivering longer life in a variety of usage conditions. NSK is targeting 1.5 billion yen in annual global sales for this new product in 2018. In the European market, the size of the drums used in mainstream frontloading washers is increasing in order to accommodate larger laundry capacity. As a result, the load placed upon drum support bearings is increasing, which can result in shorter bearing life. Due to the fact that washers have space constraints and must be energy-saving, there is an inevitable increase of load on the bearing which cannot be countered by simply making the bearing larger. In
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response to this, NSK leveraged one of its core material technologies to increase the life of the bearing while keeping it the same size as the standard product. NSK developed the material for this new bearing through a combination of alloy component optimization and proprietary cleaning control technology, enabling double the usage life under heavy load conditions. The new bearing is also reliable under harsh conditions, including those that involve exposure to contamination. 1. Twice the rated fatigue life 2. Suppression of surface-originated flaking due to stress concentration from dents caused by contamination 3. Suppression of white structure flaking 4. Suppression of flaking in hightemperature environments
Bearing News • Issue 4
January
26
Metcar Self-Lubricating, Carbon-Graphite Bearings For Louver Dampers Metallized Carbon Corporation, a global leader in the manufacture of oil-free, self-lubricating, carbon-graphite materials for severe service applications, announces the availability of bearings specially designed for louver dampers in boiler applications, such as those in coal- or refuse-fired power plants. The Metcar bearings are preferred for boiler damper blade shaft bearing applications because of their ability to cope with the extremely high temperatures of these applications. At these high temperatures, oil/grease lubricated bearings are problematic because the lubricants can melt, volatilize or carbonize, causing bearings to gaul and seize and therefore rendering the dampers useless. Because Metcar carbon-graphite bearings rely on graphite for their self-lubricating properties, they are not subject to the shortcomings associated with petroleum-based lubricants at elevated temperatures. They are dimensionally stable, not subject to deformation, and can be relied upon to provide low friction damper blade movement even after being stationary for many months. The high resiliency and low maintenance of the bearings leads to reduced costs and decreased down time.
January
29
SKF signs agreement with Volvo Cars
SKF has signed a significant agreement to supply Volvo Car Corporation with wheel hub bearing units for their future car lines. Stephane Le-Mounier, President, Automotive Market, says, “Working with Volvo Cars in the development of solutions that meet their high demands has been a successful team effort. Our focus is on developing solutions that support high performance and improved energy efficiency. Combined with our global manufacturing and technical support footprint, this was instrumental
in securing the agreement announced today.� SKF’s wheel hub bearing units with low friction grease have been specifically developed to meet Volvo Cars demands on performance, weight reduction and stiffness, contributing to a more comfortable driving experience and lower fuel consumption.
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What Happened in the
Bearing Industry First Half of
February
12
2015
PTDA releases digital Power Transmission Handbook The PTDA has released the Power Transmission Handbook eBook. This digital version of the new and improved fifth edition of the Power Transmission Handbook is a highly regarded comprehensive primer on the products, technology and concepts in the power transmission industry. The handbook is an excellent primer for new employees, a go-to reference for experienced staff and an ideal resource to train customers on installation and maintenance.
• The Bearings chapter includes a new section on linear bearings. • The Clutches & Brakes chapter reflects increased market activity in the C-face clutches and brakes; recent developments in pneumatic actuation; and more information on common applications and usage. • The Controls & Sensors chapter includes information on the new standards developed to help speed the development and implementation of these controls. • The Conveyors & Components chapter introduces a new special unit handling section; additional content on plastic belts/chains in food & beverage applications with graphic support; and expanded content in the bucket elevator section. • The Linear Motion chapter includes a new section covering electromechanical, stage, slide and table actuators. • The Motors chapter is updated to include the new U.S. electric motor regulation mandated by the Energy Independence and Security Act.
Some of the enhancements: • The Adjustable Speed Drives chapter covers new speed control technologies and the benefits they provide such as higher performance, reduced maintenance and greatly improved energy efficiency.
February
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The Power Transmission Handbook eBook is currently available in both Apple and Kindle formats and is and is available for sale through the PTDA store. You can also find the PTDA on Twitter and LinkedIn.
RKB announces the opening of its new subsidiary in Romania The RKB Group expands its direct activities and global network by establishing a new wholly-owned subsidiary in Brasov, Romania, which operates under the name of RKB East Europe Srl. The opening of this new Logistics and Distribution Center is part of RKB’s strategy to provide East European customers with a single commercial and technical point of access and a full range of RKB bearings in stock, with focus on market specific items.
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Bearing News • Issue 4
February
23
Timken Expands Housed Unit Line With New UC-Series Ball Bearing Housed Unit Line New line of Timken® U-C Series Ball Bearing Housed Units offers a range of metric and imperial sizes from 12mm to 90mm The Timken Company (NYSE: TKR; www. timken.com) today introduced its new line of Timken® UC-Series Ball Bearing Housed Units. This product line addresses global demand for standard duty metric and imperial ball bearing housed units and further expands the offering of Timken housed units. “With the new UC-series ball bearing housed units, Timken offers industrial customers a wide range of ready-tomount units with five housing designs,” said Amanda Montgomery, Timken director of marketing and product management. “The addition of the UCSeries line to our current ball and roller bearing housed unit offering means we now offer one of the broadest lines of housed units in the world.” Timken offers the UC-series ball bearing housed units in an extensive range of sizes for shafts from 12 mm to 90 mm, with the most common sizes in stock for immediate delivery. The units are manufactured to precise quality standards and rigorous requirements. Their performance is validated by extensive in-house testing and backed by decades of
February
26
The Timken Company introduced a new line of Timken® UC-Series Ball Bearing Housed Units. This product line addresses global demand for standard duty metric and imperial ball bearing housed units and further expands the offering of Timken housed units.
product performance testing experience. In addition, the Timken team of service engineers is dedicated to helping customers extend equipment maintenance cycles and maximize uptime. Log on to www.timken.com for more information about Timken UC-series ball bearing housed units and the company’s full line of housed units.
ORS launches SAP Project ORS SAP Implementation Project (a.k.a. Sprint Project) was launched on February 26, 2015 in cooperation with Vektora (SAP Certified Consultant Company). Scheduled go-live date is announced as October 2015.
of “Suite on HANA” in the discrete manufacturing industry in Turkey.
Sprint Project includes the following SAP solutions: SAP ECC (SD, PP, MM, FI, CO, PM, QM, WM, HR) and SAP Business Analytics. Additionally, Sprint Project is also one of the first implementation Page: 63
What Happened in the
Bearing Industry First Half of
March
05
2015
Able is Launching Bearings Service Line From a source of the Helicopter Association International, Able Aerospace Services is on a roll, launching a new service line providing Level 1 bearing inspection and Level 2 bearing overhaul and repair for the Bell 206 and 407. The company plans to add additional aircraft bearings services in the coming months. “Able prides itself on being a one-stop, value-add solution for its customers. We have years of experience in the bearing arena, so formalizing this service for our market at large is a worthy next step,” said Able Vice President John Jackson. “Over the coming months, we will continue to listen to customers and expand our offerings based on their needs.” “Regular, preventative bearing inspections and overhauls are two of the best ways to avoid larger, costly mechanical damage or failure. Our Dynamic Analysis sees things that traditional inspections can’t, and helps our customers gain a comprehensive view of their bearing function,” said Geno Forman, Program Manager for Able’s bearings department. “We have entered the market with Bell 206 and 407 capabilities, and plan to expand into new fleets with highly competitive fixed pricing and rapid turn times.”
March
08
NTN Develops “Grease Lubrication Type High Speed Deep Groove Ball Bearing” for EV/HEV NTN has developed the “Grease Lubrication Type High Speed Deep Groove Ball Bearing” with double the rotational speed compared to conventional products and the industry’s highest level high-speed rotation for use in motors mounted in electric vehicles (EV) and hybrid vehicles (HEV).
There is an increasing need for higher rotational speed for EV/HEV drive motors to achieve a more compact size and lighter weight. The bearings that are used also need to be capable of highspeed rotation, however conventional grease lubrication type deep groove ball bearings suffered from higher temperatures caused by distortion to the retainer due to centrifugal forces when operating at high rotational speeds, and a lack in lubrication due to the grease scattering. The newly developed “Grease Lubrication Type High Speed Deep Groove Ball Bearing” for EV/HEV features a reviewed material ratio with the use of a new plastic retainer, while the retainer shape Page: 64
and material ratio have been modified to minimize its level of distortion due to centrifugal forces when operating at high rotational speeds. A smooth grease supply along the raceway surface also helps to increase sliding between the retainer and steel balls. The filled grease has also been optimized
with a combination of consistency (thickening agents) that can resist centrifugal forces at high rotational speeds, and viscosity (base oil) that can supply lubrication constituents to the raceway surface at high speeds, resolving the lack of lubrication when operating at high rotational speeds. NTN will propose and develop markets for the “Grease Lubrication Type High Speed Deep Groove Ball Bearing” globally as a product that can contribute to more compact and lighter weight EV and HEV.
Bearing News • Issue 4
March
08
GGB Expands Production in China GGB Bearing Technology (Suzhou) Co., Ltd., is relocating its operations to a larger production facility in the Suzhou New District (SND). The company held a groundbreaking ceremony for the new plant on March 11 with its senior management team, government officials and local dignitaries in attendance. The 9,000 m2 plant will be shared with Stemco, another EnPro Industries unit which manufactures seals and hub caps for the trucking industry. It is scheduled for completion by the end of this year. “This is a major milestone for GGB in China,” said Susan Sweeney, President of GGB Bearing Technology. “The facility will enable us to better serve our existing customers here and provide capacity to further expand our base with new ones.” GGB Plant Manager Michael Feng added, “Our new plant will be twice the size of the facility we had been occupying. This will allow us to expand production to meet increasing customer demands and accommodate the rapid growth of our business. The plant will produce GGB’s main product lines to meet our local customers’ needs.” GGB opened its first manufacturing facility in China in Suzhou Industrial Park (SIP) in 2008. The company entered the China market in 2004 with a head sales office in Shanghai, and now also has offices in Chongqing, Shenzhen and Tianjin. For more information contact china@ggbearings.com.
March
14
Boca Bearing Company Expands Steel and Ceramic Ball Product Line The Boca Bearing Company is proud to announce the expansion of their line of Steel and Ceramic Ball. Starting from the rigorous testing of the wire for all crucial factors, balls are produced in specifically designed machines called Header, Flasher, Grinder and Lapper. Heat treatment is one of the most important operations that give required strength & hardness to the balls. Heat treatment makes the balls tough and wear resistant. Metal balls are rolling, spherical elements. They are usually made from alloy steel, carbon steel or stainless steel. Metal balls are characterized by the Outer Diameter, Permissible Deviation, Surface Roughness and Tolerance. The Outer Diameter (OD) is the overall width or average diameter of the ball. Permissible Deviation is the greatest radial distance in a radial plane between a sphere around the metal ball surface and any point on the ball surface. Surface Roughness measures the irregularities that form on the surface, but are not significant deviations. Basic diameter Tolerance is the maximum allowable deviation average diameter from the diameter specified. Boca Bearings stocks a wide assortment of 52100 Chrome Steel Balls, 440C Stainless Steel Balls and Carbon Steel Balls.
elements that are used in check and ball valves, bearings, and other mechanical devices that provide rotary or linear motion. They are made from inorganic, nonmetallic materials that are processed at high temperatures. Many ceramic balls are capable of achieving an extremely smooth surface finish to a high degree of tolerance. As a result Ceramic Balls have an extremely low coefficient of friction as compared to metal balls. Grinding removes cuts, scratches, scuffs, and other irregularities. Many ceramic balls exhibit much greater hardness than steel balls, resulting in longer life and improved reliability. Ceramic balls can also provide high stiffness, low thermal expansion, light weight, increased corrosion resistance, and electrical resistance. Boca Bearings stocks a wide assortment of Silicon Nitride Ceramic Balls, Alumina Oxide Ceramic Balls and Zirconia Ceramic Balls.
Ceramic balls are rolling, spherical Page: 65
What Happened in the
Bearing Industry First Half of
2015
For the first time Boca Bearing Company is now offering hollow 304 Stainless balls. These are often used in various art projects as they are more decorative in nature. Hollow 304 Stainless Steel balls are available in a 0.8mm thickness and are supplied with a mill finish and a weld seam that is ground flush. 304 Stainless Steel will not corrode or rust. Another new product offering is the S-2 Rock Bit Ball Series. S-2 Rock Bit Balls are most frequently used in oil field equipment and offshore drilling operations. Rock Bit balls provide good service in withstanding the abrasion of pulverized rock and mud slurries. They
March
15
The Boca Bearing Company is one of the most trusted names in ceramic bearing technology. The reduction of rolling resistance and conservation of energy has been our hallmark since 1987. Boca Bearings never has a minimum order and is a one stop shop for everything from prototyping to production. Whether you are looking for affordability, longevity or high speed, Boca Bearings has just the bearing for you. Wholesale discounts are available upon request.
C&U Americas Honored with 2014 Nexteer Automotive Awards Leading bearing maker cited for delivering exceptional quality and performance C&U Americas, LLC, the North American subsidiary of The C&U Group, one of the world’s top 10 bearing manufacturers and China’s largest bearing producer, recently received two 2014 Nexteer Automotive quality awards for setting the standard of exceptional quality performance among Nexteer’s supplier community. The Nexteer Perfect Launch Award recognizes C&U Americas for achieving zero complaints and zero defects during the launch and ramp up phase of the Ford S550 REPS (2015 Ford Mustang Rack Electronic Power Steering). The Perfect Quality Award was earned for a perfect delivery rating and zero defects for all part numbers shipped in 2014. Dan Carbaugh, C&U Americas Account Manager, accepted the awards during the 2014 Nexteer Automotive Direct Supplier Conference in Saginaw, MI. The award was announced by Tom Rouse, President of C&U Americas, who noted, “Nexteer Automotive is a valued customer of C&U Americas and we are honored to be recognized as one of its top suppliers. These awards are a true
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are capable of providing the toughness and strength necessary for shock loads and harsh environments.
testament to the daily dedication and commitment made by everyone on the C&U team to provide our customers with the highest standards of quality.” C&U Americas offers a full line of bearing types and styles for use in original equipment manufacturing, aftermarket replacement, and MRO operations. The C&U portfolio includes over 30,000 types of bearings in a wide range of specifications and sizes ranging from 1.5mm ID to 4000mm OD.
Dan Carbaugh, C&U Americas Account Manager, with the 2014 Nexteer Automotive Quality Awards.
Bearing News • Issue 4
March
21
Motion Industries releases video on proper bearing handling and storage
Motion Industries, a distributor of industrial maintenance, repair, and operation (MRO) replacement parts, has released a new Tom’s Toolbox video that highlights the importance of proper handling and storage of bearings. In the wind industry, many bearings are so large and expensive that proper storage is crucial, providing end users with the full bearing life that was intended. Tom’s Toolbox videos are available for viewing on Motion Industries’ MiHow2 YouTube channel, which was established in 2012. “Proper Bearing Handling and Storage with SKF Bearings” provides the viewer guidelines on how to get the most out of their bearings before they are even installed. The video can now be seen on the MiHow2 channel, under the Tom’s Toolbox heading. “Properly storing bearings helps to ensure that your investment pays off,” said Randy Breaux, Motion Industries’ Senior Vice President, Southern U.S. Operations, Corporate Marketing and Strategic Planning. “Proper storage extends the life of the bearing, and therefore reduces downtime.” Tom’s Toolbox embodies the “how-to” format, but in shorter time snippets. In the series, the witty and informative host,
March
25
Tom Clark, demonstrates a broad range of solutions designed to save viewers money and time, while keeping workers safe on the job. Each Tom’s Toolbox video short is filmed in a workshop setting or an appropriate offsite setting. The series is also available for viewing via Facebook and YouTube. Motion Industries has over 550 operations including 15 distribution centers throughout North America, and serves more than 150,000 customers. They are a leading industrial parts distributor of bearings, mechanical power transmission, electrical and industrial automation, hydraulic and industrial hose, hydraulic and pneumatic components, industrial products, safety products, and material handling.
IPH Group announces its entry into ITALY via a joint-venture with the MINETTI Group
IPH Group, one of the leaders in European industrial supply, is taking the next step in the development of its European business by acquiring 50% of the MINETTI Group, a leader of Industrial Distribution in Italy. Over the past 10 years, IPH has led the consolidation of the sector by attracting and acquiring a number of strong European players. Today IPH Group is present in particular in Germany via the brand ZITEC, in France via its subsidiary OREXAD, in the Netherlands via the
brand BIESHEUVEL TECHNIEK. The Group is now pursuing its development in Italy, gaining access to the second biggest market in Europe. MINETTI was created in 1951 and has a consolidated turnover close to 130 M
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What Happened in the
Bearing Industry First Half of
March
27
2015
RBC Bearings to Acquire Sargent Aerospace & Defense RBC Bearings Incorporated, a leading international manufacturer of highly-engineered precision plain, roller and ball bearings for the industrial, defense and aerospace industries, today announced that it has entered into a definitive agreement to acquire the Sargent Aerospace & Defense business (“Sargent”) of Dover Corporation (DOV) for $500 million, to be financed through a combination of cash on hand and senior debt. The transaction is expected to close in the second calendar quarter of 2015 (our fiscal first quarter of 2016), subject to customary closing conditions, including regulatory review. “Today we are very pleased to announce the execution of an agreement between a subsidiary of Dover Corporation and RBC Bearings to acquire Sargent Aerospace & Defense. Sargent supplies highly engineered products to a customer base that we know well and serve daily. Their manufacturing processes and design expertise align very well with and complement those of RBC Bearings,” said RBC Bearings Chairman, President and Chief Executive Officer, Dr. Michael J. Hartnett. “We are adding a very talented Sargent team who are experts in these products and we are excited to welcome those valued employees to the growing RBC Bearings team.” With headquarters in Tucson, Arizona, Sargent is a leader in precision-engineered products, solutions and repairs for aircraft airframes and engines, rotorcraft, submarines and land vehicles. The company manufactures, sells, and services hydraulic valves and actuators, specialty bearings, specialty fasteners, seal rings & alignment joints, and precision components under leading brands including Kahr Bearing, Airtomic, Sonic Industries, Sargent Controls, and Sargent Aerospace & Defense. Annual sales are approximately $195 million and the company has over 750 employees in six facilities in three countries.
March
29
JTEKT develops the world’s first thrust ball bearing with a PPS cage for refrigerator compressors
JTEKT Corporation has developed a thrust ball bearing with a PPS*1 cage for refrigerators which achieves even greater energy efficiency. Conventionally, refrigerators used slide bearings in the compressor*2. However, achieving the use of rolling bearings in the compressor enables low torque and greatly contributes to improvements in compressor performance and better energy efficiency of the refrigerator. JTEKT has succeeded in the first ever development and mass production of a bearing which, through utilization of PPS in the cage, resolves the engineering issue of resin oligomer*3 formation when using rolling bearings in refrigerator compressors. Refrigerators are home appliances which run 24 hours a day, 365 days a year, and constitute a large portion of electricity expenses. Due to this, energy efficiency is a key focus of consumers when purchasing refrigerators. To improve the energy efficiency of Page: 68
refrigerators, JTEKT has developed a thrust ball bearing with a PPS cage for application in refrigerator compressors, which up until now employed slide bearings. Refrigerator compressors use compressor oil and a refrigerant. In conventional polyamide resins, cyclic oligomers form in the resin and caused defects, and therefore rolling bearings made with resin were not employed. JTEKT has adopted PPS as the cage material to eliminate this issue, achieving greater energy efficiency for refrigerators.
Bearing News • Issue 4
April
01
DUNLOP Bearing – Transmissions – Linkages
We are pleased to announce that as of 1st April 2015, our company name has changed to DUNLOP BTL LTD formerly Medway UK Ltd. Bearings & Ball Joints are available from stock now, with additional products coming on line over the next few weeks.
Please update your system with immediate effect, only our company name has changed all other details such as contact names, location addresses, telephone and payment details remain the same, however e-mail address have changed, please replace all @medway-uk. com addresses to @dunlopbtl.com.
DUNLOP BTL is a committed European manufacturer, and wherever possible will produce within the EU; to fulfil this promise we are currently expanding our UK factory to allow the availability of a new product line by the end of this year! The new ‘Transmissions’ catalogue is available on-line to view now at www. dunlopbtl.com.
DUNLOP Bearings, Transmissions and Linkages are manufactured in the UK, across Europe and Asia; they are of the highest quality with packaging and labelling to match. V-Belts & Pulleys, Timing Belts & Poly-V Belts, Taper Bushes, Roller Chain, Rod Ends, Spherical
April
02
NSK’s High-Performance Bearings Employed in Hokuriku Shinkansen (Bullet Trains)
NSK announced that its high-performance railway axle bearings have been selected for the E7 and W7 Shinkansen trains of the Hokuriku Shinkansen Line, which began operations in March 2015. Railway bearings are important safetycritical components. They have a direct influence on the safe operation of railways and must comply with the highest safety requirements. In addition, they face the critical challenges to being compact and light in order to save energy and reduce impact on the environment. Shinkansen trains in Japan carry many passengers safely over long distances. The bearings
selected for the Shinkansen trains must be highly efficient and durable and must pass strict quality controls.
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WHAT WAS ROLLING AT THE HANNOVER MESSE 2015? 6,500 companies from 70 countries have showcased technologies for tomorrow’s production plants and energy systems. More than 220,000 trade visitors – 70,000 of whom came from outside Germany – used HANNOVER MESSE to catch up on the latest technologies and made key investment decisions. The Bearing Industry @ Hannover 2015 1359 different bearing industry related products and services where displayed by 426 companies in Halls 5, 6, 21, 22, 24, 25, 16 & 17. Hall 22 was the main Hall for bearings overwhelmed by the gigantic booths of Schaeffler and SKF. The high presence of Chinese bearing manufacturers were remarkable and confirmed by many attendees. For the first time in the Hannover Messe history it was clearly to see the high amount of partnerships and synchronization between European and Asian bearing distributors / manufacturers and further localization of common bearing brands. The evidence that the mentality of the industry is changing rapidly from ‘Where is it produced?’ into ‘How is it produced?’ The present companies could be divided generally into four groups. The common bearing producers, the special and customized bearing producers, producers who provide application related solutions and distributors. The sector is clearly in a period of major challenges and undergoes a dynamic change. The impacts of the further industrial globalization, the upcoming ‘Industry 4.0’ and the ‘Internet of Things (IoT)’ started clearly changing the landscape of the bearing industry. The gap between the common bearing producers and the customized solutions based producers is becoming bigger at fast speed.
What will we see @ Hannover 2017? The current dynamics of the industry will probably move the above mentioned four groups of bearing companies
in more than four different directions. Some of the producers will keep their production at the same range
Mr. Tom Hamlett & Mr. Paul Cuthill from GODIVA BEARINGS, The two SUPERHEROES at HannoverMesse
and quality level, while others shall try to expertise in certain types at higher quality level. There is an expectation that more and more common bearing producers will jump in the sea of industrial reliability by providing new products and services along with the bearings they produce. The bearing distributors will play the key role here for small and mid-size bearing producers for achieving this goal. The producers who follow the path of ‘industry 4.0’ and ‘internet of Things (IoT)’ will be probably more deeper in space… You can read in the following pages the summary of what was rolling at the Hannover Messe 2015.
at the Hannover Messe 2015
Performance, efficiency, intelligence rolling bearings are at the heart of new trends in technology and products The global megatrends of mobility and „Industrie 4.0“ as well as the associated further development of rolling bearings, plain bearings and linear guidance systems in terms of loading, operating life and power density are the main features of Schaeffler AG’s Industrial division’s presence at the Hannover Messe 2015. In addition to the perennial themes of increasing performance, economy and energy efficiency, the subjects of sensors, actuators and networking as well as continuous condition monitoring are key focus points in product development. “The drive components with integrated sensor technology and smart actuators we are presenting in Hannover are a prerequisite for networking machinery and plant as well as for the control of autonomous processes in our customers’ value added chain,” according to Robert Schullan, member of the Executive Board at Schaeffler AG and President of Schaeffler Industrial.
Mobility for Tomorrow
strength lies in its breadth of knowledge which covers not only the automotive sector but all other types of urban and interurban mobility such as two-wheeled transport, rail and aviation.
„Industrie 4.0“ The „Industrie 4.0“ initiative places particular emphasis on networking components, machinery and production
systems by using IT systems which are either top-down or integrated into machines. A prerequisite for this is components which can identify and transmit conditionbased information. Rolling bearings have a decisive role to play here as they are responsible for guidance and positioning as well as supporting process forces and movements.
Integrated torque measurement units for maximum precision and efficiency
Environmentally friendly drives, urban and inter-urban mobility and the broad subject of energy are the specific focus points of Schaeffler’s “Mobility for Tomorrow” strategy. As development partner and global supplier to the automotive and industrial sectors, Schaeffler has a detailed knowledge of drive train systems in both vehicles and industrial applications. Schaeffler’s Page: 72
A highlight from Schaeffler is the new magnetoelastic FAG torque measurement unit. This mechatronic solution from Schaeffler provides significantly more accurate monitoring and control of applications and processes. By offering solutions for bearings and subsystem, Schaeffler is able to provide the torque
measurement unit as a ready-to-fit solution, matched to the specific application.
FAG-TORB in X-life quality Schaeffler is presenting a new bearing design at the
Smart actuators: Innovative screw drives for electromagnetic linear actuators
2015 Hannover Messe with its FAG TORB toroidal roller bearing. This is a roller bearing with angular adjustment in X-life quality. It combines the angular adjustment capabilities of a spherical roller bearing with the axial displacement of a cylindrical or needle roller bearing.
Schaeffler is presented a new design and new operating principle to expand its range of spindles by introducing a screw drive with particularly high load carrying capacity and power density. The PWG planetary screw drive is paving the way towards “smart actuators�: extremely high efficiency electromagnetic linear actuators with minimum space requirement.
Solutions for preventing white etching cracks Schaeffler is presenting a comprehensive range of
Measurably better with X-life Considerable potential for increased functionality, economy and reliability in industrial applications is being released thanks to continuous development of rolling bearings, plain bearings and linear guidance systems. X-life is the seal of quality used by Schaeffler for products which have a considerably longer rating and operating life due to their increased basic dynamic load ratings in applications where the load and design envelope are identical.
New bearing design - toroidal roller bearing
solutions at the Hannover Messe to increase resistance in bearings to white etching cracks and to prevent premature bearing failure. White etching cracks are structural changes in the material that form below the surface of the bearing. Under the influence of external loads, this can lead to premature failure of the bearing in question. This can affect bearings in wind turbines as well as in many other industrial applications. To achieve efficient and economical reduction in white etching crack damage, Schaeffler recommends a statistically proven technical solution of through-hardened bearings combined with black-oxide coating of the outer rings, inner rings and rolling elements using the coating system Durotect B.
For the complete press kit of all our press releases for the 2015 Hannover Messe, go to: http://www.schaeffler.de/content.schaeffler.de/de/press/presskits/press_kit_hmi/ press_kit_hmi
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NN, Inc. Debuts as Exhibitor at 2015 Hannover Messe NN, Inc., a diversified industrial manufacturer of precision metal bearing components, industrial plastic and rubber products, and precision metal components, debuted as an exhibitor at the 2015 Hannover Messe
to produce a world-class bearing. Senior Vice President of the Metal Bearing Components Group, Jeff Manzagol said, “The Hannover Messe was a great opportunity for NN to show the world that we are committed to creating ever-increasing value for our customers. With dedicated resources, we continue to supply the bearing industry with the highest quality and highest precision components.” NN’s Autocam Precision Components Group, which manufactures precision metal components, also made its initial debut at the Hannover Messe in the Industrial Supply hall.
NN’s Metal Bearing Components Group was located in the Motion, Drive and Automation (MDA) hall and showcased Photo: Members from NN Global Sales Team, Purchasing, and R&D some of the company’s Headquartered in the U.S., latest innovations, NN has 4,200 employees and including precision balls and rollers, stamped metal 25 manufacturing facilities in North America, South parts, and a breakthrough new welded cage. NN gave America, Europe, and Asia. For more information, visit visitors a chance to better understand the technology, www.nninc.com. engineering, and process advancements that are needed
Carter @ The Hannover Motion, Drives and Controls exhibition Carter Manufacturing Limited was in attendance at the show for the 3rd time located in the main bearing Hall 22, stand B32-1. Show visitors were interested by the comprehensive range of specialist bearing products on show at the Carter Manufacturing Stand. The products generated an unprecedented level of enquiries and enthusiasm, especially the newer technologies such as the large Silverthin 40” Super Precision Thin Section Bearing on display at the front of the stand. Carter Manufacturing Limited is reflecting on a highly successful show with a booking already securing the stand for the next show in 2017. We would like to extend a warm thanks to all our customers and prospective customers that took the time to stop and visit us during the show. You can find more information about the other products which were displayed during the show on www.carterbearings.co.uk Page: 74
“PROSINO, The Ring Specialist” PROSINO S.r.l. is an Italian company highly specialized in the turning & heat treating of steel rings for super precision bearings and custom made bearings PROSINO S.r.l. has succesfully presented their products in Hall 24 and enjoyed a very good response from visitors (OEM’s and end-users). Dimensional range of the rings: from 8 mm of bore up to 300 mm of OD. Main focus of the company is: - High quality raw material source - Complete tracebility of production steps - Heat treatment - Geometrical and dimensional accuracy - Flexible production facility Contact: Dr. Pietro PROSINO - pprosino@prosino.com - Mob: +39 335 8361291
JESA participated for the second time at Hannover Messe! For the second time, JESA Bearing Solutions displayed their future technology, innovations and solutions at the Hannover Fair in Germany. The JESA booth was situated in the dedicated bearing producer hall where JESA presented its customized bearing solutions in combination with overmolded polymers as well as their very successful high performance guide wheels range. “We were approached by a very large number of distributors interested in promoting our new LRG rollers on their market” said Marcel Dubey, Sales & Marketing Director at JESA.
The exhibition not only creates many promising contacts but also offers existing JESA customers the chance to preview, the latest in innovation and materials, such as the JESA new high performance stainless steel “Steenox”. If you want to see what went on during the event, please visit the JESA photo gallery and the JESA Youtube channel. Visit JESA website www.jesa.com for more information. Gallery photo : www.flickr.com/photos/ jesaspinningsolutions/ Youtube Channel : www.youtube.com/user/ Spinningsolutions
NKE has participated in the Hannover Fair for the 8th time NKE Austria GmbH has participated in the Hannover Fair for the 8th time. The bearing manufacturer showed high profile at the leading trade fair Motion, Drive & Automation 2015 (MDA) in Hall 22 with a 100 square-metre stand. In attending the world’s biggest industrial fair, the company showcased its new bearings solutions for different industrial applications, especially from the segments of agricultural machinery, electrical motors and general machinery. “Our aim is to develop new solutions together with our OEM customers, and to find new ways of cooperation with our distributors”, explains Harald Zerobin, NKE’s technical Managing Director. “Customers want to have alternative bearing solutions in order to increase efficiency and reduce costs“, adds Heimo Ebner, NKE’s commercial Managing Director. “Through the trade show, we would like to improve our market position in different industrial segments.” NKE produces standard and special bearings for all industrial applications. Engineering, product development, production and final processing of components, modular assembly, quality assurance, logistics, sales and marketing are centralised at NKE’s headquarters in Steyr, Austria. A wide range of standard bearings is available from stock or at short production lead-times. NKE also provides tailored products and solutions. NKE’s products are distributed through 15 international representative offices and more than 240 distribution outlets in 60 countries. Visit www.nke.at for more information about NKE products
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SKF outlines how to Power th SKF has been presenting a selection of its leading products and innovations as well as an innovative technical discovery at Hannover Messe 2015. The company has been developing advanced solutions to customers operating across industry since 1907. The company utilizes its vast experience and industry insight to continuously produce new technologies, which deliver competitive advantages to customers, such as improved productivity and sustainability.
SKF launches innovative new bearing rating life model SKF has launched the SKF Generalized Bearing Life Model, a pioneering new bearing rating life model that is specifically designed to help engineers predict bearing life with greater levels of accuracy than ever before. The new model is a major step forward for the industry, and will play a vital role in enabling OEMs and end users to match bearings and application conditions with even greater certainty, resulting in improved machine life and reduced operating costs.
manufacturing and engineering. The document, entitled ‘Power the Future’, features contributions by specialists from within SKF and leading external authorities. It focuses on current and emerging trends in engineering technology and processes, and outlines how the factory, machinery and the workforce will evolve in the near future. ‘Power the Future’ will enable engineers and students to develop a greater knowledge of the main areas of interest that are predicted to become increasingly prevalent to future technology developments in a variety of key global industrial segments. The Power the Future report can be downloaded for free from www.skfpowerthefuture.com.
Launched at Hannover: SKF smart innovations boost mobility and connectivity At Hannover, SKF has launched a variety of new product innovations that boost mobility and connectivity in industrial applications.
SKF Enlight SKF Enlight is a package that combines a powerful new mobile app with a special Bluetooth-enabled sensor. It allows non-expert staff to gather expert data such as vibration and temperature information, using standard mobile devices on demand.
SKF EnCompass Field Performance Programme helps to meet real-world application conditions. The SKF Generalized Bearing Life Model takes both surface and subsurface failure modes into consideration.
Developed as part of the SKF EnCompass Field Performance Programme, the new bearing rating life model will enable original equipment designers and end users to more closely match bearings to actual application conditions, therefore further optimising bearing performance.
Power the future with SKF’s new report In partnership with industrial technology experts and academics from all over the world, SKF have released a new thought leadership report focusing on the future of Page: 76
The package features three main elements: a mobile app entitled Data Collect, which turns a standard mobile device such as a smartphone or tablet into a data collection device; the SKF Wireless Machine Condition Detector (WMCD), which is a special sensor that measures vibration and temperature data – and relays it to Data Collect via Bluetooth; and – if appropriate – ruggedized Atex Zone 1-compliant tablets and smartphones, if users need to collect data in hazardous areas such as oil & gas, refining, chemicals and pharmaceuticals .
he Future at Hannover TKSA 51
SKF showcased a selection of technology innovations at Hannover 2015 Visitors to Hannover Messe 2015 would also get a glimpse of a selection of SKF’s other innovations, designed for use in a variety of industries, including Oil & Gas, Automotive and many more.
Top Drive exhibit
The TKSA 51 is a new SKF shaft alignment tool, which prevents shaft misalignment. Easy to use, the TKSA 51 is the first instrument designed for intuitive shaft alignments using tablets and smartphones. The app makes it quick and easy to set up of motors, drives, fans, gearboxes, pulleys and couplings, even by first time users. It comprises two compact and lightweight laser measuring units, designed to suit almost any application. Using the versatile shaft brackets, the instrument can be mounted on small machines with limited space, whilst extension chains, rods and magnetic holders are supplied for mounting the tool on large machines.
SKF Insight
SKF Insight monitors dynamic parameters such as vibration, temperature, lubrication condition and load, and informs the user when conditions are abnormal and can threaten to cause bearing damage. When it was launched, at Hannover 2013, SKF Insight was a technology concept – a way in which maintenance engineers might improve condition monitoring by keeping tabs on bearing health. Two years on, it is a fully functioning solution running in customer pilots, capable of supplying data directly to diagnostic centers for better condition monitoring via the SKF Cloud using SKF @ptitude
The top drive exhibit showcased a range of SKF advanced solutions that are helping to improve the operational reliability of critical top drive systems in the oil and gas sector. This includes bearings, seals, lubrication and condition monitoring products.
Sliding Door Damper exhibit The Sliding Door Damper (SDD) incorporates two gas springs and an oil damper, ensuring that doors up to 400kg in weight can quickly be brought to a soft, safe final position – almost no matter how hard they are closed. As well as acting as a brake, the SDD also positions the door in its closed position and is ideal for use in a range of sliding door structures, such as barn doors, room partitions and French windows.
For further information, please contact: Press Relations: Nia Kihlström, +46 31-337 2897; +46 706 67 28 97; nia.kihlstrom@skf.com
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BMI Participated in Hannover Messe 2015 Bearing Manufacturing India participated in the Hannover Messe 2015 from 13th -17th April 2015. The company received a good response from the variety of products displayed. In synchro with the partner country for the Hannover Messe and the “MAKE IN INDIA” campaign the company showcased a vast variety of solutions for agriculture machinery steel plants, gear boxes general machinery and several other industries BMI is developing a wide variety of solutions for customers in 45 countries. Our aim is to expand distribution partners to increase our reach to OEM and MRO customers. With global recession customers are looking for alternate solution to reduce cost but not compromise on quality as well.
Groundbreaking new solutions presented by Prüftechnik At the Hanover Fair 2015 PRUFTECHNIK again presented groundbreaking new solutions in the area of shaft alignment and condition monitoring. Solutions by PRUFTECHNIK contribute to increasing machine service life and to reduce wear and repairs on bearings, seals, couplings, shafts and parts. Other benefits include lower power consumption and higher production quality. Discover PRUFTECHNIK’s latest innovations for Vertical shaft alignment, Cardan shaft alignment and Machine status on tablets and smart phones on www. pruftechnik.com Page: 78
“Through trade shows BMI would like to showcase the technical capability of BMI engineering team in developing special, non standard and customized solution for OEM and MRO customers in smaller quantity as well” explains Mr. Snehal Sheth Managing Director of Bearing Manufacturing India. More than 100 customers and prospects from 18 countries visited the BMI booth to discuss about existing and potential business opportunities to grow business further. BMI manufactures standard and special bearings for all industrial applications. The company has an entire team of engineers working on new product development and engineering for special / customized solution for customers. Around 300 standard sizes are available from stock or quick lead times from India. Visit www.bmibearings.com for more information
ATS Electro-Lube for your application ATS Electro-Lube have always looked forward to the Hannover Messe event. This year we attended with even more excitement as ATS announced the launch of it’s European distribution centre. ATS specialise in the manufacturing of automatic lubricators, supplying innovative single point and multipoint lubrication solutions to a wide range of industries. Our electro-chemical and electro-mechanical units can adapt to a variety of environments, from extreme temperatures to under water, making them the most versatile lubers available. With demand for our automatic lubricators growing across Europe, our new distribution centre will quickly and efficiently service the continent with our market leading products. While at Hannover, the support for our lubricators was overwhelming. We were able to establish strong ties with distributors across several European countries, and we are incredibly excited to watch these partnerships flourish as ATS expands it’s global reach. Visit www.atselectrolube.eu for more information.
International was there too... 47 years ago, a dream led to what is today a Movement; a movement called KG International that is going strong based on the beliefs, principals and ethics of the founding Chairman Mr. Kedar Gupta. The tiny acorn that germinated from an idea, a potential foreseen, is today a mighty oak in the shape of KG International of (Team KGI, L to R – Hamidreza Zehtabchi – Iran, Istvan Jebel Ali Free Klimon – EBT Hungary, Franco Lagna – Italy, Tozser Sandor – EBT Hungary, Rohit Gupta – CEO KGI, Zone, Dubai. Maurizio Marani – Italy, Barbara Prampaloni - Italy, Jaspreet Reen – Dubai) Sprawling over 55 countries in 5 continents, with a team size of over 100, a portfolio of over 4,000 varieties, a relationship with principals
EPTDA Pavillion at Hannover 2015 was a success! Looking forward to Barcelona. Through its formal alliance with Associate Member Deutsche Messe, EPTDA keeps on generating tangible member benefits to help member companies increase their international exposure and access to a network of market players from across the globe. The EPTDA/PTDA pavilion members (Gates, Godiva Bearings, KB Electronics Inc., NB Europe, RBC Bearings, Sedis, Uiker, Contra Praha, Belden, Fallbrook, Shanti Gears, Mondial, Tsubaki, Bervina, Esco Couplings) had the opportunity to have a central presence at this leading show, while still maintaining their individual company identity. EPTDA hosted a Reception at its Pavilion - giving a chance for its members, its partners and colleague exhibitors and visitors to network, share ideas and relax over a glass of wine and something to nibble. The EPTDA Welcome Reception was organized with the support of ConeMount Bearing Heaters. EPTDA has currently opened registrations for its Annual Convention taking place this year on the 23-25th of September in Barcelona! The high-level executive event of the year is also promising to be a great success! Visit www.eptdaconvention.org for more information
that goes back over 20 years; KGI believes in forging relationships that last. It is today one of the foremost & most respected bearing businesses in the world. The mantra till date remains commitment, quality, ethical business dealing. It has taken passion, determination, steely resolve and belief to create this reality in less than 30 years; skeptics believed it could not be done, but the passion, the dedication and a firm faith have helped make KGI a company favoured the world over for its quality, reliability, customer centricity and range on offer. KGI participated at the Hannover Messe and is pleased to admit that it was a wise decision which shall be repeated for the future editions too. The potentiality of the business that is generated was palpable in the number of visits received, the quality of enquiries received, the expectations of the visitors and the exhibitors alike and the general hum one felt in the air.
ZEN at the Hannover Fair a short review Some weeks has passed since Hannover Messe 2015. Our booth in hall 22 has been dismantled and stored, we were overwhelmed by the feedback the ZEN group got from you, our visitors. In the various and interesting conversations we had with our customers and even with our competitors, it will be very interesting to try to find the answers to the challenges that lie ahead. Have the improvements in our standard product range been enough? Will our new high end ceramic product ranges and stainless steel special bearings be accepted as successful as our other products? Will the trend for higher quality go on? What will the market require in the future? In the relaxed atmosphere at the ZEN hospitality bar we were happy to listen to customer suggestions to improve the service and make ZEN more efficient to you. Therefore we like to thank all of you for the constructive conversations we had and we look forward to seeing you again at the ZEN bar in 2016. www.zen.biz Page: 79
At the Hannover Messe, the specialist for plastics in motion introduces its new service for tribo parts 3D printing service enables fast delivery of tribo-plastic prototypes
Those who need prototypes or special plain bearings in the future will be able to get even faster solutions supplied by igus. A year ago at the Hannover Messe the expert for motion plastics and high-performance plastics for moving applications, presented the world’s first tribo-filament for 3D printers. Now igus has expanded its range of offers and will now provide a 3D printing service to its customers by delivering special parts even faster and at very affordable prices. us,” says Tom Krause, Product Manager at igus iglidur® tribo-filament. “This is what we have been occasionally carrying out in recent months and now want to offer this service to all our customers.” igus has expanded its potentials with the tribo-filament, which is 50 times more abrasion resistant than conventional 3D printing materials and delivers even more unusual geometries quickly and easily. The delivery times for printed parts are mainly dependent on the complexity of the components. ‘From 24 hours’ is a statement that is also true for these igus products Complex components such as worm gears can be implemented with 3D printing service in a very short time. Thereby they are up to 50 times more abrasion-resistant than comparable components manufactured in the 3D printing
From the Hannover Messe onwards, igus will offer a 3D printing service with the in-house tribo-filament and will take over the complete production of special parts. “Our customers can contact us with their 3D data and get their parts quickly and easily printed by
MESYS presents new version of shaft and rolling bearing analysis software MESYS AG presented its new version 04/2015 of shaft and rolling bearing analysis software. New features in bearings analysis are: support for axial and double row radial tapered roller bearings, input of deformations of bearing rings and a statistical parameter variation. New features for shaft calculations are: The parameter variation was added, position of forces can be varied in load spectra, a pulley is available as load element and hydrodynamic journal bearings are available as supports. As new calculation module a calculation for ball screws was presented. Visit www.mesys.ch for more information.
Calculate prices and order online The service for customers is made as simple as possible up to the finished component. The data can be uploaded on the igus website and the components ordered. The prices are also determined automatically online, and similar to the indication of the delivery time, the price also depends on the complexity and the structure of the component. Visit www.igus.de/de/presse for more information.
MARINE MAINTENANCE WORLD EXPO HEADS TO ANTWERP FOR 2015 EVENT • International ship maintenance and repair exhibition moves to Antwerp for three-day exhibition • New venue just minutes from Port of Antwerp • Including renowned Marine Maintenance Conference with Ship Owners and Operators Forum • 29 September to 1 October 2015; Antwerp, Belgium Marine Maintenance World Expo is back for its third year, with the 2015 event moving to a new Antwerp venue, just minutes from the international port. Less than an hour from Rotterdam, the Antwerp site will house Marine Maintenance World Expo along with the show’s ever-popular conference, bringing together the ship repair industry’s leading lights and newest technologies under one roof. Still the only global event dedicated to keeping the world’s fleets operational, Marine Maintenance World Expo is already set to be bigger than previous years, with over 100 exhibitors due to take part, showcasing the latest marine repair innovations to a unique audience of industry professionals. Ship repair yard and dry dock owners and operators, fleet maintenance and technical managers, operations directors, managing directors, marine surveyors, ship owners and operators, and offshore platform and wind farm owners and operators from over 62 countries around the world attended the 2014 event, and organisers expect even bigger crowds in 2015. The expo will also host the world’s largest conference
exclusively for the ship maintenance and repair industry, with more than 60 leading industry speakers lined up to speak in two separate streams during the three-day event, focusing on the key issues affecting the industry. New for the 2015 conference is a Ship Owners and Operators forum on the second day, designed for ship owners to meet and discuss ideas on various maintenance best practices, lifecycle extension strategies and ways to reduce operating costs and downtime, via more sophisticated maintenance techniques. A Ship Repair Yard Owners and Operators forum will provide the focus for the third day of the conference, with ship repair yard and maintenance companies coming together to discuss new technology and ways to operate a more efficient yard while reducing turnaround times and increasing profitability. To register for your free official entry badge to Marine Maintenance World Expo, and to book your place at the event conference visit www. marinemaintenanceworldexpo.com
ELGETI ENGINEERING GMBH PRESENTS BEARING ENDURANCE TEST RIG ELPAX-310 ON HANNOVER MESSE From April, 13th to 17th, Elgeti Engineering GmbH exposed two test rigs on Hannover Messe, one of the world’s most important industrial exhibitions. One of the exhibits is a bearing endurance test rig type EELPAX-310 which is suitable for lifetime testing of e. g. tapered roller bearings, spherical roller bearings and any kind of thrust bearings up to 310 mm outer diameter. This testing machine comprises two test stations on one single frame by which four test bearing can be examined simultaneously. The software allows the operator to define time-dependent testing parameters which are
speed, axial load, temperature and oil flow rate. In this context, it has to be mentioned that there are two completely independent oil circuits which do not only avoid any interference between both test stations but also allow testing with different lubricants at the same time. Typical applications of this test rig are verification of products, materials, production processes etc. For such purposes, Elgeti Engineering GmbH delivers such products to especially bearing producers. Apart from that, they operate several test rigs at their own facilities in Aachen, Germany for independent product evaluation and benchmarking. Visit www.elgeti-engineering.de for more information.
ZVL AUTO Hannover Review ZVL AUTO use to exhibit at the Hanover exhibition every two years since 2003, and is very pleased to be able to meet almost all their customers at one place. The Hanover exhibition is a good chance to find new opportunities and possibilities for establish cooperation with new companies. Meeting people from all around the world is pleasant and inspiring for the ZVL AUTO team. The company is producing tapered roller Page: 82
bearings since 1959 in Presov Slovakia. The production range includes at present tapered roller bearings in metric and inch sizes with inner diameter from 15 mm – 190 mm and outer diameter from 30 mm - 300mm. More than 10% of their bearings are with special design. 56 years of bearings production in ZVL AUTO is half a century of tradition, experiences, quality and confidence for the future. You can find more information about ZVL AUTO on www.zvlauto.sk
MDA 2015 – ISB AFTER SHOW REPORT ISB opens the exhibition season in 2015 taking part in the “Motion Drive and Automation”, held at the Hannover Messe - one of the most renowned exhibition sites in Germany – from April 13 to 17 year 2015. With special attention to the issues of energy efficiency, reduction of consumption, urbanization and sustainable mobility, MDA 2015 represented for ISB the right place to confirm its presence among “The greats” of bearings and components industry. As always, it was also a great opportunity to lay the foundations for new and profitable business relations. In particular, there have been
NTN-SNR OFFERS A BEAUTIFUL SHOWCASE FOR INNOVATION AT THE HANOVER MESSE 2015 NTN-SNR hosted several thousand visitors on the stand, set up from 13th to 17th April,at the Hanover trade show: an area of 370 m2 entirely dedicated to innovations, expertise and strategy of the third largest bearings manufacturer in the world. Professionals could discover here all the ranges standard and technical - of the NTN and SNR brands on the six centres dedicated to the five markets covered by the Group in the industry. NTN-SNR thus presented the references that it develops in: - construction and agriculture; - steel industry; - mines-quarries and cement plants; - robotics and machine tools; - railway;
many contacts from Eastern Europe, parts of the Mediterranean, North Africa, Middle East and India. With a stand of over 100 square meters and innovative graphics than ever before, the “green mark” appears alongside the great leaders of the market, against which is an excellent alternative in terms of price and quality. This has been the sixth participation of the Italian brand to the German exhibition, the proof that ISB keeps investing resources for the internationalization and continuous growth both of the brand and the company. See you at Agritechnica, Visit www.italcuscinetti.it more information.
- and wind energy. Innovation is featured at each division, with a special mention for new mechatronics and monitoring solutions of NTN-SNR. A seventh centre is devoted to the NTN-SNR sales label. Named ULTAGE, this label attests the added value of the range that is certified: increased service life, optimized maintenance costs, support throughout the life of the product, etc. ULTAGE, which integrates the product life cycle management process deployed by NTN-SNR, was be the subject of a cycle of five conferences during the week: NTN-SNR experts provided answersabout the method of selecting steel suppliers, quality of steel, heat treatment, bearing design and industrial and logistical efficiency of the Group. Visit www.ntn-snr.fr for more information about the NTN products Page: 83
Standard and special products of ZKL Group at Hannover Messe The Czech manufacturer of bearings, ZKL Group, introduced both standard and also special bearings at Hannover Messe. Visitors could find among displayed exhibits e.g. sealed spherical roller bearings B22205.2RS and B22218.2RS which are mainly designed for applications, where there is a possibility of increased humidity or impurity. The biggest added value of the sealed spherical roller bearings is that the service life can be 3 times longer. Also other new bearings, especially designed for the railway industry, were worth
seeing e.g. the slewing ball ring PLC 01-12-03 used in the joint of two carriages of city trams or the tapered roller bearings PLC 82-09-01.4 which are protected against electric current with a ceramic coating applied on the outer ring. The heaviest bearing at the ZKL stand with the weight 224 kg and outside diameter 720 mm was the large-size double row spherical roller bearing 230/500EW33MH with a one-piece brass massive cage. The main advantage of the double row spherical roller bearings is the transmission of high load and tilt, which compensate the shaft deflection. These bearings are often used in the mining or energetic industries.
Bega Special Tools introduced their BETEX 24 XLDi light weight portable heater @Hannover Developed in-house, the device design is based on the ‘Safety first’ motto. It is particularly suitable for heating rotating parts such as bearings, gears and couplings, enabling a shrink-fit. Contrary to the relatively heavy, low frequency induction heaters commonly available on the market, this new BETEX® 24 XLDi induction heater weighs merely 7 kilograms. The new model’s substantial weight reduction was realized thanks to the application of medium frequency technology, which does not require a massive U-shaped core in conjunction with heavy steel yokes. In order to guarantee a balanced heating performance, the substantially lighter coil in the new model has been combined with a specially developed electronic unit. The fact that the device components do not need to be demagnetized upon use is another advantage of Page: 84
medium-frequency technology. Moreover, the heater’s deployment does not require any preparatory activities and its energy efficient design helps to save on electricity. Regarding bearings, their original lubrication is not affected by this heater. When compared to conventionally applied heating methods, such as the use of blow torches and baths of boiling hot oil, this induction heater is the superior device for a safer, cleaner and particularly more efficient heating process. The BETEX® 24 XLDi induction heater is suitable for heating components ranging from steel cylindrical / ball bearings, with closed and open housings, to gears, couplings and rings, up to a maximum outer diameter of 180 mm in conjunction with temperatures of up to 150° C. Heating a component with the maximum size specification takes approximately 15 minutes. As standard, this BETEX® 24 XLDi induction heater package comes with heat-resistant gloves inside a plastic case specifically designed for this purpose. Thanks to the mentioned induction heater, the lifespan of the rotating components in machines may be substantially extended, resulting in a lower Total Cost of Ownership. Visit www.bega.nl for more information
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FRABEX becomes the logistics partner for the FBJ brand bearings
The well reputed Brand FBJ finally has a Premium Logistics Partner for Europe: The FRABEX GmbH in Austria has become the official EDC in April 2015! Providing the superior quality products of this experienced manufacturer with it’s over 50 years accumulated technical Know-How, FRABEX GmbH is now looking for Distribution partners all over Europe. “One or two strong partner in each EU-country would be perfect…” says Robert Jahns, Sales Manager at FRABEX. As FRABEX is receiving their goods directly from the manufacture, they offer
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even better prices, then an order from FBJ could ever be for European companies. “The biggest benefit for our partners will be huge savings in shipping time and costs coming along with manufacture’s prices … Beside the reliable quality of FBJ Bearings, of course!” says Jahns with a smile. Having about 2.000 different types on stock already, FRABEX will serve all needs from Industrial, Automotive and Agricultural sector. Guaranteeing to keep stocking up the warehouse to it’s partners needs and offered services like Just-InTime-Delivery or even of Free-Of-ChargeShipments* FRABEX will be a big gain for Europe’s Bearing market! * From a net order value of 4000,- EUR to all neighbor countries of Austria plus Poland Visit www.frabex.com for more information
NTN-SNR officially announces Mineral Circles Bearings as its UAE distributor for its SNR brand Mineral Circles Bearings (MCB) has acquired the SNR brand distributorship in UAE— a significant milestone in strengthening its local supply chain as part of its 2015 diversification strategy. Michel Peltier, NTN-SNR’s MiddleEast Sales Manager, stated “MCB has been chosen as SNR distributor because of its good reputation in the market, professionalism, and its capacity to handle a good stock level that matches the needs of the region.” Peltier added that since SNR is a premium bearing brand in both automotive and industry segment, it needs to be represented by high level distributors to fulfill the needs of the existing markets as well as the emerging ones. As the sole automotive SNR distributor in
UAE, MCB’s Marketing Director, Hassanein Alwan, mentioned that this new venture is in preparation for the increasing local demand in the automotive industry wherein six million cars are forecasted to roam the country in the next few years brought about by Expo 2020. Alwan said, “Our goals are to obtain a big local market share and to introduce to our clients the SNR kits, a pioneering line of business for MCB which we believe will be the future of the bearing industry in the region.” He added that Automechanika Dubai is the best event to Page: 87
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launch these developments because of the immense turnout of diverse visitors and high profile exhibitors.
(OEM) making them widely accepted in the industry.”
Further expanding its global footprint, MCB in the latter part of 2014 has acquired both NTN and SNR brand dealership in key African countries such as Sudan, Libya, Ethiopia, Kenya, Tanzania, and Angola to name a few.
He added, “Because of MCB’s proximity and stock availability, we foresee not just sustainable profitability for us but infinite and immediate service to our customers.”
Alwan stated, “With a reported 100 percent population increase by 2030, Africa is seen as a continent of great possibilities. We expect a fundamental long term demand in NTN and SNR bearings because they are produced by the original equipment manufacturer
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MCB’s continuous growth with NTNSNR is a solid driver of investor and consumer confidence with a perceived large sales impact within the UAE and across the MENA region.
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A new opportunity for bearing and P/T distributors worldwide has opened for subscriptions. BearingCLOUD.com provides easy access to 䄀氀氀 猀甀戀猀挀爀椀戀攀爀猀 眀椀氀氀 爀攀挀攀椀瘀攀 琀栀攀 瀀爀椀渀琀攀搀 the worldwide network of bearing and power 䈀攀愀爀椀渀最一䔀圀匀 洀愀最愀稀椀渀攀 昀漀爀 昀爀攀攀 愀琀 琀栀攀椀爀 挀漀洀瀀愀渀礀 愀搀搀爀攀猀猀⸀ transmission distributor stock-lists. All subscribers will receive the new issues of the BearingNEWS printed magazine for FREE at their company address. The subscriptions to this brand new, all-inclusive bearing and P/T products search platform can be done by surfing to the registration form on www.bearingcloud.com. Page: 88
Bearing News • Issue 4
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What Happened in the
Bearing Industry First Half of
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2015
Stefan Hantke assumes the position of President Sales and Engineering at Schaeffler Industrial On June 1, 2015, Stefan Hantke (48) assumed global management of Sales and Engineering of the Industrial division of Schaeffler Technologies AG & Co. KG. In his new position, Mr. Hantke is member of the Industrial Division’s Management Board and is responsible for the global sales management for rolling and plain bearing components and systems for around 60 different industrial sectors. He is also responsible for the 27 Schaeffler Technology Centers (STC) worldwide. Schaeffler Industrial is represented worldwide with locations and sales offices in around 50 countries, therefore enabling consultation and delivery to take place at the customers’ premises. Mr. Hantke has over more than 20 years of sales and engineering experience in the mechanical engineering sector, particularly in the field of bearing and
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After holding various management positions within the Schaeffler Group and in external companies, in 2005 he assumed the position of President of the Linear Technology business unit at Schaeffler. Most recently, Mr. Hantke was employed as President Industrial and was responsible for all of Schaeffler’s Industrial division activities in North America.
Belarus to supply India with $1m worth of bearings Minsk Bearing Plant and Shree Shyam Bearings Pvt. Ltd signed a contract on the delivery of $1 million worth of bearings to India. The document was signed during the Belarusian-Indian Business Forum in Minsk on 4 June, according to BelTA [BelaRussian News] Contracts were also signed on the delivery of car components to Belarus. Signatures to the documents were set by the heads of the Borisov plant Avtogydrousilitel and ZF Steering Gear (India) Ltd. A trilateral agreement on long-term service maintenance of BelAZ equipment and supply guarantees for the Belarusian quarry machinery was signed by BelAZ – the managing company of BelAZ Holding, Belaz-Enrika Trades and Services and Voltas Limited.
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linear technology. After completing his studies in mechanical engineering at the University of Applied Sciences in Saarbrücken, in 1992 Mr. Hantke started his professional career at Schaeffler in Sector Management at INA Linear Technology in Homburg.
Partaking in the BelarusianIndian Business Forum were about 100 people, including over 40 businessmen of India. The event included a ceremony to unveil a plaque to commemorate the interaction between Indian and Belarusian experts on reconstruction of Grodno CHPP-2. The forum featured a presentation of investment opportunities of Belarus, and mechanisms for crediting, insurance and leasing in Belarusian machinery exports to India.
Bearing News • Issue 4
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SKF signs long-term agreement with UTC
SKF has signed a long-term agreement with United Technologies Corporation (UTC) for the supply of a range of bearings and components to UTC’s aerospace business. As part of the agreement, SKF will supply UTC’s aerospace divisions with precision roller and ball bearings, including main shaft bearings, as well as seals and precision elastomeric components used in helicopter applications. Additionally, the agreement encompasses the delivery of engine bearings to Pratt & Whitney, a UTC division, to be used in their Next Generation Product Family geared turbofan engines. Rutger Barrdahl, President, Aerospace, says, “SKF and UTC have a long relationship, dating back to the 1950’s. Through this contract, we ensure that SKF’s technology and bearings continue
to play a part in the development of aircraft that are more fuel efficient, with lower engine noise and deliver improved environmental performance.” Sam Abdelmalek, Vice President, Supply Chain at UTC, says, “We are excited to continue our relationship with SKF, creating a strong foundation from which to further solidify and grow our relationship. This One UTC Company agreement with SKF is good progress in meeting our contractual governance model and ensuring an efficient procurement process.” Deliveries to UTC’s aerospace businesses have already commenced. Page: 91
What Happened in the
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‘Counterfeit FAG Rolling Bearings Raid in India’ ended with arrests
Successful raids are an important step for Schaeffler in the fight against product piracy and thus towards the protection of customers. Four companies in Mumbai have been proved to be dealing in counterfeit FAG rolling bearings. At these production, packaging and trading firms, police have confiscated tens of thousands of counterfeit FAG packaging units, more than 500 counterfeit FAG rolling bearings as well as various machines. The proprietors have been arrested, and criminal proceedings have been instituted. The arrests also serve as a means of deterrence in counterfeiting circles. Careful Planning and Observation Products of the brand FAG, which is one of the leading rolling bearing brands, are highly popular with counterfeiters. The team of investigators from the agency TACT India, which safeguards our interests in India, has identified Mumbai as a central market for these counterfeit products and identified the main protagonists. Their investigations yielded sufficient information as a basis for the raids. However, the firms involved had already learned in advance of the operations and had closed their shops or moved to new storerooms. After five days of waiting and some more observation, the investigators were able to raid four firms. In a joint operation with the local policy authorities, TACT India has impounded more than 37,000 counterfeit FAG packaging units and labels, 530 counterfeit FAG rolling bearings and 250 FAG master copies as well as various grinding machines and packaging machines. Moreover, two of the proprietors and an employee were arrested and remanded in custody.
Schaeffler’s Fight Against Product Piracy In 2004, Schaeffler set up a central department for fighting product and brand piracy. A lot has happened since then. The Brand Protection Team has Page: 92
handled several thousand cases. And these cases are by no means restricted to Asia as in this example. There were also a large number of major counterfeiting offences in Europe and the USA. This global experience forms the basis for the constant improvement and refinement of our procedure for prosecuting violations of our brand rights. Generally, the Schaeffler Group employs a zero tolerance policy towards all cases of product and
brand piracy. Our primary aim in this is to protect our customers’ interests. To protect buyers and end clients procuring INA and FAG products from distributors also, Schaeffler has assessed and certified sales partners worldwide. All authorized distributors are listed on the Schaeffler website and can be checked by entering the certificate number. If there is the slightest doubt as to whether a bearing is original, the local Schaeffler sales team or the Brand Protection Team can be contacted anytime (piracy@schaeffler. com). Bearing News • Issue 4
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A Look Inside:
DEVELOPMENTS IN THE CHINESE BEARING INDU CBIA
An Interview:
China Bearing Industry Association Page: 94
TS
USTRY Mr. Zhou Yu
Secretary General of the China Bearing Industry Association (CBIA)
Page: 95
A Look Inside:
DEVELOPMENTS IN THE CHINESE BEARING INDUSTRY CBIA
An Interview:
China Bearing Industry Association
Mr. Zhou Yu Secretary General of the China Bearing Industry Association (CBIA).
Numerous National players in the Chinese bearing industry are taking measures to strengthen their position in the domestic market in order to increase further expansion abroad. Many of them need to overcome a number of barriers, including technological issues that will allow the production of high-tech, high-margin and high-precision bearings, for which demand continues to grow worldwide. We tried to find the answers on the question ‘What’s Happening in the Chinese Bearing industry’ during an interview with Mr. Zhou Yu, Secretary General of the China Bearing Industry Association (CBIA).
“The sales value of our members is more than 70% of the total Chinese bearing industry.” What is the role of CBIA? The aim of CBIA is to Represent and protect the common benefit, to unite the power and promote the revitalization and development of the whole industry, to actively work as the bridge, the link, the assistant, the media organization, among the government, member units and users at home and abroad. The main mission of CBIA is to investigate and research the present situation and developing direction, to report the suggestions and claim to the government; to accept the appointment of the government and give suggestions on the developing plan of the industry and technology
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CBIA 的角色是什么？ 中国轴承工业协会以代表和维护全行业共同利 益，团结行业力量，促进行业振兴与 发展为宗旨。 在政府与行业企业之间、行业与国 内外用户之间、国内外同行业企业之间 发挥桥梁、纽带和参谋助手作用，是市场经济的 中介组织，积极为政府、行业和会员(企 业)服务。 中国轴承工业协会主要工作任务是：调查研究行 业的现状及发展方向，向政府反映 行业的意见和要求；接受政府部门委托，对行业 发展规划及有关技术经济政策提出建议； 组织交流企业改革、管理、技术、质量、经济等方 面经验；组织开展行业统计信息工作， Bearing News • Issue 4
economic policy; to organize the experience exchange of enterprises reformation, management, technology, quality, economy etc; to organize the statistical work, to collect, analyze and issue the technical and economical information; reinforce the building of talent team, organize the employee training and promote the use of new technologies; to organize domestic and international economic and technological exchanges, and hold exhibitions, support enterprise to explore the market both at home and aboard. Promote the development of the industry through various services.
“Annual sales value of bearings reached 164.9 billion Yuan in 2014.” CBIA sets up five branches such as Planning, Development and Consultation Committee, Technology Committee, Enterprise Management Committee, Human Resource Committee and Marketing Committee. The standing office of CBIA is located in Beijing, which is responsible for coordinating work among committees.
搜集、分析、发布行业有关经济技术等信息资料； 开发人力资源，加强职工教育，组织 人才培训，推广应用新技术、新成果；组织国内外 经济技术交流与合作，举办国内及国 际轴承展览会，帮助企业开拓国内外市场等等。 以多种服务形式，推动行业发展。 中国轴承工业协会设有规划发展咨询工作委员 会、技术委员会、企业管理委员会、 人力资源工作委员会和市场工作委员会等五个 分支机构。 中国轴承工业协会秘书处是常 设机构，设在北京，负责协会的日常工作并协调 各专业委员会开展工作，内设信息部、 专家委。为了推动和加强全国轴承行业的信息服 务和轴承专业展览工作，经批准，中 国轴承工业协会正式注册成立了“北京中轴协信 息科技有限公司”和“中轴协(北京)会展 有限公司” ，业务受中国轴承工业协会指导。 协会 的刊物和媒体有《轴承工业》、 《轴 协动态》、 “中国轴承行业网” 、 《中国轴承信息报》、
For promoting and strengthening the information service and professional exhibition of bearing industry, CBIA officially registered two companies, Beijing Zhongzhouxie Information Science and Technology Co., Ltd. and CBIA (Beijing) Exhibition Company Limited. Also CBIA has periodical publications and media such as Bearing Industry, China Bearing Association Update, China Bearing Industry Website, China Bearing Newspaper, Bearing Industry Trends, etc. Following the policy of opening to the outside world, CBIA cordially established the connections and friendly relationships with organizations of bearing and related industry all over the world, and promote the common development through various friendly exchanges.
“There are more than 90000 kinds of bearings from 0.207mm inner diameter to 12m outer diameter.” How many members do you have? Over 300 members of CBIA spread most of the provinces and cities in China, concentrating the mainly bearing enterprises and have exclusive and representative nature. The sales value of our
《轴承工业动态》等。 中国轴承工业协会遵循我国对外开放方针和政 策，热忱与世界各国同行及相关行业 组织建立联系，开展多种形式的友好交往与合作 以推动轴承工业的共同发展。 你们有多少个会员? 中国轴承工业协会现有会员单位300 多家，集中 了全国轴承行业的精华，遍布全国 各省、市、自治区，具有广泛性和代表性，覆盖面 Page: 97
members is more than 70% that of the total bearing industry. China bearing industry developed rapidly since opening to the world. It is now capable of the annual sales value that reaches 164.9 billion Yuan in 2014, the annual output is 19.6 billion sets. There are more than 90000 kinds of bearings from 0.207mm inner diameter to 12m outer diameter, from the general precision to high precision. The total import and export volume is 8.86 billion US dollars among which the annual exporting value is up to 5.09 billion US dollars and is superior in Chinese machinery-electronics products.
Can you give us a brief summary of the evolution within the Chinese Bearing Industry Association? China Bearing Industry Association (CBIA) is a national organization founded in 1988.CBIA members are voluntarily composed of bearing and its components enterprises as well as research institutes, designing institutes, universities and related industry enterprises, unrestricted by the area and department. CBIA is a social and economic community with legal personality and authorized by Ministry of Civil Affairs of People’s Republic of China.
“The total import and export volume of bearings is 8.86 billion US dollars, while the annual exporting value is 5.09 billion US dollars.” How do you analyze the China Bearing fair ‘Bearing 2014’ In the golden September, the 14th China International Bearing Industry Exhibition, as the world’s largest international bearing professional exhibition, attracted tremendous attention. Mr. Su Bo, Vice Minister of Ministry of Industry and Information Technology of the People’s Republic of China, and Mr. Wang Ruixiang, President of China Machinery Industry Federation wrote the inscription for the exhibition. The exhibition area of Bearing 2014 has reached to 55000 square meters, gathered more than 860 exhibitors from 20 countries and regions, including international large bearing groups like NTN, NSK, JTEKT, Minebea from Japan, Schaeffler from Germany, Swedish SKF and domestic well-known
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按销售总额计占全行业的70%以上。 改革开放以来，中国轴承工业取得了快速稳健发 展，2014 年全行业销售总额1649 亿元， 轴承产量196 亿套，轴承品种规格90000 多个， 从内径0.207 毫米到外径12 米，精度 从普通级到精密级，轴承进出口总额为88.6 亿美 元，其中年出口创汇达50.9 亿美元， 是中国机械行业出口创汇拳头产品之一。 您能否简单总结一下中国轴承工业协会的演变 过程？ 中国轴承工业协会成立于1988 年，是以轴承及 其零部件生产企业为主，包括研究所、 设计院、高校、相关行业企业及事业单位自愿参 加组成的不受地区、部门、隶属关系和所有 制限制的全国性行业组织。 经国家民政部批准， 具有社会经济团体法人资格。
您怎样分析Bearing2014 中国轴承展？ 金秋九月，第十四届中国国际轴承及其专用装备 展览会作为全球规模最大的国际性轴承 专业展览会备受瞩目。 国家工业和信息化部副部 长苏波和中国机械工业联合会会长王瑞祥在 展会前分别为本届展览会题词。 本届展会规模空前。 展出面积达到5.5 万平方米， 有来自20 个国家和地区的860 多家 展商，云集了像日本NSK 、NTN、JTEKT、德国 Schaeffler、Minebea、瑞典SKF 等国际大 型轴承集团和像瓦轴、洛轴、哈轴、天马、人本、轴 研科技、无锡机床、上海莱必泰、新乡 日升、濮阳贝英等国内知名的大型骨干企业及专 用装备制造企业。 专业观众超过50000 人 次，分别来自47 个国家和地区。 Bearing 2016 展会是否会有任何改变以及新项 目吗？ Bearing2016 展会，我们在继续发挥2014 年展 会优点的同时，将继续完善展会的内容、 活动。 将进一步提升上海国际轴承高峰论坛的水 平，内容更贴近市场和企业的需求，加大信 息量；进一步办好轴承与主机的对接会，扩大对 接主机领域，丰富对接的形式和内容；进一 步做好技术交流活动，让广大展商有机会展示技 术及产品实力，推广产品市场。 特别介绍的
Bearing News • Issue 4
large-scale key enterprises and special equipment manufacturing enterprises like ZWZ, LYC, HRB, TMB, C&U, ZYS, Wuxi Machine Tools, Shanghai Rabbit CNC Machine Tools, Xinxiang Sunrise, Puyang Beain. More than 50000 professional visitors come from 47 countries and regions.
“In the coming Bearing 2016, we would like to keep the level of Bearing 2014 and continue to improve the content of exhibition and activities.” Will there be any changes and new programs for ‘Bearing 2016’? In the coming Bearing 2016, we would like to keep the level of Bearing 2014 and continue to improve the content of exhibition and activities. Further enhance the level of the Shanghai International Bearing Summit, closer to the market and the needs of enterprises, increase the amount of information. Further organize the face to face meeting between bearings and main equipment manufacturers, expand the field of equipments and enrich the form and content.
是，我们将在新一届展会上更加注重轴承客户、 观众的服务：一是加大对主机行业的宣传力 度，通过各主机协会吸引更多的主机企业参观展 会；二是在展会期间，同期举办国际轴承经 销商会议；三是展会期间，通过机电流通协会，召 开轴承经销商交流会，使我们的展会、展 品更贴近市场。
你们以协会的身份还参加其他哪些国际轴承展？ 为了推动轴承行业的交流与发展，帮助企业进一 步开拓和巩固国际市场，中国轴承工业 协会针对行业需求，慎重地选择相关的国家及地 区的国际大型展览会，积极组织中国轴承企 业参加。 对于提高中国轴承产业轴承工艺及加工装备，您 有哪些推荐和建议？ 近年来，我国轴承专用装备取得了长足的进步， 但与国际先进水平还有较大的差距。 按 照为我国轴承产业转型升级、科学发展、由大到
Further improve our work on technical exchange activities, help exhibitors to display their technology and product capability, promote the products on markets. In particular, we will pay more attention on the services to bearing customers and visitors. Firstly, promote the exhibition among main equipment industry associations and attract more users to visit the exhibition. Secondly, during the exhibition, hold international bearing distributors meeting. Thirdly, co-host bearing distributors exchange meeting with CMEPCA, make our exhibition close to the market.
Which other International Bearing exhibitions do you join as Association? In order to promote the exchange and development of bearing industry, help enterprises to further develop and consolidate the international market, by the demand of the industry, China Bearing Industry Association carefully select large international exhibitions in relevant countries and regions and actively organize Chinese bearing enterprises to attend.
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强提供强有力的技术支撑这一总的要求，我 们制定了《全国轴承专用装备发展指导意见》 ，总 结了我国轴承专用装备取得的成绩和存在 的差距，提出了我国专用装备发展的目标和技术 路线及发展重点，归纳了轴承行业七个方面 67 种设备发展方向，主要技术路线： 1、生产过程智能化 推广应用数字化控制技术，实现装备性能、功能 Bearing News • Issue 4
“The World and China’s economy is in a period of deep adjustment. Great changes are taking place in the global manufacturing patterns.” Which are the recommendations and suggestionsyoumadetoimprovethebearing technology and processing equipment for the Chinese Bearing Industry? In recent years, considerable progress has been made for China’s bearing processing equipment, but there are still large gap compared with international advanced level. According to the demands of transformation and upgrading of the bearing industry, scientific development, provide strong technical support of the whole industry from big to strong, we compiled the Development Guidance of National Bearing Processing Equipments. The guidance summarizes the achievements and the existing gap of China’s bearing processing equipment, puts forward the target of the development and the technical routes, conclude the development direction for seven aspects of 67 bearing industry equipments.
的升级换代，发展以人机智能交互、柔 性敏捷生产等为特征的智能制造方式，促进工业 机器人在轴承生产中应用，推进生产制造设 备联网和智能管控。 2、自动生产线联线 研发应用先进的自动上下料、传送、节拍控制、故 障处理等联线技术。 实现短联线之间 的联线，如磨超自动生产线和装配自动生产线的 联线。 推广应用机外预调等工装快换技术。 3、在线自动检测修正 自动生产线实现在线自动检测、反馈、补偿、统 计、纠错、防漏。 4、工作表面凸度和修形 轴承零件工作表面磨超加工实现有利于降低边 缘应力，形成润滑油膜的凸度和修形。 5、高速化加工 推广应用高速磨削技术。 对引进的高速镦锻、高 速冷镦设备消化吸收再创新，实现国产 化。 6、复合加工
The main technical routes are as follows: 1. Intelligent production processes Promote application of digital control technology to realize equipment performance and functional upgrading, develop intelligent production with features of intelligent humanmachine interaction, flexible agile production etc. to promote application of industrial robot in bearing production, promote manufacturing equipment network and intelligent control. 2. Link automatic production line Research and develop advanced linking technologies of automatic loading and unloading, conveying, rhythm control and fault processing etc.. Realize linking between the short line, such as link grinding super finishing automatic production line and automatic assembly production line. Promote application of quick changing tooling technology of machine external preset etc. 3. On-line automatic detection and correction Realize automatic production line online automatic
研发应用硬车+超精、车加工+磨加工、铣+钻等多 工序复合加工。 推广应用双滚道一次 磨、双滚道双牙口一次磨、滚道挡边一次磨和双 端面内外圈套磨等多加工面复合加工。 7、多工位加工 推广应用锻造多工位压力机床、保持架多工位冲 压机床。 对引进的滚子多工位冷镦机消 化吸收再创新，实现国产化。 Page: 101
detection, feedback, compensation, statistics, error correction, leak proof. 4. Work surface convexity and modification Implement grinding and super finishing on bearing parts work surface is helpful to reduce the edge stress, form lubricating oil film convexity and modification. 5. High speed processing Promote application of high speed grinding technology. Digest, absorb and independent reinnovate for imported high speed forging and high-speed cold heading equipment to achieve localization. 6. Composite processing R &D and apply multi composite process of hard lathe + super precision, lathing +grinding, milling + drilling etc. Promote application of double raceway one-time grinding, double raceway two teeth grinding, raceway edge one grinding and double end surface internal and external trap grinding and other composite processing.
8、控性加工 推广应用气氛精确可控的热处理、温度精确可控 的锻造加热技术和装备，推广应用热、 冷辗扩成形，改善工件内部金属组织（晶粒、流 线） ，由控形制造发展到控性制造。 9、工序替代 钢球以磨代研，提高加工效率，实现定制制造。 部 分产品套圈以硬车代磨，提高加工效 率，防止磨削烧伤、裂纹。 10、节能降耗减排 提高设备能效，降低设备能耗，充分利用余热、余 压。 提高轴承钢等原辅材料利用率。 冷却液、清洗液超精液集中处理，循环使用，实现 零排放或接近零排放。 研发应用新型水剂 清洗介质，替代煤油介质。 用先进技术改造传统 装备，大力发展轴承专用装备再制造。
你能解释一下轴承产业对中国经济的重要性吗？ 轴承工业和战略性新兴产业有着密切的关系。 节 能环保、新一代信息技术、生物、高
7. Multi-station processing Promote application of multi-station forging press machine, multi-station cage stamping machine. Digest, absorb and independent reinnovate for imported high multi station roller cold heading machine to achieve localization. 8. Controlled processing Promote application of technology and equipment of precise and controllable atmosphere heat treatment, accurate and controllable temperature forging heating, Promote application of hot, cold rolling, improve the metal internal microstructure of workpiece (grain, streamline), developed from shape control manufacturing to property control manufacturing. 9. Alternative manufacturing process Grinding instead of fine grinding for processing of steel ball, improve processing efficiency, realize the customization manufacturing. Hard lathing instead of grinding for processing of bearing ring of some product, improve processing efficiency, prevent the grinding burn and crack.
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端装备制造、新能源、新材料、新能源汽车等战略 性新兴产业都离不开轴承工业的配套。 尤其是其中新能源汽车产业，包括核电、风电、太 阳能发电等的新能源产业，包括航空、 卫星及应用、轨道交通装备、海洋工程装备、智能 制造装备等的高端装备制造产业均需要 大量高速、精密、重载轴承。 新中国成立六十多年来，我国轴承工业从无到 Bearing News • Issue 4
10. Energy-saving emission reduction Improve equipment energy efficiency, reduce the energy consumption, make full use of waste heat, residual pressure. To improve the utilization ratio of bearing steel and other raw materials. Centralized process and recycling cooling liquid, cleaning liquid and super semen to achieve zero emissions or close to zero emissions. Develop and apply new aqueous cleaning medium to substitute kerosene medium. The transform traditional equipment with advanced technology, vigorously develop remanufacture of bearings special equipments.
Can you explain the importance of the Bearing industry for the Chinese economy? Bearing industry and strategic emerging industries have a close relationship. Energy conservation and environmental protection, a new generation of information technology, biology, high-end equipment manufacturing, new energy, new materials, new energy vehicles and other strategic emerging industry is inseparable from the supporting of bearing industry, especially the new energy automotive industry, including nuclear power, wind power, solar power and other new energy industry, including aircraft, satellites and application, railway transportation equipment, marine engineering equipment, intelligent manufacture equipment and so on. All these high-end equipment manufacturing industry needs a large number of high-speed, precision, overloaded bearings.
有，从小到大，与共和国一同成长。 特别 是改革开放以来，我国轴承工业持续、稳定、快速 发展。 我国已成为位居世界第三的轴承生 产大国，并以坚定的步伐向世界轴承强国迈进。 我国轴承工业已具备了一定的为战略性新兴 产业配套的基础和条件。 近年来研发了一系列为 战略性新兴产业配套的轴承，如卫星和飞船 发射、测控和应用系统轴承，风力发电机组偏航、 变桨轴承，核电站二级泵轴承，提速重载 铁路货车轴承，第三代轿车轮毂轴承单元等。 但 在一些轴承产品领域，我国轴承与国际先进 水平还有一定的差距。 在中国未来的发展当中， 轴承是高科技支撑的产品，代表了我国机械 工业基础工业水平，对于中国的工业发展，轴承 产品是装备制造业的关键基础件，为重大装 备和重点工程发挥了重要的支撑作用。 对于中国 的国防，轴承也是战略性的物资，轴承工业 为国防装备的发展发挥了保障作用。
In the more than 60 years since new China was founded, China’s bearing industry grow out of nothing and expand from small to large, grow up together with the republic. Especially since the reform and opening up, China’s bearing industry keep sustained, stable and rapid development. Our country has become the third largest bearing production country in the world, and with firm steps to bearing world powers. China bearing industry is well-qualified to support for strategic emerging industries. In recent years, developed a series of bearings used for strategic emerging industries, such as satellite and airship launch, measurement and control and application system bearings, wind turbine yaw pitch bearings, nuclear power plant secondary
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pump bearings, acceleration of heavy load railway wagon bearings, the third generation of hub bearing units, etc. In the field of some bearing products, there is still a gap with the international advanced level. Bearings are the support of high-tech products and critical components of equipment manufacturing industry, represent the basic industrial level of China’s machinery industry. For China’s industrial development, the bearing industry plays an important role in supporting of major equipments and key projects. For China’s national defense, bearings are also strategic materials, bearing industry plays a security role for the development of national defense equipments. What are some of the biggest challenges CBIA have faced and how have you dealt with them? China’s bearing industry has entered a new historical period to a higher goal. The Eighteenth Congress of the CPC puts forward the direction of the reform and development of associations. Under the leadership of CMIF and SASAC, we will actively participate in association reform, continue to increase the service ability of CBIA, leading members and bearing industry to the bearing power. We must further enhance the sense of responsibility and mission, firm confidence, forge ahead, working hard, and jointly create a more prosperous and powerful China bearing industry in the future, strive for an early bearing industrial power.
CBIA 面临的最大挑战有哪些，你们是如何处理 的？ 我国轴承行业已经进入了向更高目标迈进的新 的历史时期。 党的十八大提出了协会改革 发展的方向。 我们将在中机联、国资委的领导下， 积极参与协会改革，不断增强CBIA 的服 务能力，引领会员和轴承行业向轴承强国迈进。 我们必须进一步增强责任感和使命感，坚定 信心，锐意进取，埋头苦干，顽强拼搏，共同创造 我国轴承工业更加繁荣强大的未来，争取 早日圆梦轴承工业强国。 你如何看待世界轴承行业的未来？ 世界经济和我国经济正处于深度调整期。 全球制 造业格局发生着深刻变化，正在孕育兴 起的新一轮科技革命和产业变革将推动人类社 会生产、生活方式的深刻变革。 特别是信息技 术和制造技术的融合，将对制造业生产方式、发 展模式带来颠覆性、革命性影响，并将重塑 制造业发展格局。 轴承产业将对全球经济特别是 制造业的发展起着基础性的决定性作用。
How do you see the future of the worldwide bearing industry? The world and China’s economy is in a period of deep adjustment. Great changes are taking place in the global manufacturing patterns. That is breeding the rise of a new round of technological revolution and industrial revolution and will promote a profound change in human social production, life style. Particularly, the integration of information technology and manufacturing technology will revolutionary impact the manufacturing production mode, the development mode, and will reshape the development pattern of manufacturing industry. Bearing industry will play a fundamental and decisive role on the development of the global economy especially the development of the manufacturing industry.
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Bearing News • Issue 4
SHAFT & BEARING
ANALYSIS
Use of cases for automatic parameter variations The MESYS shaft and rolling bearing calculation software includes an automatic parameter variation which can be helpful in many cases. Some use cases are presented in the following. Rolling bearing analysis The standalone rolling bearing calculation is useful to evaluate the effect of bearing clearance/ pretension or tilting angles on load distribution or bearing life according ISO/TS 16281. Bearing life according ISO 281 is calculated by using an equivalent load calculated as , while ISO/TS 16281 uses an equivalent load for a single contact like for a rotating inner ring. This allows consideration of additional influence factors like clearance, tilting angle or centrifugal forces. A well known diagram shows bearing life over clearance for a deep groove ball bearing with maximum life for a small pretension. Figure 1 shows maximum life for a 6202 deep groove ball bearing under pure radial load (blue line) for clearance Pd=-0.015mm. On the other hand friction torque increases with pretension (green curve). With an axial load of 35% of the radial load, the maximum life is reached for Pd around zero (red curve). In case of axial load, increased clearance will lead to a larger contact angle and therefore smaller contact force, while in case of pure radial load Page: 108
increased clearance will reduce the number of balls sharing the load.
For this example no interference fits between bearing and shaft/housing were considered. Finally the calculation could be done with different positions in tolerance fields and also considering different temperatures.
Shaft analysis The rolling bearing analysis is fully integrated into a shaft calculation software. Therefore the nonlinear bearing stiffness is always considered Bearing News • Issue 4
automatically. The bearing reaction is not only an axial and radial force but also a tilting moment. In case of axial bearings, the reaction moment can get quite large. The bearing stiffness is important to consider if more than two bearings are used on a shaft or if deflections should be calculated including bearing clearance and deflections. A use case for parameter variations is shown for a simple rotor as shown in figure 2. How should the bearing clearance or pretension be selected? Figure 3 shows the first two natural frequencies for bending in red and green (the lowest natural frequency is zero for torsion) and the minimal bearing life as blue curve. Pretension increases stiffness Figure 2: Geometry of a simple shaft and therefore natural frequencies, but the bearing load is increased too. Figure 4 shows two other parameters: The friction torque (based on coulomb friction within the contact ellipse) as red curve and the circumferential ball advance. Because of a variation in contact angles each ball has a different speed which leads to variations in distance between rolling elements. If this variation is too large there will be forces between balls and cage. The minimum contact stress is larger than zero over the whole range, otherwise it could be a useful parameter as well. A compromise has now to be found between these results.
Figure 4: Circumferential ball advance and friction moment over bearing clearance
In this example a rigid pretension was considered. The same could be done by using spring pretension, which would only mean that a spring stiffness has to be considered as additional parameter. Other use cases of the parameter variation on shaft level could be the variation of direction and position of a force on an input shaft of a gearbox or the shaft of a motor. The gearbox manufacturers often don’t know the mounting conditions and for example a belt on a pulley could be mounted in any direction. Output values to be evaluated would be shaft strength and bearing life.
Shaft system calculation
Figure 5: Simple two stage helical gearbox used as example
Figure 3: Bearing life and natural frequency over bearing clearance
In the shaft system calculation, the parameter calculation could be used for bearings too, but this would be almost the same as for a single bearing Page: 109
With these inputs, 10000 calculations are run and the result can be shown as probability distribution. Figure 8 shows the distribution without profile crowning and figure 9 for crowning of 5μm. The diagrams show the probability density of maximum over average line load; the integral over each curve will be equal to one. In a report also the limits for 5%, 10%, 90% and 95% are shown as numbers.
Figure 6: Load ratio over flank line slope modification for different values of crowning
calculation. Therefore the load distribution in a helical gear pair is taken as example.As first step the parameter variation is used to change the flank line crowning and flank line slope modification of the first gear. The output parameter wmax/wavg is the maximum force per length over average force per length in the gear contact, this would be similar to the face load coefficient in the gear calculation. The optimum modification according to the diagram in figure 6 would be a flank line slope modification of -9.5μm with no crowning. This would lead to a minimum value for maximum line load on the gear pair. As there are always manufacturing tolerances, a crowning of a few μm should be preferred anyway. This leads to the question how to consider manufacturing tolerances. A statistical evaluation can be done by using the parameter variation as well. This is also possible with the bearing or a single shaft calculation. In figure 7 the inputs for the statistical evaluation are shown. Input torque has an uniform distribution between 90 and 110Nm, bearing operating clearance is set according to a normal distribution within the tolerance range and for all bearing positions a tolerance of ±0.01mm is used. The flank line slope modification has a normal distribution within 7 and 11 μm.
Figure 7: Inputs for statistical parameter variation
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Without crowning it is possible to get a small maximal line load about 1.08 times average load wavg, but it can also get as large as about 1.6 times wavg. With crowning the maximal load is about 1.2 times wavg with only a small variation. So the statistical parameter variation can be used to get insights about the sensitivity of results. This also shows that a design should not be optimized for one theoretical geometry only; because of tolerances solutions with low sensitivity against parameter variations should be preferred. While all calculations for shafts and bearings above had been done within seconds, these 10000 calculations need about 25 minutes. Several hundred calculations will usually be enough to get a first idea about the range of results, but for nice curves several thousand calculations are needed.
Figure 8: Probability for load ratio in case of no crowning
Figure 9: Probability for load ratio in case of 5mm crowning
Bearing News • Issue 4
ESTABLISHING FAILURE MODES IN
FOR BEARINGS
WIND TURBINES
John Coultate, Head of Condition Monitoring and EU Sales at Romax Technology Dr. Ashley Crowther – Global VP – InSight, Romax Technology
Wind turbine drive train failures can be expensive to remediate due to crane fees, replacement component cost, manpower costs and lost production. In order for wind turbine owners and operators to better manage the drive train lifecycle a sound understanding of failure modes and corrective actions is required. This article focuses on the techniques to establish the failure mechanism of wind turbine gearbox bearings and the process of root cause analysis (RCA) to determine the origins. The recently revised wind turbine gearbox design standard ISO 61400-4 requires the gearbox bearings to be sized per ISO 281 and ISO 76, which include calculations for two failure modes: a) sub-surface initiated rolling contact fatigue and b) yielding under maximum stress. The standard also mandates items such as bearing steel quality (to meet ISO 683-17), values for parameters involved in the sizing calculations and how design loads should be applied.
illustrates some of the factors involved in bearing performance and each or several can influence a premature bearing failure, where the life is much less than that found by the design life calculation. ISO 15243 is a useful standard to classify the damage and Figure 2 provide a few examples of bearing failures in the wind industry and the associated costs. Note that damage classification is not root cause of failure. One or more initiating factors are often behind the observed damage. The first step for a proper bearing RCA is to remove the bearing from the gearbox, separate the rings and rollers and determine the origin(s) of the failure. Prior to removing the bearing from the
The standard also provides good advice to the application from a design perspective, as often the failures seen in the field are not related to the bearing meeting the design calculation for these two failure modes. We see failures related to end loading, bearings races spinning in their fit, surface originated fatigue and retainers coming loose for example. Figure 1 Page: 114
Figure 1: Factors that must be considered for bearing selection. Incorrect assumptions on any of these factors can lead to bearing life reduction.
Bearing News • Issue 4
Figure 2: Common wind turbine drive train bearing failure modes
housing it must be photographed to document, in the ‘as found condition.’ It is helpful to write on the components with a paint pen to indicate part orientation prior to removal from housing. Look for evidence that the outer ring has spun in the housing or that the inner ring has spun on the shaft journal, abrasive wear and the nature of fretting corrosion often provide valuable clues. The bearing rings must be separated carefully without damaging any evidence. Bearings
points. Create a lifting plan to avoid dropped parts and musculoskeletal injuries. Eye protection, gloves, long sleeve shirt and a machinist’s apron are all required to protect against metal chips if using a drill press to remove cage rivets. Proper ventilation and gloves are required when using solvents to clean bearings. Once the bearing failure mode has been identified the root cause analysis work begins to determine the origin of the failure. Root cause analysis must follow an orderly process to achieve conclusive results. A typical wind turbine bearing failure RCA will incorporate the following 12 steps: • Project definition and project management • Identify potential causes • Review existing documentation
Figure 3: Images of common wind turbine drive train bearing failures. Left, initial macropit and debris damage on a tapered roller bearing. Middle, main bearing cage with imbedded debris and blackened grease. Right, cylindrical roller bearing with assembly damage at roller spacing
generally are held together by rivets in the bearing cage, snap-rings, or end covers. Bearing disassembly is not without hazards and a proper risk assessment should be conducted and reviewed by the site safety manager prior to work commencing. Some of the hazards that must be mitigated during bearing disassembly include: Bearings are often heavy with no built in handling
• Machine data review • Up tower inspection and measurements • Lubrication analysis • Factory teardown and inspection • Metallurgical investigation • Simulation • Future failure risk assessment using Weibull distribution analysis
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• Corrective action recommendations
• Surface and core hardness
• Root cause findings documentation
• Case hardness depth for carburized components
Documentation requirements, which are established in Step 1 must be followed by all parties involved in the RCA. This article focuses on two key steps in the RCA process, identification of potential failure modes and metallurgical investigation. These steps should be performed by engineers who are experts in bearing failure investigation.
• Grain size
Failure Mode Identification In order to identify all of the potential causes for failure it is essential to assemble all persons with knowledge of the wind turbines operation as well as relevant experts for a brainstorming session. The goal of the meeting is to leave no stone unturned and list out all potential causes so that they can be formally addressed and the output a Ishikawa or fishbone diagram that organizes the potential causes into groups. Once the diagram is created the group then ranks each potential cause by its perceived influence on the failure. To help guide the team to the root cause, all items with Moderate, High or Further Analysis influence factor rankings should be investigated further. The group then defines the documentation or operational data that must be reviewed or testing that must be performed prior to the item being eliminated as a potential root cause. Figure 5 shows a typical fishbone diagram for such an investigation.
Metallurgy In order to verify the items shown in the “Materials” bone of Figure 5 it is often necessary to send the failed bearings to a qualified metallurgical laboratory for testing and review by a metallurgist. At the lab the bearing may be sectioned, for example, in the axial and circumferential directions with samples prepared as shown in Figure 6. There are many tests that can be performed and an initial round of testing often includes the following: • Chemical composition Page: 116
• Steel cleanliness • Microstructure • Nital etch • Microscopic and SEM analysis of cracked regions Much can be learned about the failure mode from these tests, such as evidence of grinding burn under the Nital etch, evidence of sub-surface cracks originating from inclusions, an inadequate material hardness or a unsatisfactory steel microstructure. If any of the above tests prove that the material was insufficient then a study needs to be conducted of the manufacturing quality documentation to identify the total affected population. If the metallurgical testing does not reveal a root cause then the investigation should focus further on the gearbox design, assembly, and operation. Romax routinely performs RCA on failed wind turbine bearings and find the critical items in the investigation are generally factory teardown, metallurgical study and gearbox or bearing simulation. With a detailed approach to these tasks, buttressed by the significant application expertise, the root cause can generally be identified. This allows for the OEM or owner to transition quickly to assessment of corrective actions and risk/cost reduction. For more information, please don’t hesitate to visit the Romax website: http://www.romaxtech.com/ About Romax Technology Limited Founded in 1989, Romax is a global provider of software and services for the design, analysis and optimization of transmissions and drivelines for the automotive, bearings, wind energy, off road, rail, marine and aerospace sectors. Romax has over 220 customers worldwide, including the majority of OEMs across the transport and wind industries. It has won a number of industry awards, including two Queens Awards for Enterprise in International Trade and the British Engineering Excellence Award for Consultancy of the Year 2014. Romax is headquartered in Nottingham, United Kingdom and operates through 12 offices globally. For more information, visit www.romaxtech.com. Bearing News • Issue 4
NN, Inc. is a leading global manufacturer of high-performance precision components. • Precision Bearing Components • Autocam Precision Components • Precision Plastic and Rubber Components NN supplies components to a variety of markets, and our global manufacturing footprint enables us to serve customers around the world. We deliver precision solutions where they are needed with uncompromising quality and delivery standards, while focusing on R&D and innovations for tomorrow’s technologies. www.nninc.com
ZKL, the largest
Central European Bearings Manufacturer Modernizes Its Production
“We manufacture top-class bearings and will maintain our position”, announces ZKL from the Czech Republic. The largest manufacturer of large spherical roller, special and split bearings in Central Europa is investing 300 million CZK into its production units in 2015. The company has already modernized its main plant in Brno, which is the second largest city in the Czech Republic. “The official opening of the hall reconstructed for 38 million CZK took place in May as a part of a conference organized for our distributors”, said the ZKL general director Jiří Prášil. Distributors from Central as well as Western Europe arrived to Brno for this occasion. The actual reconstruction took less than a year. The main objective was to make the work environment better for the employees and to modernize the actual production process. Initially, workers reconstructed the southern part of the hall, which houses the assembly and final inspection areas. “The working environment of the assembly areas has improved significantly and the final inspection has obtained a respectable area for inspecting final parts prior to assembly. Moreover, the new airconditioning system secures dimension stability of the measured and assembled parts,” said Ondřej Mágr, the procedural technologist. Changes have also applied to the technological flow of the assembly, which was divided into two branches - for bearings with a diameter from 50 to 250 mm and for bearings with a diameter from 250 to 400 mm. “We have purchased two new machines for marking the bearings using laser and for completeness inspections. This technology secures Page: 118
the most modern description manner. Furthermore, utilizing a camera monitoring system, the device is also able to locate all possible defects that can occur during the assembly process - for example, damaged components,” said Mr. Mágr and added that all assembly work sites will be additionally equipped with intermediate operation handling technology. The remaining part of the hall was reconstructed as a part of further stages of the reconstruction. Upon the completion of the reconstruction, new technologies, which will carry the main load of the serial production, were installed in the hall. They include new automatic production lines, the configuration of which was based on the knowledge and experience acquired during the production of spherical roller bearings. We should mention here the production lines from O.ERRE. PI, designed for the production
Bearing News • Issue 4
segment of bearings with a diameter of up to 200 mm. Both bearing rings can be precisely sharpened on these lines. The production lines are connected to the two-disk DISKUS DDS 600 XL grinding machine. The composition of these lines will ensure that the bearing component is ready for direct assembly in the bearing. The segment of bearings with a diameter of up to 400 mm has also received new technologies, i.e. new production lines. “One of them is, for example, the BDA 400 CNC DUO unit from ČZ Strojírna, a.s. for grinding the orbits of the outer rings with a diameter of up to 400 mm. A demagnetizing machine has been also newly installed. It will ensure that the machined parts will be ready for washing and subsequent assembly,” explained Mr. Mágr. This production line for outer rings is complemented by a production line for inner rings, thus forming a technological and production unit for the given production segment. Thanks to the automation of the new work sites, the operator will have more time to monitor the production cycle and to predict possible deviances, which, if identified in a timely manner, can minimize the occurrence of inconsistent products and possible machine malfunctions. Page: 119
Production innovation The ZKL plant in Klášterec nad Ohří will be the next plant that will go through a large modernization process.. The company intends to introduce there an innovative production of roller and railway bearings. ZKL has already revitalized the production building, purchased new modern machines and will finish the actual project in August. The introduction of the roller bearings production at Klášterec will cost 159 million CZK. Additional 49 million CZK will be the price of the revitalization of the production facilities and 20 million CZK the cost of the transfer of the production of sheet metal cages from ZKL in Hanušovice to Klášterec. ZKL also plans to establish a central pressing shop and a machine innovation in the production of double-row self-aligning bearings, double-row angular-contact ball bearings and axial ball bearings in Klášterec. The company has been investing an increasing amount of money in the last few years, a fact that is related to the end of the economic crisis. “We have recorded an increased number of orders and our task is to manage our production for acceptable prices since our demanding customers put great emphasis on the price. Yet another aspect that has gotten our investments going was the opportunity to acquire grants from structural funds,” explained the general director Mr. Prášil. According Page: 120
to the company intends to continue with its investments in the coming years. It wants to focus on innovations of the existing main production segment, with the objective to offer its customers better products of a higher quality. The plant in Klášterec also seeks European grants that focus on innovations. “Shall the application be approved, a production process innovation project in the area of agricultural bearings will be implemented between 2016 and 2017,” said the executive director in Klášterec Mr. Oldřich Martínek. According to Mr. Martínek, the ZKL Group strives to expand its production segment based on the demand of worldwide customers. Yet another reason is the effort to maintain its competitiveness. The ZKL Group was established in 1999. It builds on almost seventy-year tradition of the Czech mechanical engineering. It currently employs 1,339 people. In the Czech Republic, it has production facilities in Brno, Hanušovice and Klášterec nad Ohří. Last year, the ZKL Group increased its sales by five percent to 1.569 billion CZK. The operation profit increased to 52 million CZK, which represents increase of 40% in comparison with the previous year. This year, ZKL plans sales in the amount of 1.749 billion CZK and operation profit of 105 million CZK. The growth in the sales of the ZKL products last year was also recorded in the Central European countries, including the Czech Republic, India and in South America. The export share of the company reached 80 percent last year. Bearing News • Issue 4
INNOVATIVE
ASSEMBLY PROCESS PROVES ITS
WORTH Anxious to constantly improve the production steps for its products, JESA, the Swiss manufacturer and developer of ballbearing and plastic injection solutions, has developed an assembly process that is already proving its worth. Meeting with Marcel Dubey, Director Sales & Marketing at JESA Well-known in various market segments such as automobiles, industry, medicine, consumer goods and construction, Fribourg company JESA based at Villars-sur-Glâne and a market player for more than 40 years, is positioning itself as a supplier of innovative solutions in the market for precision ball-bearings containing engineering or hybrid polymers. JESA is responsible for all stages in the process, from design to industrialization to production. “In the fast-growing automotive sector, for example, JESA figures in most mechanisms for Xenon headlamps and multi-directional LEDs. Together with the client, we’ve developed an integrated ball-bearing actuator which is an ideal
combination of plastic and metal elements, with a landmark patent,” confides Marcel Dubey, Director Sales & Marketing at JESA.
Innovative new production process JESA has implemented a new assembly procedure in order to optimize its manufacturing process for large volumes of complex units (several million pieces/year). Developed just 4 years ago by the company’s team of experts, this manufacturing process has already proven itself in the automotive market. In fact, it allows the production of complete units at a competitive price and a significant reduction in costs, as well as eliminating no fewer than 5 assembly steps.
Multiple-insert plastic injection mould for assembling several components in a single operation
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Bearing News • Issue 4
That’s a time savings of more than 50%. It also allows for just one supplier of a sub-assembly instead of five, and reduces waste by replacing injection moulding - no mean feat in a world increasingly focused on ecology. “This process allows the units to be assembled in a single step rather than the usual five or six. In addition to optimal precision and repeatability, the time saved is enormous and gives us a certain competitive advantage,” says Marcel Dubey excitedly, adding, “this new assembly process is aimed mainly at the textile and automotive markets with their especially high quality, price and volume targets.”
Marcel Dubey, Director Sales & Marketing at JESA
Success rewarded JESA has manufactured no fewer than 3 million units over the past 4 years using this fully automatic line. “The geographic proximity and tradition of innovation in Germany are the key to this success. This is especially so because our two main markets, automobiles and textiles, are very well represented there,” explains Marcel Dubey. The process gained recognition in 2012-2013 when it won the prize for innovation (SME category) of the Canton of Fribourg. Having exhibited at the Hanover Fair last April, JESA will be present at ITMA, the world’s largest fair for the textile industry, in Milan this coming November. It will present its latest innovations there.
Dynamic mechanical unit assembled by injection in 10 seconds instead of 1.5 minutes To contact JESA: Marcel Dubey Sales & Marketing Director Tel: +41 26 408 47 13 E-mail: marcel.dubey@jesa.com Web: www.jesa.com Youtube : https://www.youtube.com/user/Spinningsolutions LinkedIn : http://www.linkedin.com/company/jesa-sa/ Twitter: https://twitter.com/JesaSolutions Google+: https://plus.google.com/+JESABearingSolutions
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Bearing Installation, Application & Lubrication
Myths By: Ian A. Rubin
Are bearings making you spin
your wheels?
The wheels of industry turn on bearings, so why do the wheels often vibrate, clatter, squeak, drag and overheat? Bearings can fail for lots of reasons. Most failures (as shown in Figure 1) are related to lubrication and contamination, but myths and misconceptions handed from one generation of maintenance engineers to the next help perpetuate many easily avoidable problems. These myths fall into three general areas of bearing use: installation, misapplication and lubrication. Page: 124
Bearing News • Issue 4
Bearing Installation Myth #1: It’s okay to hammer a bearing into position if needed – FALSE.
Figure 1 - Sources of bearing wear or failures
Never strike a direct blow to a bearing. The rolling elements and raceway are hardened, but can still be damaged. A hammer blow can leave dents in the raceway that can cause noise and dramatically reduce bearing life. If installation is difficult, first check the shaft diameter, look for burrs, dirt or corrosion on the shaft. If needed, use a press to slide the bearing on. Apply pressure equally on the face of the inner ring to avoid damaging the raceways and rolling elements.
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Bearing Installation Myth #2: Off-theshelf TGP shafting is the best option – FALSE.
bearings return to steady-state temperatures.
It’s much more important to know the shaft’s tolerance range to be sure it meets your bearing manufacturer’s spec for diameter and roundness. Review the bearing manufacturer’s recommendations and measure/specify the correct shaft diameter.
Bigger bearings with a higher load capacity may show a higher fatigue life, but if the load does not achieve the minimum requirement, the rolling elements can skid along the raceway instead of rolling. This can cause high temperatures, excessive wear, lubrication breakdown and bearing failure.
Bearing Installation Myth #3: It’s fine to hand-tighten setscrews one at a time – FALSE.
Bearing Application Myth #3: Sealed/ lubed-for-life bearings will last forever – FALSE.
Setscrews should be tightened to the manufacturer’s recommended torque. Under tightening can allow the bearing to slip on the shaft. Over tightening can distort the raceway or crack Scratching, gouging and general wear in the bore of an inner ring and the inner ring. on the OD of a shaft are indications of loss of lock. Sometimes, the setscrew tips will also be worn. Fretting wear can be present on the Use the “halfsurfaces and is sometimes a precursor form of wear prior to loss of lock. full/full” rule This can be caused by improper tightening of the locking mechanism, for tightening undersized/worn/damaged shafting, frequent start/stop operation, setscrews – or hardened or stainless steel shafting that prevents set screw penetration or holding. tighten the first setscrew to half the recommended torque, the second setscrew to the full torque, then go back to the first setscrew and apply full torque.
Bearing life depends on grease life, which is affected by the operating conditions (speed and load) and environment (temperature and contamination). Grease life can be improved with enhanced seals, proper installation and proper grease selection. Ultimately, the best bearing is the properly lubricated bearing.
Bearing Application Myth #1: Bearings should not be hot to the touch – FALSE. Normal bearing operating temperatures can range from 80°F to 150°F, but certain applications may run higher or lower. Most bearings are rated for -20 to 220°F, but can be supplied with special grease, seals or heat stabilizing processes that allow them to operate at higher temperatures. Bearings normally run hotter at start up or right after re-lubrication because excess grease increases drag and friction in the bearing. Spikes up to 50°F are normal at startup, and 30°F after re-lubrication. As the rolling elements purge excess grease through the seals, the
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Bearing Application Myth #2: Bigger bearings are always better – FALSE.
Surface smearing, peeling and skidding are forms of adhesive wear that occur when operating with insufficient oil film thickness. Under these conditions, sliding occurs between the rolling elements and raceways causing surface deformation, cold welding and/or material transfer. Causes include: • Inadequate lubricant properties • Lubrication breakdown • Ineffective relubrication • Mixing of incompatible lubricants • Insufficient load at high speeds • Sudden acceleration/deceleration
Bearing Lubrication Myth #1: Relubrication once a year is sufficient – FALSE. Start by reviewing the bearing manufacturer’s lubrication recommendations. These will give amounts and intervals as suggested starting points, but actual lubrication intervals may vary quite a bit, depending on load, speed, temperature, or environmental conditions. Applications with higher
Bearing News • Issue 4
speeds, temperatures, or heavy contamination sometimes require frequent re-lubrication, possibly weekly or daily. By contrast, a mounted ball bearing in a lightly loaded, low-speed, clean environment may do fine with re-lubrication at 12 to 24 month intervals. Certain applications may need to be monitored and lubrication intervals/amounts adjusted accordingly. Re-lubrication replenishes grease when the current grease breaks down or deteriorates because the base oil breaks down due to temperature. Without this, the lubricating property is gone and the result is metal-to-metal contact. Re-lubricating the bearing replenishes the oil, maintaining the proper film. Pumping new grease into a bearing also helps flush away contamination. Many mounted bearings are designed to allow grease to enter the bearing cavity as close to the rolling elements as possible. As more grease is added, the old grease is pushed out of the seals (if the seals are purgeable). The purged grease carries out contaminants and keeps dirt away from the seals.
Bearing Lubrication Myth #2: Always add grease until it purges from the seal – FALSE. If you pump grease into the bearing until it purges out the seal, you probably have completely filled the bearing cavity. Excess grease can increase operating temperature and may create enough pressure to blow the seal out. However, in lowspeed or dirty conditions where contamination may easily enter the seals, filling a bearing with grease may help improve performance. Application experience will dictate when the entire bearing cavity should be filled.
Bearing Lubrication Myth #3: If a bearing makes noise, grease should be added – FALSE. If a bearing is making noise, internal damage has likely occurred. This increases over time, with the potential for catastrophic failure. Adding grease may provide temporary relief, but a noisy bearing should be closely monitored and
replaced at the first opportunity. The root of the failure should also be investigated either with independent or manufacturer failure analysis (manufacturer analysis requires removal of the bearing as soon as possible to aid in a more accurate diagnosis of the problem).
Bearing Lubrication Myth #4: Any grease will do – FALSE. Greases DO differ. Some may be incompatible because of the different thickeners (soaps) used. When two incompatible greases are mixed, they may thicken and harden or become thin and leak out of the bearing. For example, many electric motors use a polyurea thickener while some mounted ball bearings use lithium-complex thickeners. These greases are borderline compatible, and depending on the actual make up, may not work together. Grease types can also be incompatible based on the viscosity or type of oil in the grease, so consulting a lubrication supplier is always recommended.
Bearing Lubrication Myth #5: Just shoot grease through the fitting – FALSE. Always clean grease fittings and the grease gun tip. It’s good practice to put the grease gun tip in an oil bath or wrap it with a plastic cover to protect it. Your plant’s uptime and OEE may “turn” on your bearings’ good health. If you are not achieving the desired operational life for some of them, a bearing manufacturer can assist you with proper selection and troubleshooting. Ian A. Rubin is Director of Marketing, mounted bearings, for Sealmaster, System Plast and Browning-branded products at Regal Power Transmission Solutions. For more information, visit powertransmissionsolutions.com. About Regal-Beloit Regal-Beloit Corporation (NYSE:RBC) is a leading global manufacturer of innovative and efficient solutions for motion control, air flow and power generation. Headquartered in Beloit, Wisconsin, the company serves customers from its facilities located in the United States, Canada, Mexico, South America, Europe, South Africa, Asia and Asia Pacific. The company’s common stock is a component of the S & P Mid Cap 400 Index and the Russell 2000 Index. Contact Jackie Catalano / Director, Global Marketing Communications Regal Beloit America, Inc. Power Transmission Solutions Jackie.catalano@emerson.com Tel: 859 727 5271 Page: 127
Why Why Bearing Manufacturers and Suppliers Should Adopt Compliance Programs If you are a small or medium-sized bearing or precision instruments manufacturing company or supplier operating regionally and have limited international presence, I’m certain you have asked yourself why your company should implement an antitrust compliance or anti-corruption program or policy. After all, any potential risk is remote and you must operate according to local conditions and requirements. Hopefully this note will provide you with a framework to reconsider your approach. Over the past decade OECD countries especially have been strengthening competition, anticorruption (FCPA), and anti-money laundering (AML) legislation and enforcement. Because the legislation is derived from cornerstone OECD guidelines, the precepts in all OECD countries are rather uniform and variations (if any) laws and regulations are relatively minimal. Internationallyoperating companies and financial institutions filing public records are required to implement processes and procedures that adequately account for all transactions to ensure that they are engaged in fairly, legally, and ethically. This requirement also has a business-driven objective that goes beyond accounting. Since adequate controls make it more difficult to make payments that are not accounted for, the costs and risks associated with bribery and extortion decline. As more and more companies sign on, corruption will have an increasing tendency to be ferreted out and eliminated. But it’s not only business. Anti-corruption has been recognized as good government policy. The World Bank, for example, requires compliance with its procurement and investment rules because of the proven correlation between corruption and poverty. The more corrupt a governmental entity, the greater the poverty Page: 128
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In the community. You need only look at the infrastructure of a corrupt state to visibly see the direct correlation between high corruption and poor infrastructure (and social services). More and more, research over the past fifteen years has shown that the more compliant companies are with laws and regulations, the more likely they they are to have long-term sustainable growth. a higher number of retained and loyal employees, and broader (more permanent) market penetration. Corporate social responsibility matters. It makes a difference to the bottom and top lines. Of course implementing a compliance and anti-corruption program from scratch is not easy. Sometimes even, it may require a complete rethinking of a company’s business processes and a reorganization of its operations. In other cases, it may require the implementation of complex and costly monitoring and control systems that may include the adoption of six sigma-oriented control systems even for legal and regulatory compliance. During the 1990s, I was charged with drafting, developing, and implementing an international antitrust and business practices program for a Japanese manufacturer that had distributors and sales channels in all major markets on all continents Bearing News • Issue 4
(save Antarctica). Ensuring that the program was properly developed and designed required many hours at headquarters reviewing and fine-tuning them to the new realities of global compliance. What followed was a review of the agreements with all distributors and agents worldwide. The review included an analysis of local law requirements in 30 to 40 countries where the company held a major market share or where earnings were robust. This was followed by an international tour that included visits to local affiliates and subsidiaries and major distributors and outlets. Last, but not least, export and import processes, materials procurement procedures, and product delivery, shipment, and logistics practices were reviewed at all manufacturing facilities and modified appropriately. Implementation took two years. And it was certainly worth the time and the expense. The company earned a reputation for being not corruptible, for having sophisticated processes in place, and for being an internationally-qualified manufacturer and seller of quality (and compliant) goods. With enhanced reputation, sales went up and so did production. Most importantly, many
years later when government investigations sent senior management of the company’s competitors to jail for price fixing and illegal market manipulation, the company avoided liability and reputational fallout because it had an effective compliance program in place. If you would like to educate yourself more on compliance and on how to structure an effective compliance program, I recommend Professor Boghraty’s upcoming MOOC taught at Boston University School of Law: http://www.bu.edu/ law/news/bu-law-first-us-law-school-to-offermooc-in-compliance.shtml. Please do contact me if you would like further information about how to design an effective compliance program or if you would like to have me help you adopt one. Peter Manda is former in-house counsel to ball bearing and automotive parts manufacturers. He is currently working toward an LLM in International Business Law at Boston University School of Law and works as an attorney in the New York metropolitan area. You can contact Peter Manda (petermanda@ comcast.net) for all your request for suggestions of legal topics you are interested in. Page: 129
KS PERMAGLIDE® plain bearing Low-maintenance and maintenance-free plain bearings Bearing material development has the objective of linking two opposing goals: to always find an optimum between high mechanical load bearing capacity and high wear resistance (hard material), while providing good adjustability and emergency running properties (soft material). As a global supplier to the automotive industry, KSPG’s expertise in air supply systems, emission control and pumps and in the development, manufacture and spare-parts supply of pistons, engine blocks and plain bearings puts it right at the top of the markets. KS Gleitlager is the specialist for high-precision sliding elements in the KSPG Group. The introduction of new technologies in production and surface finishing, innovative material developments and a clear customer focus have made KS Gleitlager into one of the world’s leading suppliers of metallic bearings and metal-plastic composite bearings (Permaglide®). The name Permaglide®, a registered trademark of KS Gleitlager GmbH, embodies the product characteristic of permanently low-wear sliding. Low-friction plastic compounds in porous bronze structures are used in applications where there is no lubrication using oil or grease available. This has created low-maintenance to maintenancefree plain bearing solutions for use in vehicles, machinery and many other applications. By using plastic on a metallic base material, a material combination is created which offers both good sliding characteristics and the bearing capacity and thermal conductivity of metal. The use of solid lubricants in the plastic matrix makes it possible to use Permaglide® plain bearings even without oil or grease lubrication. Depending on the customer’s requirements and application, there are a number of maintenance-free and lowmaintenance materials available. Their structure is basically the same: a porous bronze sintered structure, applied to a steel or bronze back, is impregnated with the respective Page: 130
plastic mixture. The solid lubricant creates a lubricating film between the interacting sliding parts. It is responsible for low-noise operation with constantly low friction values throughout the entire service life of the component. This is achieved in the series of maintenance-free products by means of a mixture of PTFE (polytetrafluoroethylene) with wear-retardant and thermally conductive additives. It is not always possible to carry out plain bearing application tasks using products made from maintenance-free material. In such cases, low-maintenance materials are the perfect solution. In this instance, the sliding surface taking up the wear load is formulated from a PVDF (polyvinylidenfluoride) matrix. To reduce the friction value and improve thermal conductivity, special additives are mixed into the matrix. In addition, the surface of the sliding layer may optionally be equipped with oil distributing pockets to accommodate grease or oil. For Permaglide® bearings for extremely high performance requirements, KS Gleitlager applies a PEEK (polyether ether ketone) plastic matrix that is compounded with special nanoscaled bulking agents to improve its tribological properties. Similar to petrol and diesel engine bearings, increasing technical demands and minimised installation clearance determine the development efforts for Permaglide® bearings. This demonstrates the immense know-how of KS Gleitlager specialists. In line with customer requirements, not only are geometries and shapes selectively developed but the optimisation of sliding layer systems creates products with purpose-adjusted kinetic momentum. Moreover, customers do not need to adapt the design of their assemblies to suit the sliding element; the Permaglide® bearing optimally adjusts to the assembly group design.
Bearing News • Issue 4
Maintenance-free KS PERMAGLIDE® P1 plain bearings, suitable for dry running
Low-maintenance KS PERMAGLIDE® P2 plain bearings, lubrication required
KS PERMAGLIDE® P1 models
KS PERMAGLIDE® P2 models
The unique features of KS PERMAGLIDE® P1: • universally applicable • low friction values, high wear resistance • extremely good dry running, • as self-lubricating
The unique features of KS PERMAGLIDE® P2: • high wear resistance • good chemical resistance • low swelling tendency • insensitivity to shocks and impacts • remachining mechanically possible post installation to achieve the utmost in guidance accuracy
Plain bearings for maritime applications
effort required to seal it is best suited in installation locations which are hard to reach.
The bearings in technical systems in a maritime environment are usually quite a challenge. The harsh operating conditions often place demand on the bearing system’s efficiency many times over. A maintenance-free plain bearing with minimal
In order to eliminate the risk of water contamination, dryrunning or media-only-lubricated bearings are permissible. Plain bearings fit these broad-ranging loads best. Regardless Page: 131
of salt or fresh water, offshore or in hydroelectric plants. Permaglide plain bearings can be used wherever there is need for a reliable and robust bearing.
and embedded solid lubricant is corrosion-resistant and maintenance-free. Maintenance work must be carried out on the chain only after 16 years due to the worn gaskets.
Although the corrosion resistance of metal-plastic composite bearings must be classified as lower than full polymers, KS Gleitlager uses two types of material specifically developed for outside use.
Application of Permaglide P11 bushes
The materials Permaglide P11 and Permaglide P147 feature corrosion resistance figures better than the classic metalpolymer plain bearing materials based on PTFE available from the competition. P147 is a multi-layer composite system with a sliding layer made of tin-bismuth bronze. The back of the steel bearing is galvanised, transparently passivated and coated with a layer thickness of 0.012 mm. The solid lubricant consists of a PTFE compound specifically for outdoor use. Permaglide P147 complies with the salt spray test in accordance with DIN 50021 and has stood the test of time a million times over in automotive applications. The material Permaglide P11 contains a full-bronze back with a sliding layer made of porous sintered bronze. The solid lubricant used is a PTFE/lead compound. The bronze alloy containing phosphorous also improves the corrosion resistance as well as the thermal, mechanical and tribological properties. These are so-called wrought alloys that are resistant to stress crack corrosion and pitting corrosion-type attacks. They also offer good resistance to sea water. Permaglide materials have extremely low absorption properties and therefore do not tend towards swelling.
Link chain at a barrage gate Large gates on locks or dams stand firm against the water pressure. Heavy link chains are used to move the gates. The pin bearing in every link is fitted with a Permaglide P11 bush. The pins are hard-chrome plated and finely polished, so that extremely high compression forces in the tensile direction with peaks of 320 N/ mm^2 can be applied. Any arising axial forces are absorbed by Link Chain at a barrage gate 2 axial discs per chain link made of Permaglide P11. A rubber seal protects the bush from coarse contamination. The material with bronze backing Page: 132
30 years ago, after an accident at a dam in Norway, the old sluice was destroyed. As a result, the water level dropped and a close-by village as well as a hospital could no longer be supplied with sufficient water. Because of this emergency situation, a new type of sluice was developed within two days, in which Permaglide P11 bushes were installed, “the weir gate or better known as the Eccentric gate�. This sluice was patented and so far over 200 more have been built in which approx. 5000 P11 Permaglide bushes have been used.
Stator blades in pumps and turbines In storage power stations, water is pumped into higher-lying storage reservoirs using cheap night-time electricity. At energy demand peaks, the water is allowed to flow back down to drive a turbine. In the process, the turbine drives a generator to produce electricity. In order to set the optimum operating point in the pump as Hoover Dam Turbines well as in the turbine operation, swivel-mounted stator blades are fitted between the ring channel and impeller. The bearing for the stator blades are manufactured with maintenance-free plain bearing bushes made from Permaglide P11. This has eliminated the need for additional lubricant. High static compressions arising from the flowing medium permanently affect the bearing. In addition, there are high-frequency vibrations. The plain bearing has direct contact with the water. The material with bronze backing and PTFE sliding layer does not display any signs of corrosion. Similarly, tribocorrosion does not occur because the sliding metals are separated by the layer of PTFE. Permaglide P11 does not absorb any water, allowing the plain bearing to maintain its dimensions. Moreover, the high wear resistance always provides a constant operating bearing clearance, which would otherwise have a negative influence on the efficiency of the pump or turbine. The service life of bearings made of Permaglide P11 is thus exceptionally long, with costly maintenance intervals being reduced.
Bearing News • Issue 4
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