BearingNEWS Magazine February 2017 by Bearing-News.com

www.bearing-news.com

2017

P18438 - 2017/01

FEBRUARY ISSUE 07

BEARING INDUSTRY MAGAZINE

World’s Largest Big Size Bearings Test Centre

EVOLUTION IN BEARING CAGE DESIGN QUALIFICATION OF GLOBAL BEARING MANUFACTURING PRACTICES

DIGITALIZATION, NETWORKING AND COMMUNICATION OF MAINTENANCE

BEARING RELIABILITY CONFERENCE &EXPO

REGAL

Steve Quintijn Interview

ZKL

Jiří Přášil Interview

FIM

Bruno Grandjean Interview

2017

DORTMUND10-12 OCTOBER

24 - 28

APRIL

VisiT

hAll

2017

And 22, sT

c24

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CUSTOM

TRACK ROLLER

ISO RANGE

OVERMOLDED

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In our industry, the highest standard we can achieve for our Quality Management System is the ISO 9001 certification - awarded by TUV Rheinland. It is the global benchmark that guarantees a total focus on customer service and continual improvement.

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The Digitalization of Bearing (Predictive) Maintenance It’s fascinating to see the latest developments and achievements in the field IOT (Internet of Things) and Industry 4.0, which is transforming the classical industrial approaches in a new era of possibilities. For the bearing application, the further digitalization means more precise implementation of predictive maintenance. Apart from the past, maintenance techniques are today designed to help determine the condition of in-service equipment to predict when maintenance should be performed. This is currently nothing new, “condition monitoring” is already implemented for a while. What is new however, is the information that can now be extracted from condition monitoring systems. With the aid of intelligent software, the data acquired in real time allows the operator to carry out a service or replace worn bearing (or other components) at precisely the right time – with no fixed service interval, and before the bearing in question fails. For the bearings, these reference variables are mainly the vibration, temperature and revolutions per minute. These are continuously monitored and analyzed so that any irregularities can be detected and their effect on the life of the bearing calculated. At the same time, any bearing that is running hot can be identified by temperature monitoring. This allows an increased reliability in critical applications such as wind turbines, rail vehicles, energy, mining and aerospace. The system itself can perform the analysis and the condition of the bearing can be checked from anywhere in the world via the Internet; similarly, the remaining life of the bearing can be calculated based on the actual load spectra. We tried to figure out in this edition of the BearingNEWS magazine how the digitalization will result in the further development of the SMART bearing, which is expected to elevate the performance limits; easier to maintain; optimized for the specific application and improve the energy efficiency in applications. 2017 will have 2 key industrial events which will focus more in depth in the digitalization of bearings predictive maintenance. The first key event is the - Hannover Messe MDA show - which will take place from 24-28 April and the - Bearing Reliability Conference & Expo -, which will Page: 4

be held in Dortmund on 1012 October 2017. Further in this issue, we have ‘a BearingNEWS classic’ three exclusive interviews with the leaders of bearing and power transmission organizations in the industry. The first interview is with Mr. Steve Quintijn, the Marketing / Product Manager for Rollway, McGill and Sealmaster at Regal Beloit in the Power Transmission Solutions business segment. Our second interview is with Mr. Jiří Přášil, the Executive Director of ZKL Bearing CZ, a.s. an East-European bearing manufacturer with 70 years’ experience in production of roller bearings. We tried to reveal the story of his company during this interview. The third interview is with Mr. Bruno Grandjean, the President of the Federation of the Mechanics Industries in France. He shares in this interview his thoughts about innovation, creativity and industrial cooperation in Europe. What’s rolling in the bearing industry? A brief summary of what happened during the last six months in the bearing industry; the exhibitions, event & conference agenda for 2017; various case studies on bearing applications, use of ultrasound to improve lubrication practices, slow speed bearing monitoring, and Top20 tips for bearing reliability by Per Arnold Elgqvist...Together with all these interesting topics, many other bearing industry related articles, insights and developments can be discovered in this February issue of the BearingNEWS magazine. 160 pages full of BearingNEWS, We hope you will enjoy it.

Kenan M. Özcan Editor in Chief BearingNEWS

Bearing News • Issue 7

What’s Rolling What’s Rolling...

MAINTENANCE: HOW TO USE ULTRASOUND TO UPGRADE LUBRICATION PRACTICES RESEARCH: GOING TO THE ATOMIC SCALE EVENT: MDA SHOWCASES PREDICTIVE MAINTENANCE APPLICATIONS IN HANNOVER ACTUAL: SCHAEFFLER PREPARES THE WAY FOR DIGITALIZATION INTERVIEW WITH STEVE QUINTIJN: OPTIMIZE YOUR TCO WITH BEARING SOLUTIONS

PRODUCTION: AN EVOLUTION IN BEARING CAGE DESIGN NEWS: DEDICATED RANGE OF TAPERED ROLLER BEARINGS TO FULFIL DISTRIBUTORS’ NEEDS FOCUS: THE ULTIMATE GUIDE TO FULL CERAMIC BEARINGS IN WATER PROCESSING, WATER FILTRATION AND LIQUID HANDLING CASE STUDY: ELIMINATING MOISTURE DAMAGE TO BEARINGS ON CRITICAL STEAM TURBINES FOCUS: QUALIFICATION OF GLOBAL BEARING MANUFACTURING PRACTICES Page: 6

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10 12 16 20 30 36 40 43 50 54 page

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Bearing News • Issue 7

g... INTERVIEW WITH JIŘÍ PŘÁŠIL: 70 YEARS TRADITION OF BEARING MANUFACTURING NEWS: KOYO INTRODUCES NEW JHS-3i PILLOW BLOCK ACTUAL: WORLD’S LARGEST BIG SIZE BEARINGS TEST CENTRE RECEIVES ITS HEARTPIECE RESEARCH: CONDUCTIVE LUBRICANTS WILL PROTECT ELECTRIC MOTORS OF THE FUTURE MAINTENANCE: SLOW SPEED BEARING MONITORING

What Happened

in the

Bearing Industry Second Half of

140

2017

2016

AGENDA:

EVENTS EXHIBITIONS CONFERENCES AGENDA

EVENTS, EXHIBITIONS AND CONFERENCES AGENDA FOR 2017, 140 KEY INDUSTRIAL EVENTS IN 35 COUNTRIES

2ⁿ Edition of

will be held from 10 to 12 October 2017 The Bearing and Reliability Conference & Expo

EVENT: BEARING RELIABILITY CONFERENCE & EXPO 2017

Due to the great success of the BRCE event that ran on 22 – 23 March 2016 and the request of many participants to run it again, the agenda is set for 2017. The ﬁrst edition of the Bearing Reliability Conference & Expo is held with over 120 participants from 11 diﬀerent countries, where the industry players found the chance to come together during a two days' knowledge & networking event.

KNOW-HOW: TOP 20 TIPS FOR BEARING RELIABILITY

All the attendees experienced for two days long 28 powerful speakers from both the bearing & reliability competences, listened to selected experts presenting their strategies to make the bearing and their assets more reliable. There were in total 8 workshops designed to help implementing the best strategies and the chance to visit the key industrial players at the Exhibition center. Aﬅer the mega successful ﬁrst edition of BRCE2016, the decision is made quickly to continue with this great concept and to run BRCE2017 in the Westfalenhallen Dortmund in Autumn 2017.

RESEARCH: IDENTIFYING & CORRECTING THE CAUSES OF BEARING FAILURE

• 32 Bearing and Reliability Application Presentations (30 Minutes each) The Best Practices in Maintenance (2 corners in the expo area) • A memorable dinner for fun, sharing experiences and networking

Industrial Maintenance and Reliability Other Topics DAY 1 Key Topics

BRCE Agenda 2017 Key Applications and the Maintenance Other Topics DAY 2 Key Topics Vibration Monitoring

Sensors

Bearing Monitoring

Remote Monitoring

13:00 17:15

Maintenance Strategy

RCM and RCA

Asset Reliability

Safety

Planning and Scheduling

KPI’s

Inventory Management

Human Resources

Root Cause Equipment

Consultancy

Tools and Equipment

Lean Manufacturing

IOT - Internet of Things

5S and TPM

Industry 4.0

6 Sigma

Lubrication and Training DAY 3 Key Topics

Other Topics

Lubrication Reliabilty

On Line Trainings

Storage and Handling

Classroom Training

page

59 63 64 70 74 79 95 100 104 116 page

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Page: 7

MAINTENANCE: CONDITION ASSESSMENT SOLUTIONS FOR LOW-SPEED BEARINGS FOCUS: SOLUTIONS FOR THE AGRICULTURE MECHANICS INTERVIEW WITH BRUNO GRANDJEAN: INNOVATION, CREATIVITY, AND INDUSTRIAL COOPERATION IN EUROPE CASE STUDY: BEARING DESIGN CONSIDERATIONS FOR ENCODERS CASE STUDY:

CORRECT INSTALLATION OF BEARINGS MAXIMISES OPERATING LIFE IN CRITICAL APPLICATIONS

CASE STUDY:

HOW TO PROTECT VFD-DRIVEN MOTORS FROM BEARING DAMAGE

SOFTWARE:

STIFFNESS OF ROLLING ELEMENT BEARINGS “DOES BEARING STIFFNESS ALWAYS INCREASE WITH LOAD?”

TECHNOLOGY: A REVOLUTION IN THE PRODUCTION OF SLIDING BEARINGS MAINTENANCE: CHOOSING VIBRATION MONITORING METHODS ACTUAL: RECORD DAKAR FINISH OF THE CRAFT BEARINGS DAKAR TEAM Page: 8

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118 120 126 128 132 137 141 145 149 152 page

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Bearing News • Issue 7

AVOID THESE 3 MISTAKES WHEN LUBRICATING BEARINGS Friction is all around us. Without it we would find it very difficult to run, walk, or even stand on our own two feet. We need friction to drive our cars and fly our airplanes; and we need friction for our motors to drive pumps. But when it comes to our plant machinery, friction is both friend and foe. If part of your job is greasing plant machinery then you know well the battle against frictional forces that threatens the useful life of rolling element bearings. Lubrication of rolling element bearings is one of the most misunderstood and abused tasks in industry. Can it be true that 40% of bearings never live to their engineered life cycle and that bad lubrication practices are the leading cause of this mortality? Bearings depend on grease to reduce friction levels. By avoiding three common mistakes when greasing bearings you can predict the right time to grease, know how much grease to apply, and be confident in the bearing’s overall health.

Mistake n°1 - Lubricating based on TIME instead of CONDITION Lubricating a bearing once per week or once per month may seem like a sensible thing to do. After all, performing scheduled maintenance at regular periods is an age-old concept. Bearings need grease for one reason only; to reduce friction. As long as the lubricant is performing that service well, there should be no need to change it, or add more. Page: 10

Yet we frequently do, with catastrophic results. Lubricating a bearing just because your calendar told you “time is up!” is the first mistake. Monitor, measure and trend friction levels with ultrasound to know when it is the right time to grease.

Mistake n°2 – Over and under lubrication The second mistake we must avoid is adding too much, or not enough grease. Too much grease builds pressure, pushing the rolling elements through the fluid film and against the outer race. The bearing now has to work much harder to push the rolling elements through a mud bog of grease. The increased friction and pressure from too much grease raises the temperature inside the bearing. Excess heat could decrease the effectiveness of the lubricant causing the oil to separate from the thickener. Not adding enough grease has the same life-shortening effect. How do we know when just the right amount of grease has been added? By monitoring the friction level with ultrasound as new grease is applied… slowly, one shot at a time. Listen to the bearing and measure the drop in friction as the grease flows in to the bearing. As the decibel level approaches a minimum value and stabilizes pay close attention. Add single shots. Should the decibel level begin to increase slightly, stop! The job is done.

Mistake n°3 – Using a “Listen-Only” ultrasound Bearing News • Issue 7

HOW TO USE

ULTRASOUND TO UPGRADE LUBRICATION PRACTICES instrument Like any job there is a right way and a wrong way to do things. Simply listening to a bearing with an ultrasound device that gives no measurement feedback is a recipe for disaster. The audible feedback alone is too subjective to draw any comparative conclusions. No two people hear the same and there is no way to remember what the bearing sounded like a month ago. The third mistake is depending solely on subjective ultrasound noise when precise quantifiable data is available. Therefore always use an ultrasound instrument with digital decibel metering. Better still, use a device that provides multiple condition indicators. Max RMS and Peak dB measurements indicate alarm levels and greasing intervals while Ultrasonic Crest Factor provides insight about the bearing condition in relation to its lubricant. Crest Factor helps us differentiate between bearings that need grease and bearings that need to be replaced. Before greasing

Machines that are properly lubricated require less energy to run. Imagine that reducing the amount of money spent on grease will actually lead to lower energy bills. Machines that consume less electricity run cooler and machines that run cooler have longer life cycles. Ok, the real reason to optimize bearing lubrication is to extend the life of bearings by making sure they have the right amount of grease, but not too much. When everything is running according to plan lube-techs will spend less time greasing bearings that do not need it. So when counting up the benefits of your ultrasound program does not forget to add “decreased labor” to the long list. Finally, by monitoring the condition of your machinery’s lubrication, you are at the same time collecting valuable condition data about the machine itself. Dynamic and static ultrasound data coupled with condition indicators such as Overall RMS, Max RMS, Peak, and Crest Factor are all indicators of bearing health. A practice that does not use this SDT combination is not a real solution when lubricating bearings. Who knew so much good could come from such a simple shift from calendar to condition based maintenance? Now You know.

After greasing

When the ideal lubrication level is reached, the dB microvolts value returns to its normal level. This is perfectly audible in the headphones, in the reproduction of the dynamic signal and visible on the screen of the SDT device.

Clear benefits of avoiding the three mistakes Ultrasound assisted lubrication of plant assets offers significant benefits that calendar-based lubrication cannot. Lubrication serves a primary purpose, which is to create a thin layer of lubricant between rolling and sliding elements that reduces friction. So it makes sense that the best way to determine the lubrication requirement of a machine is to monitor friction levels; not time in service. Optimizing lubrication of plant machinery with ultrasound will result in a significant reduction in grease consumption. Having an ultrasound program in place will help create a better culture involving cleaner storage practices, sampling, and avoiding mixing greases. Page: 11

BEARING RESEARCH:

GOING TO THE

ATOMIC SCALE AUTHOR: SEBASTIÁN ECHEVERRI RESTREPO, RESEARCHER, SKF ENGINEERING & RESEARCH CENTRE (ERC), SKF B.V., NIEUWEGEIN, THE NETHERLANDS

TECHNOLOGY Imagine if one could become so small that he or she could dive inside solid materials and see the structure of the atoms – how they interact, move and respond when an external force is applied and how the external temperature influences their properties and changes their structure. If this were possible one could better select, process and design the materials used to manufacture products and machines. At the SKF Engineering and Research Centre (ERC) in the Netherlands, research is done with the objective of virtually diving into the materials that make up SKF’s products to achieve a better understanding of their behaviour. This enables SKF to respond to requests from customers and, more importantly, to develop new materials for its products that increase their quality, durability and other specific properties. In most of the cases, the use of experimental methods is enough to gain sufficient understanding of how external constraints might affect the materials from which products are made and to find preventive and counteractive solutions. Nevertheless, even with the use of state-of-the-art Page: 12

fig. 2: Structure of vanadium carbide (VC) including two-dimensional cuts of the charge density. Image produced with the software XCrySDen.

experimental techniques, it is simply not always possible to get sufficient understanding of the effect that certain phenomena can have on the materials. In addition, in some cases such as with a new material or product that is in the design phase, being limited to the use of laboratory test tools is not always time-efficient or cost-effective. This is why computational methods are essential.

Bearing News • Issue 7

fig. 1: Length scales of the different simulation methods used within SKF, namely density functional theory (DFT), molecular dynamics (MD), dissipative particle dynamics (DPD) and the finite element method (FEM).

This article provides insight into the four main lines of research through modelling at SKF: bearing steel, fatigue mechanisms, polymer design and tribology. In the past few years SKF has been expanding its knowledge with atomic scale simulation methods such as DFT, MD and DPD, to understand how materials behave in its products. This has enabled and will continue to enable SKF to innovate and cope with everincreasing technological challenges by ensuring that every atom is in the place it belongs.

When it comes to mechanical parts, e.g., rolling bearings, most design issues can be worked out using “large scale” simulation techniques, such as the widely used finite element method (FEM). However, some special issues go beyond the capabilities of this modelling tool and require being treated with alternative mesoscopic and

microscopic simulation methods. To get a thorough understanding of SKF’s products and be able to tackle the issues that might have an origin at particular time and length scales, scientists at SKF are constantly developing their know-how in the use and advancement of multi-scale simulation methods. This means that there are different tools (imagine magnifying glasses, all with a different magnifying power) that can be used to understand specific phenomena that determine the behaviour of a material in application conditions. This is why the models that are applied at SKF range from quantum mechanical to continuum (fig. 1). The deeper one dives inside the material, the more calculation power and time are needed to make simulations. For this reason, a high-performance computer cluster with 1,536 processors is being used in SKF facilities. Currently, there are four major lines of research for which meso- and micro-scale methods are used.

Steel design fig. 3: Atoms of hydrogen present at the boundary between iron and a precipitate composed of vanadium and carbon. Image produced with the software XCrySDen.

The first line of research is part of the project “MultiHy” Page: 13

[1], short for Multiscale Modelling of Hydrogen Embrittlement. This project is led by a consortium formed by various European industrial and academic partners and is funded by the European Union. The initial motivation for this project is that there is ample experimental evidence [2] that supports the idea that hydrogen decreases the fatigue life of bearings and structural steels. This effect of hydrogen is known within the technical jargon as hydrogen embrittlement. SKF’s main interest in MultiHy is to be able to predict how hydrogen diffuses into and through bearing steels and, more importantly, to discover how available hydrogen can be trapped and immobilized to neutralize the impact of hydrogen embrittlement on bearing service life.

with each other when a crack is initiating and propagating through bearing steel (fig. 4). The understanding of this phenomenon will enable SKF to find ways to increase the life and overall per-formance of SKF products.

Polymer design The third application deals with the study of filled rubber materials used in the manufacturing of seals. The overall goal is to identify and quantify the physical phenomena taking place at different scales that influence the quasi-static and dynamic stress-strain behaviour of filled rubber. This project is being carried out by SKF in collaboration with scientists from Tsinghua University in China and from the University of Barcelona in Spain.

Such simulations on hydrogen mobility and its effects on fatigue life complement other ongoing research dealing with various sources of hydrogen, e.g., humid environments and possible degradation of lubricants. From the atomistic point of view, simulations are being carried out using a computational quantum mechanical modelling method called density functional theory (DFT), which is commonly used to investigate the electronic structure of many-body systems (fig. 2). More specifically, simulations are being done to evaluate the mechanical properties and the influence of hydrogen in a new experimental vanadium-containing bearing steel (fig. 3) in which hydrogen can be trapped to avoid embrittlement [3]. The results of the MultiHy project can help with the final development of this new steel, so that it can eventually be considered for applications where hydrogen resistance is needed.

Fatigue mechanisms The second line of research is aimed at the atomic description of the microstructure of bearing steels and its influence on the behaviour of the material when subjected to rolling contact fatigue. For this project, the molecular dynamics (MD) method is being used to study how the atoms move and interact

fig. 5: Sample model used for the simulation of a polymer with the dissipative particle dynamics (DPD) method. The dark blue particles represent the filler, and the purple particles represent the polymer chains. Image produced with the software Ovito.

Dissipative particle dynamics (DPD), a meso-scale simulation tool that enables analysis of the dynamic properties of fluids and polymers (fig. 5) at scales that go beyond those that can be treated using MD, is used here. By employing DPD, the effect of various factors, such as the interaction between filler particles and polymer chains and the topological changes in the polymer network in the static and dynamic mechanical behaviour of sealing materials, can be fully considered.

Tribology The final application addresses the lubricated contact between two surfaces [4], such as that between a rolling element and a raceway in a hybrid bearing. The method used for this work is also MD. The goal is to explain the fundamental differences in friction and wear between steel/steel and steel/ceramic surfaces to improve the performance of hybrid bearings. Also, chemical reactions between the lubricant and the surfaces can be considered. So far, the modelling has revealed that there are fundamental differences between steel/steel and hybrid contacts related to friction and wear. More importantly, the results have shown that hybrid contacts present lower friction than steel/steel contacts. References

fig. 4: Detail of the front of a crack propagating in iron. The colours of the atoms represent the atomic strain. Image produced with the software AtomEye.

Page: 14

[1] http://www.multihy.eu. [2] R. A. Oriani, Annual Review of Materials Science 8, 327 (1978). [3] B. Szost, R. Vegter, and P. Rivera-Diaz-del Castillo, Materials & Design 43, 499 (2013). [4] D. Savio, Nanoscale phenomena in lubrication: from atomistic simulations to their integration into continuous models, PhD thesis, Institut National des Sciences Appliquées de Lyon, Karlsruher Institut für Technologie (2013). This artcile is published on the EVOLUTION magazine on Tuesday 29 March 2016

Bearing News • Issue 7

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MDA showcases predictive maintenance applications in Hannover

DIGITALIZATION, NETWO COMMUNICATION OF MA

ORKING AND AINTENANCE

Predictive maintenance is currently a hot topic and will play a central role at MDA within HANNOVER MESSE 2017. Operators of machinery and vehicles do not want to wait until a vital component fails, but they also do not want to replace it ahead of time. And now they no longer have to, because leading suppliers of power transmission and fluid technology have developed systems that permit continuous monitoring of key components such as roller bearings, electric motors, gears, hydraulic pumps, and compressed fluids.

“Predictive Maintenance is an important part of networked production and Industry 4.0. Intelligent components use integrated sensors to capture and evaluate data in real time. Predictive Maintenance is a terrific strategy to effectively harness the interaction between mechanical engineering and IT,” says Peter Synek, Deputy Managing Director, Fluid Power Division, German Mechanical Engineering Industry Association. This is actually nothing new: “condition monitoring” was already a main topic at past MDA shows. What is new, however, is the information that can now be extracted from condition monitoring systems. With the aid of intelligent software, the data acquired in real time allows the operator to carry out a service or replace worn components at precisely the right time – with no fixed service interval, and before the part in question fails. Roller bearings are a good example of how this works in practice. The reference variables in this case are vibration, temperature and speed (revolutions per minute). These are continuously monitored and analyzed so that any irregularities can be detected and their effect on the life of the bearing calculated. At the same time, any bearing that is running hot can be identified by temperature monitoring. For example, Schaeffler offers such a service for roller bearings used in wind turbines and rail vehicles. Schaeffler’s dedicated cloud analyzes the collected data and generates the results in plaintext format. So the user or operator no longer needs to have any expertise in analyzing sensor data, as is the case with condition monitoring. Instead, the system itself performs the analysis and the condition of the bearing can be checked from anywhere in the world via the Internet; similarly, the remaining life of the bearing can be calculated on the basis of the actual load spectra. Demand for this kind of “micro-servicing” via data-based Page: 18

Bearing News • Issue 7

HANNOVER MESSE – Get new technology first! The world’s leading trade fair for industrial technology will next be staged from 24 to 28 April 2017 in Hannover, Germany. With its core focus on “Integrated Industry,” HANNOVER MESSE is the world’s leading showcase for the digitalization of production (Industry 4.0) and energy systems (Integrated Energy). The upcoming HANNOVER MESSE will feature seven parallel shows: Industrial Automation, MDA – Motion, Drive & Automation, Digital Factory, Energy, ComVac, Industrial Supply and Research & Technology. Poland will star as the Partner Country of HANNOVER MESSE 2017. predictive maintenance is currently very high, and not only in electromechanical power transmission. Predictive maintenance systems for hydraulic drives, for instance, can incorporate particle counters. Parker will present such a system at MDA – not only at its own exhibit, but also in the VDMA Forum in Hall 19. Stefan Nilgen from Parker Hannifin tells us: “With our ‘Total System Health Management’, we can acquire data from every part of the system, including peripherals, then analyze it and use it to take the necessary measures. That way, we can keep an eye on the overall productivity as well as the total cost of ownership of complex systems such as hydraulic installations or fluid power transmissions, and can carry out whatever preventive maintenance might be needed. So ideally, any corrective measures will become unnecessary, or at least foreseeable, so that we can plan ahead and avoid the unexpected breakdowns of the past. For the user, that translates into cost savings, thanks to a longer service life and higher productivity.” The predictive maintenance tool developed by Bosch Rexroth is called OdiN, and it will also be on display at this year’s HANNOVER MESSE. The acronym stands for Online Diagnostic Network, and along with sensor

technology and cloud-based applications it also employs the methodology of machine learning to perform preventive maintenance – and with a high degree of precision. Tapio Torikka is the man responsible for developing the system: “A human expert monitoring the installation continuously by conventional means will detect a fault with 43 percent probability. Our system has a fault detection rate of 99 percent.” Predictive maintenance has gained additional momentum as a result of Big Data and other topical themes associated with Industry 4.0. It is becoming progressively easier to collect and process relevant data for servicing and maintenance. This trend is driven in part by cross-sector collaboration, such as that between manufacturers of sensors and manufacturers of power transmission systems. Aventics and sensor specialist IFM are planning to work together in future to monitor and analyze operating data – e.g. for pneumatic cylinders – entirely online, and independently of machine control functions. This is a classic predictive maintenance scenario. Schaeffler and IBM have entered into a strategic partnership with the aim of continuously monitoring power transmission systems in critical applications such as wind turbines and railway trains using machine learning to optimize performance based on the data acquired. Systems of this kind are discussed under the collective heading of “predictive analytics”. Visitors to MDA with a special interest in this development would be well advised to take a close look at two of the other trade shows taking place in parallel, namely Industrial Automation and Digital Factory. Here, leading companies from the IT industry will be presenting their ideas and visions for Industry 4.0 and the Industrial Internet of Things, including the whole area of preventive maintenance.

Page: 19

SCHAEFFLER PREPARES THE WAY FOR DIGITALIZATION

Automobiles are part of the Internet of Things where machines share data with each other to provide better solutions for people. “This development is an enormous opportunity for Schaeffler,” explains Gerhard Baum, Chief Digital Officer for the company. “Our components and systems are needed precisely where stresses, forces and torques occur: In the powertrain and in the chassis.” If these components, such as the bearings used in the Schaeffler´s comprehensive expertise allows significant fuel economy improvements without compromising comfort chassis, are fitted with sensors which measure for processing large amounts of data, generating valuable torques, forces, vibrations and temperatures, it is possible insight to transform its operations. From October 2016 to capture vital information on the condition and use of the resulting Schaeffler Cloud will be available for the first both the module and the entire system. user cases and applications. Schaeffler has already laid the technical foundations for the integration of these sensors and actuators into components by developing the Sensotect bearing which collects measurements using nanostructured coatings. “The important thing here is not just that we are capturing data but that we are also able to interpret them correctly and convert them into actions,” emphasizes Mr. Baum. “Schaeffler has the necessary expertise in this field, not just in the automotive industry, but in other sectors as well, such as the wind power industry.”

Strategic partnership with IBM As part of its “Mobility for tomorrow” strategy, Schaeffler is digitizing its entire organization. With IBM as its strategic partner, Schaeffler is creating a digital platform Page: 22

Strategic partnership between Schaeffler and IBM: Gerhard Baum, Chief Digital Officer Schaeffler AG, Ivo Koerner, Board Member Sales, IBM Germany, Prof. Peter Gutzmer, Deputy CEO and Chief Technology Officer Schaeffler AG, Juergen Henn, Executive Partner, IBM Global Business Services, and Harald Giesser, Chief Information Officer, Schaeffler AG.

Bearing News • Issue 7

In the coming years, the automotive and industrial supplier, Schaeffler, wants to recruit up to 600 experts across the world to work on digital solutions for tomorrow’s mobility. The planned new positions are part of a digitalization offensive the company started last year. A central pillar of the strategy is the development of intelligent products. Schaeffler is showing how visions of automated driving, electrification and networking can be turned into reality.

“We are constantly working to offer significant added value for our customers. Our aim is to connect data from across products and processes. Using analytics we turn this primary data into valuable insight which is used to increase the efficiency of our operations and develop innovative services for our customers. We are very pleased to have found the ideal partner with IBM,” said Prof. Peter Gutzmer, Deputy CEO and Chief Technology Officer of Schaeffler AG.

Schaeffler has a wide range of products for efficient electrification of the powertrain

Schaeffler has chosen IBM as its strategic partner for its digital transformation. IBM will act as the technology provider, consultant and development partner for a digital ecosystem to support Schaeffler in the integration of its mechatronic components, systems and machines into the rapidly expanding world of the “Internet of Things” (IoT), as well as implementing market ready new business models based on digital services. As a first milestone the two companies have built a digital platform for all of Schaeffler’s added-value digital services from October this year. Schaeffler is working closely with IBM to develop innovative solutions for Schaeffler’s own transformation and for customers using design thinking and agile development methodologies. An open, digital ecosystem is being built to form an environment in which Schaeffler can work smoothly with its customers and partners, with the digital platform as the technical foundation.

Schaeffler’s digital agenda Gerhard Baum, Chief Digital Officer of Schaeffler, commented on the company’s approach for digital transformation: “We are concentrating on expanding the integration of sensors into our existing products as well as developing new products with integrated cognitive software. Not only will the machines and transport infrastructure within the production environment at Schaeffler be connected, but individual plants will also be digitally linked to the whole supply chain. At Schaeffler, we want to digitally optimize processes and procedures as well as create new service-oriented processes, and thus drive the digital interaction between people and IT systems.” “The joint implementation of Schaeffler’s digital agenda is the perfect fit to leverage and promote our new cognitive IoT capabilities for the manufacturing sector,”

Page: 23

SCHAEFFLER PREPARES THE WAY FOR DIGITALIZATION said Ivo Koerner, Board Member Sales, IBM Germany. The base will be a global, hybrid cloud infrastructure using IBM’s application platform “Bluemix” with Watson IoT to create differentiating applications and mobile apps for the Internet of Things.

Consistently connecting and integrating big data Schaeffler’s components such as bearings or clutch release systems are used in important parts of machines and vehicles which produce Digital product portfolio from Schaeffler critical information about condition and movement. Schaeffler has put significant investment into research and development in recent years and has incorporated sensors, actuators and control units with embedded software into these products. With this, it is now possible for these parts to collect and process valuable data on the condition of a machine and then convert this data into added-value services.

During the first phase, the partnership will focus on: Optimizing maintenance in the wind energy sector: Schaeffler is an important player in the renewables industry producing the huge bearings that help turbines to spin freely. Replacing these bearings is complicated and expensive as it results in downtime and lost energy. Through the new agreement, IBM and Schaeffler will explore how machine learning can reveal additional insight about the performance of equipment in different

Schaeffler offer the right solution for every bearing position and a holistic concept that further increases the reliability of the rolling bearings in wind turbines

Page: 24

operating conditions. Sensors in the equipment and even in the bearings themselves will report on the actual condition of components in realtime. Using wind forecasts from the Weather Company (an IBM company), turbine operators will be able to plan ahead and replace parts during less windy periods. Digitized monitoring and optimization of trains: With many decades of experience in the railway sector, Schaeffler works closely with rail manufacturers and operators providing bearings and other parts for any application in passenger trains and freight vehicles. Using cognitive insights from the cloud, Schaeffler will enhance its predictive maintenance systems for railways, helping to increase efficiency and safety. Smart bearings will be able to measure their own vibration, temperature,

Monitoring systems with local software and cloud-based analytics extend the range of applications for trains, improve their operational safety and reduce operating costs.

Bearing News • Issue 7

torque and speed triggering alerts and informing railway operators about possible safety issues.

Connected vehicles: Schaeffler is leading the way in the development and manufacturing of products for engine, transmission and chassis applications. New technologies will allow Schaeffler to extend the functionality and lifespan of components for the automotive industry. Real time analytics and cognitive systems will turn data from components and systems into valuable insight which can be used by manufacturers to increase the reliability of cars and offer new value-added services to customers.

Industry 4.0 for Tooling Machines: IBM’s cognitive technologies will support Schaeffler’s Industry 4.0 strategy for tooling machines helping to improve overall equipment efficiency (OEE). This includes the optimization of production processes, real time analysis of data and context-driven maintenance, networking and optimization of multiple machines within a production line. The objective is to continuously optimize production and supply chain. Focus is on internal optimization to increase efficiency and to leverage this for the creation of new service offerings for customers and partners.

New technologies will extend functionality and lifespan of automotive components through data generation and distribution (shown here in the active roll control system). Schaeffler’s digital platform technologies are being used for the tooling machine 4.0 to systematically improve OEE (overall equipment efficiency).

Connected Equipment Operations Center:

Electromechanical actuators will be able to provide data in the future

Experts are monitoring the condition of thousands of machines and pieces of equipment on and off site. Big Data is transmitted to the Operation Center and processed in the Schaeffler Cloud. Algorithms and cognitive approaches will analyze data helping to make predictions about machine performance and create opportunities for optimization. Irregularities and potential faults are automatically identified and corresponding actions rapidly initiated.

Making smart products smarter New technologies will allow Schaeffler to extend the functionality of components and systems through data generation and preparation. Real-time analysis and cognitive systems will convert the generated data into valuable information and recommended actions.

Sensotect ® makes data transmission in real time possible

Schaeffler is showing an active mechatronic roll control system. It keeps the vehicle’s structure horizontal when driving round curves and irrespective of the condition of the road surface. In this mechatronic system from Schaeffler, which is now in volume production, a

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SCHAEFFLER PREPARES THE WAY FOR DIGITALIZATION

The task of gathering data for this automatic rolling bearing diagnosis falls to the new generation of the FAG SmartCheck condition monitoring system, which is equipped with an interface that allows the measurement data to be transferred to the Schaeffler cloud. The Schaeffler cloud offers greater processing power and more extensive analysis options thanks to the combination with other machine and sensor data.

particularly efficient electric actuator compensates the rolling motion of the vehicle for the first time. The next generation of this actuator will have the potential to also act as a sensor which will capture 3D data on the condition of the road. If combined with accurate GPS and intelligent evaluation systems, it would be possible to produce real-time information which could be useful to vehicles following on behind or to the infrastructure operator. Energy supply is becoming increasingly important in the electrification of road traffic. A further pilot project will ensure that wind turbines can operate more efficiently. Schaeffler is already offering solutions which can check that wind turbine components are functioning correctly.

At the Hannover Messe, Schaeffler will be presenting available solutions for digitalized production and machine monitoring with its “Drive Train 4.0” technology exhibit. The focus of this exhibit will be on two new digital services: The calculation of rolling bearings’ remaining useful life and automated rolling bearing diagnostics.

In the future, it will be possible to calculate the remaining operating life of each individual component with the aid of learning algorithms, so that each turbine can have its own optimized operating strategy. This will reduce unexpected failures to a minimum.

With FAG SmartQB, a ready-to-use monitoring solution for electric motors, pumps, and fans that is very easy to install and does not require any specific knowledge about vibration diagnosis is available in the industrial sector for the first time

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This new digital infrastructure and initial set of applications are just a part of Schaeffler’s digitalization offensive. “We are also digitizing processes in our own production facilities as well as in many other areas of the company,” says Mr. Baum. “As we are combining our systems expertise from the automotive and engineering industries with digitalization, we are a very attractive employer for data analysts, data architects, design thinking experts and app developers.”

Bearing News • Issue 7

“Optimize your TCO with our bearing solutions.” Steve Quintijn Regal Beloit

Regal Beloit Corporation (NYSE: RBC) is a leading global manufacturer of airflow, motion control, power transmission and power generation solutions used in commercial, industrial and residential applications. From electric motors and generators to mechanical gear drives, bearings and couplings to electronic controls, Regal’s products and systems convert power into motion and motion into power to help the world run more efficiently. Regal has sales, engineering, manufacturing and distribution facilities throughout the Americas, Europe, Asia, Africa, and Australia. Power Transmission Solutions - one of Regal’s business segments - is much more than an array of well-respected product brands. Together they provide solutions. Solutions that deliver superior performance. Solutions that blend the latest in technology with their years of experience and expertise. Solutions that keep your business moving ahead.

We meet Steve Quintijn in Regal’s EMEA Bearing Headquarters in Kontich, Belgium. Steve is marketing / product manager for Rollway, McGill and Sealmaster at Regal Beloit in the Power Transmission Solutions business segment. He is since 6 years with the company and has a vast experience in international marketing.

“One of my first jobs was at the Belgian Marketing Foundation where I had the pleasure to work in an environment with marketing, advertising and communication leaders. That was the true start of my marketing passion. After that period, I have been working for international leading companies like Epson (printing business), Komatsu (mining and construction equipment manufacturer) and Altran (global leader in innovation and high-tech engineering) before entering the bearing world in 2011. Komatsu has been my longest experience till now with almost 8 years of service in the Belgian location (EMEA parts distribution center and European machine sales center).”

How does your experience help you in your current job?

in 1908, Rollway provides over 7.000 different types of ball and roller bearings. These bearings can be used in various industries like oil & gas, mining, agriculture, and various applications like pavers, harbor cranes, gearboxes, steel mills and many more. McGill was founded in 1905 and patented the CAMROL® cam follower bearing, which today is offered in more than 1.400 different combinations and configurations. McGill products also include aerospace bearings, needle and single row spherical bearings. Sealmaster, the master of mounted bearings, was founded in 1935 and is the industry’s preferred bearing product, known for its premium-quality mounted ball-bearing line, as well as its mounted roller bearings.“

Do you focus on specific industries?

“Belgium is a small yet important country in international business. Business has brought me in many countries in EMEA, Asia and the Americas and I have learned to blend in in other cultures. Knowing the basics about a culture like history, gestures, sensitive subjects and liking the local food still opens many doors. My previous functions also helped me getting a close view on several industries like earthmoving equipment, food & beverage and I have worked with great people in Kaizen, systematic innovation and lean manufacturing.”

“Due to the very diverse and international customer base we have, I am more of a generalist working closely together with our industry specialists and engineers. The past years I have been to many customers and have seen successful applications in very diverse industries. Main goal with all these customers is optimizing their TCO with our bearing solutions. For instance, a famous European brewery was doing many actions for lean and clean operations and wanted to find a solution for the excessive lubrication of their bearings.

Which bearing brands do you have in your portfolio?

We advised them our Sealmaster PN Gold reduced maintenance bearings that do not require any additional re-lubrication. This was a durable and environmental healthy solution for the brewery. There was also a huge potato chips plant where starch was a nightmare for the

“Rollway, McGill and Sealmaster are the main bearing brands we support from our location in Belgium. Founded Page: 32

Bearing News • Issue 7

“Rollway bearings do what they need to do: they keep your application moving.”

bearings and caused a too short lifetime. We were able to satisfy the customers’ needs with Sealmaster PN Gold and even overachieved the set target, we doubled the lifetime of the previous installed bearings. Rollway is an interesting brand since we have a range from very small up to the large sizes. My favorite is ball bearing 618/1500, because on the outer diameter it’s as tall as I am. This bearing is used in a centrifugal casting machine and the customer choose Rollway because the brand they used before didn’t reach the desired life. A sweet solution was provided in the food industry where we provided spherical roller bearings that are mounted in a chocolate refiner. For a chocoholic like me it’s good to know we were able to reduce the customers’ downtime. You can also see us in many harbors as one of the world’s leading RTG cranes (Rubber Tired Gantry) OEM’s uses several sizes and types of our Rollway bearings as first-fit. Rollway bearings do what they need to do: they keep the application moving.“ There are many success stories for every brand, so also for McGill. A fish processing plant was incurring sizeable costs to maintenance and repair of their machines with standard cam followers that seized due to the corrosive environment. Our stainless steel CRES CAMROL product has been designed to operate in these taxing conditions, improving machine reliability and extending operating life. This fish processing plant uses equipment specifically designed to remove viscera and roe. The standard cam followers installed within the machines are exposed to highly corrosive conditions. Consequently,

standard cam followers corrode and seize, resulting in damage to the cam in which they ride. The cost incurred to replace the entire cam is prohibitively more expensive than simply replacing the cam follower, and machine downtime creates significant production inefficiencies for the plant. To help reduce these significant replacement costs, Regal recommended the dimensionally interchangeable McGill CRES CAMROL line, which is designed with 440C stainless steel to help resist corrosive environments. The Lubri-Disc+ seal also provides significant protection against wash downs, more than 5 times compared to our standard Lubri-Disc seal. To further improve bearing life, we recommended a crowned outer diameter, which allows for greater misalignment while maintaining even load distribution. Always great to see a customer smile when we provide solutions!”

What do you expect from 2017? “I keep Conan O’Briens quote in mind: ‘If you work really hard, and you’re kind, amazing things will happen’. Get in touch to see which magic we can do for you and your TCO in 2017.”

“Sealmaster, McGill and Rollway will be at the HannoverMesse trade show in Hannover, Germany from 24 till 28 April. Come visit us in Hall 24 in the EPTDA Pavilion.” Page: 33

Do’s and don’ts of cam follower installation If you have cam follower bearings installed in your facility, then maintaining a great performance from those bearings will be something you are interested in. You can help obtain great bearing performance if you keep some particulars in mind during installation.

DO 1. Do install the oil hole plug in applications where the bearing will not be re-lubricated. Because it’s an optional part of the installation, in applications where re-lubrication will be performed, the user may be inclined to discard the oil hole plug. Installing the plug helps protect the bearing from contaminant entry, such as fine grit, metal dust or liquids, promoting longer life. Longer life means less down time and fewer bearing replacements. Plugs are provided with all McGill stud type cam followers, so better safe than sorry. 2. Using a press fit on the stud helps to create proper support of the stud in application; it can be used when installing stud-type cam followers. Press fitting is when you have an interference fit requiring you to apply pressure on the stud end face of the bearing. Be sure to apply the pressure through the stud end face, preferably using an arbor press. 3. Specifically, for the yoke type bearings: please do back up the bearing’s end plates. Yoke type bearings require a housing to support the end plates. Do not shirk on keeping the end plates supported. Keeping those end plates supported maintains the bearing’s proper assembly in operation, and helps avoid premature application breakdown and possible injury due to disassembly. It will also prevent unnecessary bearing replacement and unnecessary cost. 4. You may know that stud type cam followers require a certain amount of torque applied to the locking nuts, in order to adequately lock Page: 34

Scan the QR code to watch The Do’s and Don’ts of Cam Follower Installation on our Power Transmission Solutions YouTube channel

the stud in place. Clamping torque info is provided in our bearing catalog, as well as in instruction sheets. Do torque McGill bearing nuts accordingly! Those charts are there for a reason. Overtorque can cause bearing damage and undertorque can allow bearing disassembly. Excessive torque can result in stud elongation or fracture. Inadequate torque can allow the cam follower to become disassembled from the housing. Keeping the proper torque as shown in the bearing’s chart will maintain clamping pressure adequate to lock the stud in place, keeping the bearing in its intended position. 5. Some applications need little maintenance, such as those involving slower speeds, fairly clean environments and ambient temperatures. However, re-lubrication becomes more crucial as application speed, temperature, or contamination levels increase. Do regularly inspect and as necessary re-lubricate your bearings. Keeping your bearings in top condition maximizes their operational performance and life. Regular check-ins are also a good opportunity to inspect the state of their installation and working environment.

DO NOT 1. During installation, do not hammer directly on the bearing! Doing this can cause damage to your bearing or injury to those involved. 2. Don’t neglect your bearings. I don’t need to tell you that negligence can result in permanent damage and shorten operating life. In short, you’re wasting money. Steve Quintijn Product Manager Bearings EMEA Power Transmission Solutions Regal Beloit McGill.PTSolutions@regalbeloit.com

Bearing News • Issue 7

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Introduces an Evolution in

BEARING CAGE DESIGN

Bowman International, a leading innovator in bearing design and manufacture, has introduced to the market a revolutionary bearing cage, designed to offer up to three times longer life expectancy and 40% higher load bearing capacity. In an industry where increasing bearing performance by as little as 5-10% is considered significant, Bowman’s patent pending ‘Evolution’ cage technology is truly a stand-out innovation. Split bearing cages The Evolution cage boasts a unique interlocking structure which uses the rolling elements to pin together each section of the cage. This revolutionary, design creates enough additional space around the circumference of the cage to incorporate two to four* more rollers than comparative products. It is these additional rollers which allow the load to be spread over a higher number rolling elements that increase the performance of the overall cage, making it a suitable specification choice for any application which would benefit from higher load capacity or extended life expectancy, without having to amend any other part of the bearing assembly. Jacob Turner, head of Bowman Additive Production explains: “By using the roller to pin together the cage Page: 36

structure, we essentially create additional space for more rollers, increasing the load bearing capacity and therefore lifespan of the component. “This unique structure also facilitates easy mounting and maintenance with no fiddly pins or clips to manoeuvre or maintain.”

Low to medium run non-split bearings Evolution cages are manufactured without tooling and therefore offer a highly competitive cage option for low to medium run bespoke bearings across many sectors, not limited split bearings. Manufactured from engineering grade ‘printable’ nylon (PA1102) with bronze-alloy inserts made from the world-renowned ToughMet®3, the cage delivers the wear properties of ultra-high load bronze with the design Bearing News • Issue 7

complexity synonymous with 3D printing. The cage delivers greatly reduced wear on rolling elements when compared with conventional steel cages. Unlike other market-leading competitors, the Evolution cage has been precision engineered to almost touch the inner and outer races (race riding) and give full contact support of the rolling elements. These features both help to increase stability and reduces vibration and noise, further improving load capacity. Jacob Turner adds: “The Evolution cage combines the very latest in SLS (Selective Laser Sintering) 3D printing with world-renowned materials science. Together, this offers OEMs and plant maintenance engineers a split bearing cage which delivers superior performance and longer product life, alongside simplified mounting and maintenance procedures – not forgetting less vibration and noise during operation. “The cage design integrates a number of complex forms, which means additive production with Nylon 11 is the only

manufacturing method capable of bringing this concept to reality in an economically viable way. Combining this new production method with Bowman’s extensive experience in materials innovation has proved a formula for success for the split bearing market.” High grade Nylon 11, or PA1102, is Bowman’s preferred choice of additive manufacturing material – a polyamide characterised by its elasticity and high impact resistance. Whilst most manufacturers remain focussed on using aesthetically tuned materials for visual prototyping, Bowman AP will join a select group of companies in the UK able to offer this engineering specific material for the production of functional parts. Bowman’s new cages are designed and manufactured entirely by Bowman’s new additive manufacturing division, Bowman Additive Production, in its main facility in Oxfordshire in the UK. Paul Mitchell, Managing Director of Bowman International, concludes: “The Evolution cage is a Page: 37

demonstration of our commitment to bringing to market products which are designed for purpose, longevity and performance. The class-leading design and precision engineering, together with state-of-the-art technology and materials, sets the benchmark for future product developments under the Bowman brand. “We are proud innovators within our marketplace and we are already seeing that our pioneering work, combining the power of additive manufactured plastics with high performance alloys, is already garnering interest on a global scale, across a wide range of industries. “We are incredibly excited to see how the future of manufacturing evolves, and how we can maximise the new technologies available to us.” To find out more about how Bowman’s ‘Evolution’ bearing technology or production additive manufacturing expertise could benefit your application, call our dedicated sales team on 01235 462 500.

Evolution in bearing cage technology: • Patent pending design • ToughMet®3 bronze alloy / Nylon 11 composite construction • Race-riding design • Full roller support (no point loading on rolling elements) • Unique split design allows more rollers and ease of use • Up to 40% increase in load capacity • Up to 300% life expectancy *Number of additional rollers depends on size of cage.

Page: 38

Bearing News • Issue 7

DEDICATED RANGE OF TAPERED ROLLER

750 REFERENCES TO DISTRIBUTORS’ NEED NTN-SNR is launching a dedicated range of tapered roller bearings (TRB) for distributors operating in industrial markets. With the most extensive metric and imperial range in the market, NTN-SNR has cemented its status as a leading supplier capable of addressing industry’s most demanding needs for this type of bearing. NTNSNR has created a range of 750 clearly identified references, so that distributors can focus on an instantly available range of Japanesemanufactured premium bearings delivering superior performance, most of which are available in casehardened steel. In addition to the 750 references in this dedicated range, NTN-SNR still offers its customers close to 3,000 tapered roller bearing models.

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Bearing News • Issue 7

BEARINGS:

O FULFIL DS A comprehensive core range of TRBs to satisfy distributors and industry With its dedicated TRB range for distributors, NTN-SNR is offering a two-in-one core range that addresses the vast majority of needs for single-row tapered roller bearings, whether metric or imperial. With 200 metric references, NTNSNR covers all the most widely used bearings, while its 550 imperial references satisfy nearly all the most frequently requested bearings. NTN-SNR has strengthened its reputation as a major supplier of all tapered roller bearings in response to the needs expressed by industrial distributors. To develop this programme and the associated dedicated ranges, NTN-SNR has worked on its supply chain to ensure that products are always available to European distributors and has also focused on creating a clear pricing structure for the range and enhancing its visibility. Consequently, distributors have access to a wealth of specific documentation covering the range and can easily look up and order products from the NTN-SNR e-shop.

THE RANGE

Single-row tapared roller bearings Metric • 10 series • 200 references • Bore diameter from 15mm to 369 mm

Imperial • Over 200 series • 550 references • Bore diameter from 15.875 mm to 196.850 mm

Premium quality and superlative performance for the entire range All the tapered roller bearings in the dedicated range for distributors are premium-grade parts, manufactured in the Group’s Japanese factories and offer high performance for such demanding applications as construction equipment, agricultural machinery and steelworks. Our stringent supplier selection process guarantees that all bearings are made from steel of the hest quality. 70% of the range from case-hardened steel Over 70% of the range is manufactured from casehardened steel, whose reference numbers can be identified by the 4T prefix. The 4T prefix guarantees that each component (inner and outer rings and rolling elements) is produced from case-hardened steel. This steel initially features a low carbon content. During the process of transforming the steel into bearing components, additional carbon is infused into the surface layer of the steel (called the case-hardening process), but not into the core. Once hardened, the steel presents the following characteristics: • High superficial hardness of the component, which is ideal for guaranteeing bearings with a long service life • Good core resilience (soft core), meaning the ability to absorb the application’s impacts and heavy loads These characteristics help increase bearing service life by 40%. Superior geometric design Finally, accurate control over the bearing’s internal geometry reduces the torque and significantly improves roller performance, while increasing the number of rollers in the same space to raise the dynamic capacity bar by over 30% for NTN-SNR tapered roller bearings.

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DORTMUND, 10 - 12 OCTOBER 2017 subscribe now on www.bearingreliabilityconference.com

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THE ULTIMATE GUIDE TO

FULL CERAMIC BEARINGS IN

WATER PROCESSING, WATER FILTRATION AND LIQUID HANDLING

Bearings are essential mechanical components of machinery used in a variety of industries. A bearing’s purpose is to help facilitate desired motion, limit undesired movement, and reduce friction. Bearings are thought to date back as far as the ancient Egyptian era, when wooden bearings were used to assist with the movement of heavy objects. Since then, the concept has developed considerably; bearings now come in a variety of forms, and are made from many different types of materials. Bearings are an essential component in the majority of mechanical designs and equipment. It is important to consider the most effective materials when designing industrial machinery, especially in applications where water, or other liquids are present. Many materials will be unable to overcome the challenges associated with operating in a wet or corrosive environment. To

overcome the challenges faced by industries involved in water processing, water filtration and liquid handling, full ceramic bearings should be used. This paper will outline the properties of full ceramic bearings, and enable you to determine whether they are the most appropriate type for your mechanical processes.

COMPARING FULL CERAMIC MATERIALS’ PROPERTIES There are a number of ceramic materials that can be used to produce full ceramic bearings. While these share a number of properties, they also offer distinct characteristics, which will help you to determine the most suitable material for your machinery. Here’s a guide to the most common materials used to produce full ceramic bearings:

Zirconia Oxide (ZrO2) Zirconia Oxide was first used in the 1960s. It was used in space travel, creating a thermal barrier to enable space shuttles to enter the Earth’s atmosphere. It copes well with high temperatures, but doesn’t handle thermal shock resistance to the same extent as alternative ceramic materials, such as Silicon Nitride. It’s best used in high temperature environments that involve minimal loads. It’s highly resistant to corrosion, which makes Zirconia Oxide the perfect choice for use

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Bearing News • Issue 7

with highly corrosive liquids. It’s an incredibly strong material, which also makes it ideal for use in mechanical applications involving fracture risk. ZrO2 has an operating temperature range of -85°C to 400°C

Silicon Nitride (Si3N4) Silicon Nitride is a ceramic material produced using a series of chemical reactions, creating a full ceramic material with distinctive properties. The material is dark in color, and is one of the most superior types of ceramic material in terms of quality and durability. This material is relatively expensive, but the extra cost is worthwhile if you’re looking for something that can withstand high temperatures and harsh mechanical conditions. In terms of withstanding high temperatures, silicon nitride is superior to alternative metallic solutions, and it has a lower thermal expansion coefficient than many alternative ceramic materials. This makes it an excellent choice when thermal shock resistance is a high priority. Si3N4 has an operating temperature range of -100°C to 900°C.

Aluminum Oxide (Al2O3) Aluminum Oxide is the most popular ceramic ball material, and its common uses expand far beyond the realms of ceramic bearings. It’s produced through the process of calcination of aluminum hydroxide, which creates a durable and highly resistant ceramic material. This material is best known for its high compression strength, and its ability to resist corrosion when faced with a variety of abrasive chemicals, even when the environment involves extremely high temperatures. Less expensive than some of the alternative ceramic materials, aluminum oxide is readily available and is the most popular choice ceramic bearing for projects in which the available budgets are limited.

Silicon Carbide (SiC) Silicon Carbide is produced by chemically combining carbon and silicon atoms. It has excellent mechanic properties, which makes it a fantastic choice for use in the creation of bearings. Grains of silicon carbide have been used for many years as an abrasive, most commonly in the form of sandpaper. However, these grains can be combined through sintering to create the highly durable ceramic material used to create silicon carbide bearings. This is a strong, durable ceramic material with a low density, low rate of thermal expansion, and fantastic thermal shock resistance, making it suitable for use in a wide variety of applications.

ENSURING EXTENSIVE LIFESPAN OF BEARINGS Generally speaking, ceramic materials are extremely

Page: 45

durable. Most of them are man made using chemical processes, and consequently can withstand extremely high temperatures and corrosive materials. Full ceramic bearings have a much longer lifespan than hybrid ceramic bearings or the steel alternatives, particularly when they aren’t placed under a considerable load. This can be attributed to many properties of full ceramic bearings. Firstly, ceramics are much stronger. As a result, the balls or races of the bearing do not become distorted when placed under load. However, the superiority of full ceramic material increases with the load, and full ceramic materials are still at risk of premature failure in these cases. The main limitation of ceramic bearings is the fact they can be quite brittle. Consequently, you must analyze the load to ensure the chosen material can cope with the stress. Zirconia Oxide will handle large loads better than the rest of the full ceramic materials.

ELECTRICAL INSULATION WITH CERAMIC BEARINGS The ceramic bearings are also non-magnetic, and, with the exception of Silicon Carbide, provide good electrical insulation. Silicon Nitride offers the best electrical resistance, but is closely followed by Zirconia Oxide, which is readily available and fits within most budgets.

IMPROVED PERFORMANCE OF BEARINGS IN WATER AND OTHER LIQUIDS Research has demonstrated that full ceramic bearings perform better than any alternatives when placed in water. Depending upon the material used, the lifespan can be up to 70 times longer than stainless steel bearings, a common alternative. The best ceramic materials for use in water processing environments are Silicone Nitride and Zirconia Oxide. Hybrid ceramic bearings also perform better than steel, but their lifespans are significantly shorter than full ceramic materials, which in some cases have a lifespan 5 times longer.

RESISTANCE TO CORROSION It is not feasible to use metallic bearings within industries handling water or other liquids, as they will corrode rapidly. When selecting the most appropriate material for the ceramic bearings, you should also consider the types of liquids the bearing will encounter. If the bearings will be used in environments containing corrosive materials, the lifespan will be significantly altered. Silicon Nitride offers good resistance to the majority of chemicals, so is often a good choice when the budget permits.

TEMPERATURE CONSIDERATIONS When deciding which material to use, it’s important to

Bearing News • Issue 7

consider the technical properties of each material to evaluate their suitability. One of the most important aspects to consider, particularly when working with liquids that may reach high temperatures, is the temperature of the environment in which you will be using the bearings. Silicon Nitride can be used in environments reaching up to 1050Â° F, without loading.

Page: 46

However, this can change significantly when used in industries handling liquids, as the bearings can encounter significant loading. The coefficient of thermal expansion is possibly a more useful characteristic, as it provides you with an indication of the materials ability to cope in response to heating and cooling. Full ceramic bearings offer relatively low coefficients, compared to the non-ceramic alternatives. For example, Silicon Nitride has a coefficient of 3.2 x 106/k and Silicon Carbide offers 3 x 10-6/k. Zirconia Oxide and Aluminum Oxide are considerably higher, at 10.5 x 106/k and 8.5 x 10-6/k respectively, but both of these are much lower than bearing steel, which has a coefficient of 12.5 x 10-6/k. In environments with considerable temperature changes, Silicon Nitride and Silicon Carbide are the best choices. These materials also offer good thermal shock resistance (up to 1112oF in Silicon Nitride, and 752Â°F in Silicon Carbide), which indicates minimal risk of fracture due to the changing temperatures.

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www.bowman.co.uk | info@bowman.co.uk | +44 (0) 1235 462500 | @BowmanInt

RESISTANCE TO FRACTURE UNDER LOAD The material’s ability to resist fracture is essential when used with liquids, such as water processing, as pressure is increased when submerged. Therefore, another characteristic that must be considered is fracture toughness. This indicates how capable the material is at resisting fractures in high-pressure environments. Zirconia Oxide offers the best resistance, with a fracture toughness of 10 MPA*m1/2, closely followed by Silicon Nitride at 6.2 MPA*m1/2. These are consequently the best materials to use in a high-pressure environment, where the risk of cracks and fractures is high.

Wild Goose Engineering Success Story Wild Goose Engineering is an engineering and machining company in Colorado. They partnered with a local brewery to develop an automated canning line specially designed for the craft beer industry. The canning system they created was not without its challenges. When you are dealing with any liquid, corrosion becomes a potential concern. Frequent wash-downs and the beer itself can cause some mechanical components to corrode, gum up, or fail completely. One such issue they found was that in their can lift and seamer, the constant spray of beer was causing the bearings to go bad very quickly. Downtime is a problem in any automation process. Wild Goose Canning turned to Boca Bearing Company for help. They were able to identify the issues with their application and were able to offer the solution in the form of Full Ceramic Bearings for the can lift and seamer. Ceramic bearings don’t need lubrication, so there was no danger of chemical contamination, and they are FDA certified, and most importantly, ceramic won’t corrode if it is exposed to water, cleaning chemicals, or the beer. Boca Bearing Company and Wild Goose Canning are helping breweries to can their beers, and keep them operating safer, longer and more efficiently, so at the end of the day, they can kick back and enjoy a cold one. The development of mechanical equipment for use in wet environments is no easy task, and selecting the right materials is vital to ensure the success of your business. Mistakes can be expensive, so it’s important to understand the properties of the available resources. When it comes to bearings, metallic or hybrid options are simply not an option if significant contact with water is expected. Instead, full ceramic materials should be used to ensure the machinery will be built to last, and will operate efficiently for the duration of its use. Check www.bocabearings.com for more information.

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Bearing News • Issue 7

B USA /TC , IN VA

ISO 9001:2008 10000099 QM08 ISO/TS 16949:2009 10000099 TS09

www.novausa.us

AUTHORS: John Harms • Reliability Engineer at Mosaic Fertilizer, Louisiana Operations, email: John.Harms@mosaicco.com Chris Rehmann • Business Development Manager at AESSEAL, Inc, email: chris.rehmann@aesseal.com

ELIMINATING MOISTURE DAMAGE TO BEARINGS ON CRITICAL STEAM TURBINES INTRODUCTION

LABYRINTH BEARING PROTECTOR DESIGN

Mosaic Fertilizer, Louisiana Operations, produces phosphate fertilizer. Steam turbines are used as primary drivers (in place of electric motors) to utilize steam produced by waste heat generators. During normal operations, steam leaking past the carbon rings caused moisture ingress into the bearing housings which the OEM standard seals could not effectively stop.

Labyrinth bearing protectors have been gaining popularity and replacing lip seals as the preferred form of sealing bearing housings at reliability-focused plants over the last 25 years. Recent design improvements have greatly improved the labyrinth seal’s ability to contain valuable lubricating oil, and to exclude moisture and other contaminants.

Mean Time Between Repairs (MTBR) for the turbines was only 4-12 months with the OEM seals. Turbine rebuilds cost $35,000 and up. Several seal designs were tried to exclude the moisture from the bearing housings, but none were successful. Mosaic installed labyrinth-style bearing protectors designed specifically for steam turbines on a Terry GAF4 turbine. The results have been excellent, with zero water in the oil, and no repairs required over the last 24 months (and counting). Mosaic has selectively scheduled Labtecta retrofits for all steam turbines with chronic moisture lube oil contamination, and is aggressively retrofitting critical acid service pumps and gearboxes which have root cause failures associated to lube oil contamination. Page: 50

Figure 1:

The basic elements of any rotating labyrinth isolator are (a) a stationary portion which fixes to the machine housing and contains the lubricating oil, (b) a rotary portion which fixes to the shaft and excludes moisture and dirt, and (c) a “shutoff” mechanism which seals the oil chamber when the machine is stopped, but which Bearing News • Issue 7

allows the air in the oil chamber to expand outward during operation. The basic design of a rotating labyrinth bearing protector is shown in Figure 1. Figure 1: Modern rotating labyrinth bearing protector (diagram courtesy of AESSEAL, Inc), with 5 important design features: 1. Removable/replaceable ring for easy fieldrefurbishment, 2. Two shut-off o-rings that land on a smoothlycontoured surface, 3. Two drive o-rings on shaft provide better drive and more stability, 4. Two water expulsion ports, 5. Two oil-retention mechanisms. The seal in Figure 1 is widely used on pumps, motors, gearboxes, fans, pillow-block bearings, etc. This design has been adapted to fit the narrow space envelope and special operating conditions of a steam turbine, as shown in Figure 2. You can see that this seal also utilizes two drive o-rings, two shut-off o-rings that seal on a smooth surface, and easy refurbishment capability. But the steam-turbine isolator has two unique adaptations as shown in Figure 2. First, a ring of graphite packing

has been placed on the side nearest the steam to help protect the Aflas o-rings from the intense heat. Second, the design of the rotating unit has been changed to create a “steam deflector” which repels the impinging steam.

Figure 2: Modern rotating labyrinth bearing protector design for a steam turbine (courtesy of AESSEAL, Inc).

“This results in a payback period on the initial investment of less than THREE WEEKS, with ongoing savings of $50,000 per year thereafter.” Page: 51

in, which is literally a “cloud of steam”.

Figure 3: Cutaway diagram of a typical steam turbine, showing the escaping steam (red arrows) passing by the split carbon rings and simple OEM labyrinth seals (in circles), and entering the bearing housings.

THE PROBLEMS WITH STEAM Like many other types of rotating equipment, steam turbines have bearings which support the axial and radial loads. These bearings must be properly lubricated in order to achieve L10 life cycle. Turbine bearings are exposed to high temperatures, high transient thrust loads, long states of idle readiness and a moisture laden environment; severe operating conditions at best. Of all operating environments, the state of idle readiness introduces the highest level of contamination exposure to a turbine bearing and lube oil system because the rotor and, in most cases, lubrication system is in a static state while live steam leaks past the carbon shaft seals.

Figure 5a and 5b: Photo of thrust bearings (left) and drive end bearings (right) after one year of service with inadequate bearing protectors. Note severe corrosion. (photos courtesy of Mosaic Fertilizer)

the bearing housings (see Figure 5).

Mosaic Fertilizer, Louisiana Operation’s reliability engineer has studied MTBR’s and performed root-cause failure analysis on a wide range of rotating equipment failures (turbines, pumps, gearboxes, trunions, etc), and concluded that bearing failures were frequently caused by lube oil contamination that was the result of the steam in the operating environment entering

“The payback period for a set of 3 labyrinth seals for one steam turbine is less than three weeks, with documented savings of $50,000 per year per turbine afterwards.”

Mosaic Faustina Ammonia Plant’s Terry GAF4 steam turbines were suffering from water contamination of the bearings, leading to an MTBR of as little as 4 months. This had been a chronic problem for the last 40 years. Just replacing the bearings on this turbine costs $14,000. A full turbine rebuild costs about $35,000. An emergency rebuild in August 2010 of an Elliott EPG-4 turbine and 90P single stage compressor due to water related failure cost over $300,000. A solution was needed to stop this frequent and expensive damage.

As the steam makes its way past the OEM labyrinth bearing housing seals, which function properly only in the dynamic state (i.e. when the shaft is rotating) it condenses on the cooler inner surfaces of the bearing housing and collects in the sump. When the turbine is put in service the bearings will fail prematurely due to moisture contamination. The location of the escaping steam can be seen in the turbine cross section diagram of Figure 3, which shows the rather simple, stationary labyrinth isolators (in circles) which are provided by some OEM steam turbine manufacturers. Figure 4 is a photo of the actual environment which a steam turbine operates

To reduce the ingress of moisture, and improve the MTBR of the turbine bearings, Mosaic attempted the following modifications: • Tighter running clearances of the OEM labyrinth seal, • Air buffer porting, • Low pressure reducing baffle, • Instrument air purging the oil reservoir, to prevent ingress of moist air, • Nitrogen purging the oil reservoir, to prevent ingress of moist air,

Figure 4: Steam turbine bearings operate in a difficult steam-laden environment

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Bearing News • Issue 7

Figure 6: Pristine condition of the thrust bearing side after one year running with modern labyrinth isolators. (photo courtesy of Mosaic Fertilizer)

• Desiccant vent filters, to dry the air entering the housing, • Vent check valves, to allow one-way flow of air from the housing, • Synthetic lubricants, with improved moisture separating qualities. None of the above modifications were completely successful. Several well-known after-market bearing isolators were then investigated and tested. Most labyrinth isolators showed some improvement over the OEM seal, but none fulfilled all of Mosaic’s requirements (i.e., no oil leakage out, and no water entry in).

“Oil samples are taken from the turbines and evaluated weekly, and show ZERO water in the oil on steam turbines which have modern labyrinth isolators installed.” THE SOLUTION TO THE PROBLEM In July, 2008, a set of 3 LabTecta bearing isolators (Figure 2) were installed on a Terry GAF4 turbine. The cost for these isolators was $2,400. This turbine is still running fine after 24+ months, and Mosaic estimates that for this initial investment in state-of-the-art bearing protection, it has avoided at least 3 turbine repairs over this time period, for a total savings of $100,000. Weekly oil samples taken from this steam turbine with modern labyrinth isolators continue to show zero moisture in the oil. Turbines with LabTecta isolators that are taken out of service for other reasons have no corrosion and pristine conditions inside the bearing housings, see Figure 6. Using an asset criticality matrix and tribology study, Mosaic’s reliability manager identified turbine seal

Figure 7: Magnetically-energized face-seal bearing isolator used on API 610, 10th ed. oil mist applications at Mosaic River plant (courtesy of AESSEAL, Inc.)

upgrades with the most profitable ROIC. In addition to steam turbines, Mosaic has also standardized on this bearing isolator design for all rotating shafts up to 3.00” diameter on pumps (Ash, Wilfley, Denver-Orion, GIW), gearboxes (Falk, Marley, Philly, Lightnin’), and trunions. Shafts over 3.00” diameter are evaluated by the Rotating Equipment Engineer on a case by case basis. Bearings that are lubricated with oil mist are sealed with a contacting face-seal, magnetically-energized type of bearing isolator (see Figure 7).

CONCLUSIONS Steam/moisture entry into the bearing housings of steam turbines and other rotating equipment was a major source of costly bearing failures at this plant. The OEM bearing protectors were determined to be inadequate for the severe conditions surrounding steam turbines. Mosaic River tried numerous housing design and lubricant changes to eliminate or at least minimize the effect of the water in the oil. Mosaic investigated and tested a number of different bearing housing seals and isolators, and standardized on the modern labyrinth design shown in Figure 1 for its pumps and gearboxes, and Figure 2 for its steam turbines. Labyrinth seals installed in July 2008 are still running fine as of the time of this writing, 24+ months later. Turbines which contain labyrinth seals and which were torn down for other reasons show absolutely pristine condition of the bearings and bearing chambers.

Page: 53

QUALIFICATION OF

GLOBAL BEARING MANUFACTURING

PRACTICES

Napoleon Engineering Services, the largest bearing inspection and testing facility in North America educates on global sourcing Page: 54

Bearing News â&#x20AC;¢ Issue 7

Global manufacturing by original equipment manufacturers (OEM) and purchasing of bearings from global sources for industrial applications has skyrocketed over the last two decades. The playing field for the purchasing of bearings has changed significantly over this period of time. Historically, there were only a handful of bearing manufacturers who were called upon and trusted to supply bearings for high-reliability applications.

Today there are many hundreds of bearing manufacturers claiming to provide the same level of quality and service. Furthermore, the top name bearing manufacturers have exponentially increased their global footprint to ensure their own sustainability within the global market. So, how do design engineers and supply planning professionals mitigate risk when called upon to utilize global bearing sources when vast differences in design and manufacturing quality of bearings within the global supply chain may exist? Napoleon Engineering Services (NES) has been leading OEMs through the global bearing qualification process for nearly 20 years providing technical information through bearing inspection, modeling, and testing programs to evaluate bearing design, manufacturing capability, overall quality of workmanship, and the relationship these attributes have on bearing life. NES president and chief engineer, Chris Napoleon states, â&#x20AC;&#x153;I have two decades worth of inspection and testing data showing that not all bearing are created equal, even from the same source of supply. There are two reasons for this. The quality standards governing the design of a bearing are minimal, leaving plenty of opportunity for creativity. That is not necessarily bad until you compare a world class bearing manufacturer with substantial research and development behind their product to a manufacturer who lacks those resources. Another challenge affecting the industry is the large quantity of acquisitions and joint ventures taking place,

primarily by the large bearing manufacturers looking to establish a global manufacturing presence. I regularly find different design and manufacturing characteristics from a bearing manufacturer who has multiple plants around the world. However, this does not mean that a successful global supply base for bearings cannot be achieved. It just requires the use of a qualification program that provides the correct amount of risk reduction.â&#x20AC;? Consider the internal design of a tapered roller bearing. It possesses several very important rolling and sliding contact surfaces that require evaluation. The cone raceway, cup raceway, and roller OD contours play a major role in stress distribution, reduction of roller end stresses, and the ability of the bearing to adequately support misalignment in the application. In addition to raceway contour or profile magnitude, there are different forms created by the manufacturing process that can be compared and analyzed. (SEE file with Contours data). Cone rib flange and roller end are also important. The contours and surface finish values of these mating surfaces play a major role in bearing heat generation as well as break-in characteristics. Differences in surface finish and relationships between roller end and rib flange profiles can significantly affect the lubricant effectiveness. These are just a few characteristics requiring examination to adequately judge a bearingâ&#x20AC;&#x2122;s quality level and reduce risk for the OEM. With that said, the capability of the manufacturing and inspection equipment used to produce and manage these characteristics has improved

Page: 55

dramatically in recent years providing more bearing manufacturers with the ability to carry out design intentions that were not possible 20 years ago except by a select few. That’s good for the global purchaser, but validating their true capability through a detailed Source Qualification Inspection (SQI) program is vitally important to ensure application success for the OEM. By measuring bearing characteristics an actual stress distribution analysis can be performed through modeling software. Depending on the criticality of the application a dynamic lab test based on expected failure mode should be performed to further reduce risk. For example, if the failure mode is fatigue related then a rolling contact fatigue test should be conducted to determine the combined effects of design, manufacturing, and material quality have on the empirical life. An NES standard bearing test rig would allow for radial, axial and possibly moment loading at some predetermined speed and lubrication condition. (SEE picture for Test Rig) The bearing supplier provides production bearings for testing that are run until failure. A Weibull analysis estimates the life of the population and allows for comparison of the empirical L10 life to theoretical life, based on the test conditions. This information is invaluable to the design engineer and often imperative to risk mitigation when global sources are considered for critical applications. (SEE file for Weibull plot) The use of inspection and testing programs to support bearing qualification programs is most valuable to the design engineer when used in combination. The addition of a solid inspection of a sample population of product before dynamic testing serves two purposes. First, if Page: 56

the inspection determines that the product possesses significant deficiencies in design, manufacturing or quality of workmanship, there may be no need to perform dynamic testing until the issues are addressed and corrected, saving valuable time and money on dynamic testing. Second, if dynamic testing shows one supplier to be significantly better than another, the addition of the inspection data in the analysis phase may allow the design engineer to assign cause to or explain the difference in the test results. Specific changes can now be made to the product that should result in improved bearing life and qualification of a new source of supply. NES believes that successful utilization of global bearing suppliers requires: 1. Having a good understanding of the application and failure modes. 2. Defining the criticality of the bearing within the application. 3. Using a Source Qualification Inspection program and modeling software. 4. Use of standard bearing lab tests for empirical life comparisons. 5. Commitment in time and money for proper bearing qualification programs. Napoleon indicates, “It takes more work on the part of the OEM than in past years to qualify todays’ global bearing supplier; however, if performed correctly there are significant benefits to be gained in having better control of your own destiny regarding product availability and cost, plus we’re here to help.” Visit www.nesbearings.com for more information.

Bearing News • Issue 7

Mr. Jiří Přášil

An Interview With

THE CZECH SPECIALIST FOR BEARING MANUFACTURING Page: 59

“70 Years Tradition of Bearing Manufacturing” ZKL Group is a result of the integration of Czech bearing industry with 70 years’ tradition providing research, development, manufacturing and sales of ZKL bearings. ZKL Group with its products is a well established company with stable sale on domestic market. Besides of European markets it has its representations in India, Latin America and in many other countries of Asia We tried to reveal the story behind this European Bearing manufacturer during an interview with Mr. Jiří Přášil jr., the Executive Director of ZKL Bearing CZ, a.s.. What´s the history and evolution of the ZKL Group? The joint-stock company ZKL, a.s. integrates the Czech manufactures of bearing under the trademark ZKL. It was established in the year 1999 as a purely Czech private company. ZKL Group has 2 production companies – ZKL Brno, a.s. and ZKL Klášterec nad Ohří, a.s. The production companies that are included in ZKL Group have their own long-lasting history which we fully acknowledge and therefore these production units are implementing the continuity of development and manufacture of ZKL bearings in the Czech Republic. First bearings in the Czech Republic started to be manufactured in a small town Pernštejn near Klášterec nad Ohří in a plant owned by German company Fichtl and Sachs in the year 1923. This plant was later taken over by Swedish SKF. After the second world war the production of bearings was transferred to the town Klášterec nad Ohří, where in the year 1952 the national enterprise ZKL, n.p. Klášterec nad Ohří was established. It was incorporated in ZKL Group in the year 1999. The history of roller bearings production in Brno is somewhat shorter. Production of bearings started in the year 1947 under the Page: 60

license of British company Hoffmann in the framework of the company Zbrojovka Brno – Líšeň. So we will celebrate 70th anniversary of bearings production in Brno this year. Unceasing demand for new types of roller bearings and growing requirements of technical level in the research, design, technology and quality inspired to establish the Research and Development Institute of Roller Bearings. The roller bearing production at that Zbrojovka Brno and research and development activities became the groundwork of present joint stock companies ZKL Brno, a.s. and ZKL Výzkum a vývoj, a.s. Inseparable part of the traditions in research, development and production of ZKL bearings is also the history of formation its distribution network. Nowadays the continuity of the sales role is in hands of ZKL Bearings CZ, a.s. which is engaged in sales of ZKL bearings worldwide. Presently ZKL Group structure is oriented to efficiently develop and strengthen its competitiveness with the topmost roller bearings manufacturers of the world. It has its own design and development Bearing News • Issue 7

base, sufficient production capacities and dynamically evolving distribution network by the net of distributors.

Which are the biggest challenges you expect to deal with during 2017 -2019?

What are the strengths of the ZKL brand?

We will continue to deal with appearance of fake ZKL bearings and initiate strict actions in this matter. Research and development is working on projects that are focused on construction and material processing technology. As result of this we will widen our portfolio in the horizon of upcoming years.

The biggest strengths of ZKL brand are the quality for competitive price, a flexible approach to customer´s requirements. We offer our customers support of research and development. ZKL – Výzkum a vývoj, a.s. helps.

What is the added value of ZKL products? We offer our customers support of research and development company ZKL – Výzkum a vývoj, a.s. We are able to suggest the best solution for application, offer assistance and supervision during the application or evaluate the current fatigue state of bearing and estimate the reason of failure so it could be eliminated. This leads to higher productivity and lower maintenance costs. .

Another challenge is to continue working on recognition of ZKL brand as the European manufacturer with quality yet affordable products for promising segments such as railway industry and renewable energy.

As you are the Executive Director of ZKL Bearings CZ, a.s. responsible for worldwide sales – In which markets/ countries is ZKL active? ZKL Group is very strong on domestic market, but we export more than 80% of products. Besides of European markets we serve also Latin America, Asia and our presence is also visible on African continent. Our opportunities are in Spanish speaking countries, Russian speaking countries and China. Page: 61

MOVING THE WORLD since 1968

YOUR ENGINEERING SOLUTION PARTNER In 1968 began a dream, a dream led to what is today a Movement; a movement called KG International that is going strong based on the beliefs.

To further strengthen our Movement, aiming to become your engineering solution partner, KGI extends its ball & roller bearings business to include power transmission products:

Sprawling over 55 countries in 5 continents, KGI believes in forging relationships that last.

• • • •

It has taken passion, determination, steely resolve and belief to create this reality, to make KGI a company favoured the world over for its quality, reliability, customer centricity and range on offer.

Gearboxes from Bonﬁglioli of Italy Oil Seals from Taiwan Linear Motion Guides & Ball Screws Industrial Chains

We continue to follow our mantra – ever onwards, so come JOIN THE MOVEMENT….

MOVING

EUROPE

www.kginternational.com

DUBAI |

INDIA

info@kginternational.com

Introduces New JHS-3i Pillow Block A new generation of Koyo Pillow Blocks

New Seal Design

Koyo Bearings, a division of JTEKT Corporation, is introducing its new range of “JHS-3i” high performance Pillow Blocks providing further improvements in the housing stiffness and the sealing- and lubrication performance.

The next challenge was to improve the sealing performance to keep foreign particles and substances out of the bearing while keeping the grease in, under the most demanding conditions. After intensive bench testing of different seal designs a new version was developed with a special seal lip configuration using an inwards facing lip to make sure that the grease flows back to the balls and raceway during operation and several “defenses” against intrusion from outside (Figure B1).

Improved Housing One of the challenges for the Koyo engineers was to increase the stiffness of the housing itself and to assure a more firm mounting of the housing on the supporting frame. After extensive FEM (Finite Elements Method) analyses and a thorough assessment of the stress concentrations in the old design a more robust design could be developed which increased the strength by up to 30% (depending on the direction of the applied forces – see Figure A1 ), while reducing the weight by around 7% at the same time.

Figure B1

The new seal design showed considerable improvement in a dust sprinkle rotation test as can be seen in Figure B2 and was selected as the new standard for the Koyo JHS-3i Pillow Block.

Figure A1

Additionally the Pillow Block bolt seat area was increased and the bottom optimized (the seat with recess was replaced by a flat design), leading to a much more accurate and rigid Pillow Block/frame mounted assembly and thereby increasing robustness and eliminating any possible vibrations (Figure A2).

Figure B2

* Test was stopped before failure

Upgraded Grease

Figure A2

The third improvement for the JHS 3i Pillow Block is the newly applied high quality Lithium Complex grease providing several critical improvements compared to the traditional lithium soap based lubricants. The new grease features a wider allowable temperature- and speed range, resistance against water contamination, vibration and high pressure as well as heavy- and shock loads. For further details about the Koyo JHS-3i Pillow Blocks, please consult the related flyer, which can be obtained via our website: www.koyo.eu, or via your local Koyo office or Koyo distributor.

* Test stopped before housing fracture, due to earlier insert fracture

Page: 63

GIANT

“UFO” LANDS IN

SCHWEINFURT WORLD’S LARGEST

BIG SIZE BEARINGS TEST CENTRE RECEIVES ITS HEA

ARTPIECE

WORLD’S LARGEST

BIG SIZE BEARINGS TEST CENTRE RECEIVES ITS HEARTPIECE

SKF is currently building the world’s most powerful large-size bea in Schweinfurt, Germany. With the findings from the centre’s two n investment, which totals 40 million euros, will help tailor future LS in question much more precisely and efficiently than previously po facility’s centrepiece has now arrived on site: a 125-tonne “UFO” h larger of the two new SKF test stations. This colossal disk – it has seven metres – will push test pieces to breaking point. The disk rotates within an even larger housing, which contains 64 axial and radial cylinders that are capable of generating enormous dynamic forces of several Meganewtons. Their purpose: to simulate the forces and strains acting on LSBs in everyday operation, for example in wind turbines. “To maximise efficiency, bearings of this kind should have a lifespan of 20 years or more”, explains Dr. Martin Göbel, Manager of the test centre project at SKF. “With our new test centre, we will be able to realistically simulate these 20 years, complete with all conceivable loads and stresses acting on the bearings in that time.” As well time and costs, this will also save energy, not least since the heat energy from by the test facility will be utilised through a heat recovery system. This is one reason why the project is supported with around 1.9 million euros by the Bavarian government.

Thanks to the extremely rugged seven-metre disk, the forces that can be applied to the large bearings being tested are much higher than is possible with conventional test rig designs. Basically, the 64 cylinders, together with the disc can apply forces along all axes that together are several times higher than those of the most powerful current test installation. Made by Augsburg-based RENK Test System GmbH, the test stand will be spinning at up to 30 rpm – an extremely high speed for the size of the tested bearings. It will be capable of testing not just a single main bearing but a complete bearing unit all at once, including any custom Precision work: the lower housing parts, which hold the test rig, Just landed in the heart of Germany: A 125-tonne “UFO” – the centrepiece of the 200 M80 threaded bolts. larger of SKF’s two enormous new large-scale bearing test stands. components.

In the highly efficient stress tests, the hydraulic cylinders of the large test stand act on the newly installed 125-tonne disc, which transfers the generated forces to the test piece that is mounted on the disc with an adapter. “This is an innovative concept”, says Göbel, “and has a major advantage: The forces acting on the tested bearing are not limited through the intrinsic stability of a bearing that itself exerts a force.”

Page: 66

No wonder, then, that project manager Göbel is convinced that “thanks to the enormous disc, the future SKF test stand will put all existing facilities in the shade with its combination of dynamics, level of forces, bending torques and speeds. The insights gained with this stand will Bearing News • Issue 7

aring (LSB) test centre new test rigs, the SBs to the application ossible. The high-tech has touched down at the a diameter of about

allow us to complete current numerical simulation models and therefore to customise future generations of largescale bearings for their later task much more precisely and efficiently.”

Forces under control The completion of the test centre will yet involve some heavy work: Two of the 125-tonne test rig’s six segments alone weigh around 60 tonnes each. “We have anchored these segments to their plinths with a total of about two hundred M80 threaded bolts and a preload force of several Meganewtons” reports Andreas Büchner, Senior Project Manager in the SKF Test Center team.

To avoid a negative impact of the generated forces on the building that g, are anchored to their plinths with about houses the rig – whose light, graceful appearance belies its true purpose – the 3000 tonne foundation that the plinths are part of is isolated from the building’s structure. In view of the enormous substructure, the precision work on the interface between Page: 67

the plinths and the building’s substructure is remarkable: “The contact surfaces have tolerances of just a few tenths of a millimetre” explains Andreas Büchner, “and that over a distance of around ten metres!” The next task will be to assemble the three remaining building segments around the disc. Two of these weigh in at about 70 tonnes each. “Ultimately, this will take the test stand to a total weight of about 700 tonnes,” continues Büchner, “making it sufficiently stable to apply its enormous forces to the tested bearings under precise control.”

The tested bearings are typically used in application areas such as shipbuilding, mining and the cement and steel industries. This makes it exceptionally versatile. Despite this flexibility, this test stand, too, will be a highly stable giant, being expected to weigh about 300 tonnes.

“Our small test stand will develop forces of at least six Meganewtons”, explains Martin Göbel, “and, of course, achieve significantly higher rotational speeds than its larger counterpart, on which mainly wind turbine bearings will be tested. In this case we are talking about far in excess of 200 revolutions per minute.” The combination of forces and speeds of this magnitude Smaller, faster, more means that even though dwarfed by its larger counterpart, the flexible smaller of the two new SKF test Although the smaller of the two stands is unrivalled anywhere It’s all relative: Even though dwarfed by its larger counterpart, the smaller of the new SKF new SKF test stands appears in the world, as the test centre test stands is capable of delivering a combination of forces and speeds that is unsurpassed less monumental than its anywhere in the world. project manager explains. With enormous counterpart, it is no its special capabilities, the smaller test stand will also less capable: its 130-tonne test head holds four axial and provide the rolling bearing experts at SKF with insights two radial cylinders, which, with the help of outer and into certain internal processes that cannot yet be reliably inner ring adapters, can act upon various LSB designs. simulated by any computer program. Furthermore, the It’s all relative: Even though dwarfed by its larger counterpart, the smaller of the new SKF test stands is capable of delivering a combination of forces and speeds that is unsurpassed anywhere in the world.

Far from being science fiction, the “UFO” will soon benefit many customers in the harsh reality of global competition, with the SKF test centre scheduled to go online in mid-2017.

test stand is expected to reveal significant energy and material savings potential in the production of new LSB generations. That is one of the reasons that the German environment ministry is supporting SKF with funding of about 1.6 million euros under its environment innovation programme. “The data gained from the tests will help us optimise existing LSB lifespan calculation models for higher accuracy. The test results will, of course, also be utilised in product development, for example to maximise the durability of the next generation of LSBs while keeping

their weight and friction in each application scenario as low as possible. All in all, this saves resources, in both the manufacture and the use of future SKF large-scale bearings, which benefits both the environment and the user”, summarises Martin Göbel. The SKF test centre is scheduled to go online mid2017. Far from being science fiction, therefore, the “UFO” that has landed in the heart of Germany will soon benefit many customers in the harsh reality of global competition.

CONDUCTIVE LUBRICANTS WILL

PROTECT

ELECTRIC MOTORS OF THE

FUTURE

In the future, electrically conductive lubricants will protect electric motors from the surface damage that can result from electrical discharging in the bearings. With these findings, which are the result of a joint research project, a group of German basic and industrial engineers have taken an important step toward achieving the sustainable electromobility of the future. The project is funded by the German Federal Ministry for Education and Research. The initiative was launched to prepare for the vehicles of the future, which will require higher voltages than current models. At present, 12 volts are required to provide all automotive electric systems – from lights and radios to air conditioners – with sufficient power. Within the next few years, the figure is expected to rise to 48 volts, as electric power is required for a growing number of functions. The voltage levels of electric and hybrid vehicles are even higher: these vehicles can require as much as 400 volts.

Stronger alternating electric fields “In alternators and electric motors, higher voltage levels mean that alternating electric fields are stronger than they once were,” says Dr. Gerd Dornhöfer, one of the Bosch associates taking part in the “SchmiRmaL” project (Switchable intelligent tribological systems with minimal friction losses and maximum lifespan). This

Page: 70

can cause, for instance, electrical discharge in the ball bearings of motors and alternators. When this occurs,

sparks may fly that can melt tiny areas of the metal’s surface. This, in turn, leads to uneven raceways. As a result of this, the ball bearings first begin to make noise, and then to malfunction too soon. “We can already prevent this from happening reliably with the lubricants we have developed,” says Dornhöfer as he looks at the measurement results on his computer. The chief expert for lubrication technology works for the corporate research department in Gerlingen, close to Stuttgart. Anyone who has ever gotten a small electric shock from a doorknob is familiar with static charges. When the finger is just a few millimeters from the doorknob, an electric spark jumps between the two. The higher the electric tension, the further the spark travels. The air between the door handle and the finger acts as an insulator until the finger is close enough to the knob.

Lubricant film acts as an insulator The same thing can also happen when a current is generated between the shaft and housing of an electric motor, as the lubricant coating in the bearing acts as an insulator. As rotation speed increases, the lubricant greases in the ball bearings separate the bearings from the raceway. This is comparable to hydroplaning on wet roads. Unlike on roads, however, this phenomenon is Bearing News • Issue 7

Dr. Gerd Dornhöfer testing materials at the Bosch laboratory

BASIC AND INDUSTRIAL RESEARCHERS ARE DEVELOPING NEW GREASES • Progress on the road to sustainable e-mobility • Ionic liquids already effective • Very promising research findings The vehicles of the future will require higher voltages than current models. New electrically conductive lubricants will help protect electric motors and alternators from wear. Thanks to the joint efforts of basic and industrial researchers in Germany, the new substances required to achieve this have already been developed.

desirable in ball bearings, as it minimizes the friction generated by the bearings as well as the surface damage. However, this can also lead the bearings to recharge when the lubricant film is intact, similar to a capacitor. When the built-up voltage is sufficient, it can penetrate the insulating lubricant grease. This energy suffices to briefly melt a tiny area of metal on the bearing’s surface. If this happens repeatedly, tiny imperfections eventually appear on the bearing. “We want to prevent this at all

costs, as it can result in greater damage to these spots over time,” says the Bosch scientist. Engineers refer to this as electrical pitting. The process results in damaged areas on the raceway that are comparable to potholes. In the future, the energy of these discharges may become greater as the power density and voltages of automotive electric systems increase. In light of this potential problem, the SchmiRmal project’s strategy focuses on developing new lubricants, whose substances remain conductive even at higher voltage levels. As a result, these lubricants do not act as insulators to begin with. Voltage levels no longer build up, nor does potentially destructive electrostatic discharge. “This can be achieved in several ways,” said Dornhöfer. “One could, for instance, add fine metal particles

A microscope comparison of intact/damaged raceways

Page: 71

to the grease to conduct the current. But this would mean that the lubricant grease would also act as an abrasive, and of course we want to avoid this.” Here, ionic fluids are more suitable. In chemical terms, these comprise molecules known as ions that conduct an electrical charge. “Ionic fluids conduct electricity, and this is why we add these substances to our lubricants,” said Dornhöfer.

Resistance reduced by a factor of ten million Following countless tests, the scientists have now come up with greases that are less and less resistant to electricity. In other words: the lubricant conducts electrons as desired in the ball bearing and thus prevents the dreaded electrical flashovers. The initial material was a commercially available industrial lubricant. “By using the right ionic fluids combined with conductive carbon, its resistance can be reduced by a factor of ten million,” says the Bosch scientist. This is enough to prevent the unwanted electrical discharges. While the new grease is black, it otherwise largely resembles its predecessor. At present, Dornhöfer is focusing in part on investigating all of the grease’s characteristics. To ensure a long life cycle, ball bearings must be heat resistant and have cold flow properties. Moreover, the new additives should not compromise the grease’s corrosion protection properties. And it goes without saying that the new grease should not pose a hazard to human health or the environment. All of this is currently being tested as part of the BMBF project. “So far, our findings have been very promising”, Dornhöfer says. Many scientists from a broad range of disciplines and sectors have contributed to this success. “No one can find these solutions alone. We are all contributing and learning from one another,” Dornhöfer says. The project is set to run until April 2015. “Chances are high that the new lubricants will find industrial application after the project.”

A longer service life for many machine components The benefits of the project’s work go well beyond applications for electric motors. The new lubricants can also increase the service life and reliability of machine elements that experience high levels of strain, especially roller and plain bearings and transmission components. Moreover, performance can be improved for motors of the same size, or maintained if motors are smaller. At the same time, the lubricants contribute to reducing energy consumption and to increasing efficiency. Page: 72

Diagram of conductive lubricants in a bearing • The infographic shows the effect of insulating (upper right) andelectrically conductive (lower right) lubricants. In the former, the insulating lubricant (yellow coating) can cause electrical discharges (as illustrated with the red lightning bolts). When this occurs, the bearing’s raceways can be damaged. However, if the lubricant is conductive (green coating), no electrical discharges occur.

The project participants Klüber Lubrication SE & Co. KG (Munich) is one of the world’s leading and most innovative specialty lubricant manufacturers. IoLiTec-Ionic Liquids Technologies GmbH (Heilbronn) develops ionic fluids. Schaeffler Technologies GmbH & Co. KG (Herzogenaurach) is an automotive supplier that develops and manufactures rolling bearings. The company’s role in the project is to assess how new types of oil can improve the service life of bearings. Inprotec AG (Heitersheim) develops highly effective coatings that protect against abrasion. Over the course of the project, SCHUNK GmbH & Co. KG (Lauffen/Neckar) is working on improving the durability of a valve. Using computer models, the Fraunhofer Institute for Algorithms and Scientific Computing SCAI (Sankt Augustin) is making forecasts about the potential environmental impact of new ionic fluids. Over the course of the project, the Fraunhofer Institute for Mechanics of Materials IWM (Freiburg im Breisgau) is focusing mainly on the potential lubricating effect of ionic fluids. Bosch is applying these new lubricants and testing their suitability under real-world conditions. The German Federal Ministry of Education and Research is funding the project. Additional information is available online at www.bosch.com Bearing News • Issue 7

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SLOW SPEED BEARING MONITORING Introduction

Bearing Inspection with Ultrasound

As maintenance and reliability professionals, we must ensure that the assets that we are responsible for are operating as they were designed and installed for. The hope is to move more towards predictive maintenance rather than reactive maintenance when a machine fails. It has been proven that when plants and facilities have a robust proactive maintenance program, that facility will operate more safely, with less downtime, and with improved product quality.

Vibration analysis has long been the instrument of choice to use for bearings and other rotating equipment. More commonly, ultrasound is being used in conjunction with vibration analysis to help technicians confirm the condition of mechanical assets. Because of the versatility of ultrasound, if a facility does not have a robust vibration analysis program in place, ultrasound can be implemented to detect early stage bearing failures, as well as other issues. If the vibration analysis is performed by an outside service provider on a quarterly or monthly Bad Bearing: 1 rpm bearing on a furnace application. Note all of the basis, ultrasound can anomalies that appear in the Time Wave Form from the “crackling and popping” sounds that were produced by bearing fatigue. be used during the

Maintenance and reliability professionals have tools at their disposal to use to monitor asset health on a routine basis. Similar to the way a doctor may use a stethoscope to listen to a patient’s heartbeat, or a thermometer to measure the patient’s temperature, the maintenance and reliability professional uses condition monitoring tools that can help to assess the health of a mechanical asset.

Page: 74

Bearing News • Issue 7

ultrasound may be used first over vibration analysis is with the monitoring of slow speed bearings. Slow speed bearing monitoring with ultrasound is actually easier than you might think. Because most high end ultrasound instruments have a wide sensitivity range and frequency tuning, it is possible to listen to the acoustic quality of the bearing, especially at slower speeds. In extreme slow speed bearing applications (usually less than 25rpm), the bearing will produce little to no ultrasonic noise. In that case, it is important to not only listen to the sound of the bearing, but more importantly to analyze the recorded ultrasound sound file in a spectrum analysis software, focusing on the time wave form to see if there are any anomalies present. If “crackling” or “popping” sounds are present, then there is some indication of a deformity occurring. In bearing speeds above 25rpm, it is possible to set a baseline decibel level and trend the associated decibel level readings over time.

interim. This will help the facility to know the condition of some of the more critical assets prior to the service provider entering the facility; therefore, the service provider’s time can be used more efficiently because the plant knows if there are any eminent problems with the assets that are being monitored by ultrasound. The service provider can then prioritize based off of the ultrasound findings. Another scenario in which

The Ultraprobe 15000 is a great ultrasound instrument for bearings monitoring and inspection.

To get the most out of an ultrasound bearing condition monitoring program, it is best to establish routes for data collection. Through this effort, maintenance technicians can set baselines and bearing condition alarm levels. This approach is called the Historical Method. Using this method, the inspector first establishes a route in the ultrasound software of the points where the data will be collected. Once the route is created, the inspector loads the route into the ultrasound instrument. While collecting the initial data to build the history, the technician should record both the decibel level readings and the sound file recordings. It may also be necessary to collect the readings more frequently than necessary to establish the history until the baseline and alarm levels are set. Once the baseline has been established, alarm levels can be set. For most bearings, an increase of 8dB above baseline represents a lack of lubrication for that bearing. An increase of 16dB above baseline means the bearing is in a failure mode this is beyond just a lack of lubrication. For slow speed bearings, these alarm levels may need to be adjusted since slow speed bearings do not produce as much high frequency sound as bearings that are rotating at faster speeds. The alarm levels for slow speed bearings should be set according to what the initial historical decibel level trend shows.

An ultrasound instrument, used with a stethoscope module, can identify bearing failures at a very early stage, including in slow speed bearings.

Page: 75

Once the baselines and alarm levels have been set, it is only necessary to record the data or dB readings. From that point forward, a sound file recording is only taken once the point has reached either the low alarm, or the high alarm. The alarm level sound file recording can then be compared to the original baseline sound file. This is important in diagnosing what the current bearing condition is. In a spectrum analysis software, technicians may also be able to compare the baseline sound file FFT to either the current sound file, or compare up to as many as four identical points on four identical machines.

Ultrasound Assisted Lubrication Studies have shown that the majority of premature bearing failures can be attributed to poor lubrication practices. Whether it’s using the wrong grease for the wrong application, lubricant contamination, over lubrication, or even under lubrication. Either way, most premature bearing failures are due to lubrication. Ultrasound can be used to prevent over and under lubrication related failures. Additionally, when using ultrasound for bearing lubrication, the move is more towards condition based lubrication rather than time based lubrication. The concept is simple. It’s based off of friction. When a bearing is in need of lubrication, there is an increase in amplitude or the decibel level. If a technician is using ultrasound to listen to the bearing while greasing and watching the associated decibel level on the ultrasound instrument, if the bearing needs grease, there will be a gradual drop in the dB down to a more normal or baseline dB. At that point, the technician should stop lubricating. If the bearing is already sufficiently lubricated, the technician would start to see a gradual increase in the dB as grease is added. As more grease is added to an already sufficiently lubricated bearing, there is an increase in both pressure and friction inside the bearing housing; therefore, more noise. In this scenario, the

The on-board Spectralyzer on the Ultraprobe 15000 allows for a sound spectrum overview on the testing point – a great help when inspecting slow speed bearings.

Page: 76

technician should stop applying grease when an increase in dB is noted. If the technician is applying grease to a bearing, and there is no change in the dB, then a followup inspection with either recording the ultrasound sound file again, or a complimentary technology such as vibration analysis should be used to determine why the dB did not change during lubrication. If the bearing has physical damage, or is in a failure mode beyond a lack of lubrication, then there will be little to no change in the dB while greasing.

Conclusion Airborne and structure-borne ultrasound instrumentation has become a must-have technology for any maintenance and reliability program. Due to its enhanced sensitivity and ability to detect slight changes in the amount of high frequency sound produced by rotating equipment, ultrasound is ideally suited to detect early stage bearing fatigue lack of lubrication in rolling element bearings. By translating the high frequency sound into the low frequency or audible range, these instruments allow the users to hear, see, and diagnose bearing faults. Through ultrasound assisted lubrication, bearing and machine life can be extended, and failures due to over or under lubrication can be eliminated.

The Ultraprobe Grease Caddy 401 is the perfect tool to develop a lubrication program, which will dramatically reduce bearing failures.

Bearing News • Issue 7

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What Happened in the

Bearing Industry Second Half of

2016

What Happened in the

Bearing Industry SecondHalf of

July

2016

Thomas Witzler is new General Manager of NKE Austria As of 1 July 2016, Thomas Witzler has taken over the position of General Manager of NKE Austria GmbH. After 20 years at the helm of NKE, the founding members and previous general managers of NKE, Heimo Ebner and Harald Zerobin, will focus on strategic issues within the company in the future. „They will continue to support NKE with their competence and experience “, says the new General Manager. At the beginning of this year, NKE has formed a partnership with Spanish bearings manufacturer Fersa Bearings. The tasks the new General Manager will face include “a fast realisation of the new opportunities and synergies within the group of companies”, Thomas Witzler says. “As well as implementing the new impetus in specific applications, we will strive to develop new products that can solve real-life customer problems.” As of 1 July 2016, Thomas Witzler has taken over the position of General Manager of NKE Austria GmbH.

Thomas Witzler, MSc, graduated in business administration from the Vienna University of Economics and Business Administration. He spent seven years at Hewlett-Packard, for the last years as sales manager for Austria, Switzerland and Eastern Europe. From 1999 to the end of 2008 he was active as executive partner of an enterprise in the IT sector and lectured at both the University of Economics and Business Administration and the University of Applied Sciences in Vienna. His career at NKE began in 2009 as Human Resources manager with a focus on personnel and organisational development as well as recruiting. In 2013 he became Sales & Support manager before being appointed General Manager of NKE in February 2016.

July

The NKE founders Harald Zerobin (left) and Heimo Ebner (right) with new General Manager Thomas Witzler (centre).

BOWMAN Announces New UK Manufacturing Facility Leading manufacturer and supplier of bearings and sintered components, Bowman International, has unveiled its new UK manufacturing facility. The facility has been specifically designed to offer a faster and more efficient end-to-end service on larger, non-standard sized wrapped bearings above 75mm in diameter. Housed at Bowman’s headquarters in Abingdon, Oxfordshire, the manufacturing centre contains an array of marketleading machines capable of working a variety of materials in line with the distributor’s vast product portfolio. Paul Mitchell, managing director of Bowman International said: “The key driver behind our decision to manufacture on home soil is speed. Producing non-standard components here, instead of through one of our trusted international manufacturing partners, means we can fulfil special or urgent orders in days rather than weeks. “We can create OEM prototypes too, supporting tight design and build schedules with a reliable service which will be unrivalled for accuracy, quality and speed.” In addition to producing larger non-standard sized wrapped bearings, the site will also be equipped to make alterations to standard components, which will once again deliver time and cost efficiencies to the customer. Paul concludes: “Consistent quality and fast service are a prerequisite when you order standard bearings and sintered components from Bowman. Now, with a manufacturing facility in the UK, we can offer the same speed of distribution on larger non-standard items and special orders too; something which is already proving to be of great benefit to many of our customers.”

Page: 80

Bearing News • Issue 7

July

Timken acquires Lovejoy including its subsidiary R+L Hydraulics On 8 July 2016, The Timken Company, manufacturer of tapered roller bearings, announced its acquisition of Lovejoy, Inc. and its subsidiary, R+L Hydraulics GmbH. Lovejoy, a manufacturer of industrial couplings, universal joints and hydraulics, was purchased for approximately 66 million USD. “The acquisition of Lovejoy is a great strategic fit, and we are pleased to add their strong brand to our growing portfolio of industrial brands,” said Richard G. Kyle, Timken’s president and chief executive officer. “Lovejoy and R+L Hydraulics feature premium products used in challenging applications across diverse markets. While our two companies operate in many of the same markets and channels in North America, the acquisition provides exciting growth opportunities.” Headquartered in Downers Grove, Illinois, USA, with additional locations in the USA, Canada and Germany, Lovejoy is widely recognized for its flexible coupling design and as the creator of the jaw-style coupling. Lovejoy also manufactures a line of universal joints, vibration dampening products and hydraulics. For the 12 months ending 31 March 2016, Lovejoy sales were approximately 56 million USD.

From left to right: R+L Hydraulics’ managing directors Dr. Peter Jaschke and Mathew W. Happach, and former managing director Lothar Gädtke, who will retire on 31 December 2016.

“Following the acquisition of our parent company Lovejoy by Timken, we are convinced that we will strengthen our activities in the field of power transmission products and will penetrate further market areas,” says Dr. Peter Jaschke, managing director of R + L Hydraulics. The former managing director of R + L Hydraulics, Lothar Gaedtke, will retire at the end of 2016. Mathew W. Happach has already taken over his position as additional managing director of R+L Hydraulics. This acquisition adds to Timken’s growing portfolio of mechanical power transmission products. In recent years, Timken has been diversifying its offering, completing a number of acquisitions featuring products adjacent to its core bearing lines. This includes belts, chain, gear drive systems, lubrication systems and a variety of related services, all marketed under brands including Timken, Philadelphia Gear, Carlisle, Drives and Interlube. Timken expects the acquisition to be accretive to earnings in the first year of ownership, excluding one-time transaction costs.

August

Microfinish attachments for turning, grinding and milling machines The German machine manufacturer Thielenhaus Microfinish presents a range of attachments for base machines for these applications and for small batch sizes. With these solutions, the advantages of the Microfinish technique can also be enjoyed using conventional turning, grinding and milling machines, meaning that the surface, roughness, waviness and contact ratio of the components being worked on can be improved in a reliable manner. In virtually all technical fields, the requirements placed on the quality of individual components are increasing. As a result of this, surfaceimproving and geometry-improving superfinishing techniques are becoming more important. Today, even smaller suppliers must be capable of working to the finest tolerances in dimensional accuracy. All of the attachments consist principally of an electric drive unit for high short-stroke movements and the oscillating tape or stone tool. The workpieces are held in the base machines between centres or, if no centering bore is present, tensioned from one side with a chuck or a collet. For the machining, they are set in rotation, with the oscillating stone or tape tool being pressed onto the workpiece pneumatically or using spring tension. The removal, which is performed in a sine-wave form due to the oscillation, removes the ‘soft layer’ generated during the hard turning or grinding process, drastically improving the roughness and contact ratio. Using this process, surface roughnesses of Ra 0.01 µm with rolls and Ra 0.3 µm with bearing positions can be achieved. At the same time, the surface can be given a structure with defined, criss-crossing grooves to improve its tribological properties.

Thielenhaus Microfinish’s attachments represent a cost-efficient opportunity to machine small batch sizes with finish tapes and stone tools using the base machines that you already own.

Even though they’re small and good value for money, the devices are nevertheless high-performance units geared towards three-shift operation. They are principally used for geometrical improvements in roundness, evenness and cylindrical forms. Surfaces can also be smoothed to a mirror finish and definable levels of roughness can be produced. The residual compressive stress can also be raised in order to make the surface more wear-resistant. As well as chamfering edges and smoothing joints, the attachments can be used to achieve visual, cosmetic surface textures. Page: 81

What Happened in the

Bearing Industry SecondHalf of

August

2016

Version 08-2016 of MESYS shaft and rolling bearing analysis software is available A new version of the MESYS shaft and rolling bearing analysis software including new functionality is available. The bearing analysis software allows the calculation of the load distribution within the bearing and bearing life according ISO/TS 16281 and it is integrated in a shaft system calculation with additional possibilities like modal analysis, strength calculation according to DIN 743 for shafts and interfaces to gear calculation programs. The shaft system calculation allows a calculation of shafts coupled by cylindrical, bevel or worm gears. The software is mainly used by bearing manufacturers, spindle manufacturers and gearbox manufacturers.

General changes in program usage Some general improvements are: • Better support for HighDPI displays. Also multiple monitors with different DPI ratio can be used. • Support for 3D mouse in all 3D graphics • Opening files by drag&drop

New features in the bearing calculation The main new features in the bearing calculation are: • Consideration of elastic expansion/compression for rings with clearance fit • Angular cylindrical roller bearings as additional bearing type • Track roller calculation with elastic outer ring now also supported for double row tapered roller bearings • Load spectra for track rollers can consider loading on multiple points • New 2D view for the load distribution showing the pressure distribution on the raceway • Custom setting for rolling element temperature • Import of additional encrypted bearing databases

New features in the shaft calculation The main new features in the shaft calculation are: • New graphic windows for bearing overviews show the same graphic for all bearings in a system • CAD Import of shaft geometry as 2D DXF or 3D Step • CAD export of geometry as 3D Step • Import of 3D Housing as Step file which can be connected to the supports in the system • New calculation method for harmonic response • Global setting for Raleigh damping • Shaft geometry shown as background image in diagrams • Optional measurement lines for forces and supports in 2D view of shaft geometry • Shaft temperature per segment can now also be accessed in load spectra

August

Simatec launches “Lubechart” – the lubrication plan for experts “Lubechart” is an online programme for the creation and management of lubrication plans for simalube lubricators. This user-friendly online tool was developed by simatec to provide a constant overview of the lubricators in use and manage them accordingly. The use of “Lubechart” is free of charge. “Lubechart” is easy to use and has many important/useful functions, making management of your lubrication plans child’s play. The programme offers worldwide access, around the clock, 365 days a year. Furthermore, no software is necessary to use “Lubechart”. Access is possible via any public internet access and is protected by a personal password. Lubrication plans can be set up individually by entering various parameters. Within each lubrication plan, multiple lubrication points can be entered and their properties defined. Whenever it is necessary to replace or inspect a simalube lubricator, the user is automatically notified by e-mail. The intervals at which these notifications are sent can be chosen at will and the e-mail can be sent to several recipients. The replacement of lubricators will no longer be forgotten and the planning and execution of lubrication work is consequently simplified. In the online programme, it is always possible to call up the lubricators required at any given time. “Lubechart” also has a function that allows you to retrieve specific material and to-do lists. Finally, follow-on orders can be made directly in the online programme by e-mail. It can be summarised that the “Lubechart” online programme helps considerably to increase operational safety of your machinery, because it guarantees the timely replacement of lubricators and, therefore, continuous lubrication. Thanks to the automatic e-mail notifications, you are constantly reminded of the need to replace lubricators, which can thus no longer be forgotten. To register for “Lubechart”, please visit the simatec web site, www.simatec.com, in the “Service Center” section under “Online Tools”.

Page: 82

Bearing News • Issue 7

September

Guangzhou Customs intercepts 2000 counterfeit Timken bearings The Customs Control Office of Guangzhou City (China) declared that 2000 bearings, which were announced under the trade mark Timken are seized recently. The office interfered because of irregularities in the export declarations and doubts about the authenticity of the bearings. After inspection, violation of intellectual property was confirmed. The Information about the counterfeit bearings was reported to the legal brand owner Timken. China Customs Administration launched a consultation and training program supported with manuals created together with brand owners; which will allow the Chinese customs officials prevent the export of counterfeit bearings and other counterfeit products.

Photo: General Customs Administration of China

Guangzhou is one of the largest cities, industrial centers and logistics hubs in China. In 2015, through the urban cargo port it has been exporting more than 500 million tons of cargo (5th place in the world and 4 in China), and through Baiyun Airport; 1,893,300 tons (19 in the world).

According to customs statistics for January-July 2016; the value of the exported goods was 165 billion USD; including products for the product group “bearings” for a value of 27.9 million USD.

September

BUENAVENTURA GINER INC. to enter into a strategic alliance with IPH Group To further enforce its market position and prepare itself for the challenges of the future, BUENAVENTURA GINER INC. has decided to join forces with IPH Group. BUENAVENTURA GINER INC. is a leading technical distributor created in 1939 with today’s sales above € 30 million developed through 12 sites in Spain. A constant growth has led the company to become one of the most important references in Spain in the business of Industrial Supplies. BUENAVENTURA GINER INC. has a broad range of products including roller bearings, power transmission and drive technology, pneumatics, hydraulics, sealing technology, lubrication technology, tools and services for maintenance. With sales of more than €1.1 billion, IPH is one of the most important technical distributor groups in Europe. Over the past 10 years, IPH has actively driven consolidation of the industry by adding a number of powerful European players. Today, IPH Group is present in Europe with many strong brands, notably ZITEC and KISTENPFENNIG in Germany, OREXAD in France, MINETTI in Italy and BIESHEUVEL TECHNIEK in the Netherlands. “This is the right step and the right time to now become part of a European entity with IPH Group, one of the leading companies in the industry in Europe,” explains Federico GINER, President of GRUPO GINER and son of the founder of BUENAVENTURA GINER Inc. “This will strengthen the development of BUENAVENTURA GINER Inc. As part of this process and in line with our long-term commitment to the industry and to BUENAVENTURA GINER Inc., the family remains deeply involved in the development of the company on the Spanish market.” Jose Ramon SURROCA, CEO of BUENAVENTURA GINER Inc. emphasizes: “The market is changing fast. The alliance with IPH will allow us to prepare ourselves better for the changes in the markets and continue on our dynamic growth path. Furthermore, it will give us greater flexibility in particular in the areas of

September

Steenox, the new high-tech anti-corrosion steel Always at the forefront of technology, JESA again proves innovative thanks to the use of our new high-tech anticorrosion steel, Steenox. Steenox is a ground-breaking combination of a martensitic stainless steel and a special heat treatment. This technology increases the performance of the material, both in terms of fatigue- and corrosion-resistance. The new steel, Steenox, is the solution for use in bearings in a particularly corrosive environment where service life is critical. Compared to conventional stainless bearing steel, AISI 440C (DIN 1.4125), a salt-spray test demonstrated 15 to 20 times superior resistance to corrosion.

Steenox, the ideal solution for the specific needs of the food industry In recent years, the demands in terms of speed, caustic cleaning agents or loads have increased steadily. Cam followers deteriorate in a short time due to heavy loads and a very aggressive environment (appearance of rust on stainless steel). The ideal solution to this problem? The use of Steenox, an extremely resistant stainless steel. This technology is currently used with a variety of bearings and has clearly shown its strengths for our customers in the food industry. Steenox has been used with custom-made bearings where increased resistance to corrosion is critical in an aggressive environment.

Page: 83

What Happened in the

Bearing Industry SecondHalf of

October

2016

Schaeffler invests 120 million euros in distribution center Schaeffler is building a new logistics center in Kitzingen to supply its customers in Europe quickly and reliably. On October 5, the groundbreaking ceremony was held at ConneKT-Park with representatives from Schaeffler as well as from participating companies Max Bögl/Mauss Bau (ARGE), SSI Schäfer and the Mayor of Kitzingen, Stefan Güntner. Oliver Jung, Chief Operating Officer at Schaeffler, explained: “Due to the good general conditions, we have decided to build the center in Kitzingen. We’re going full steam ahead.” Deliveries to customers are expected to begin in the middle of 2018. The new distribution center will employ around 200 people. Investments amount to approximately 120 million euros. “The distribution center in Kitzingen is the last component that completes our logistics project in the Industrial Division. Our goal is to bring the Schaeffler Group’s logistics activities up to the latest industrial standards, optimize existing processes and considerably improve delivery performance,“ said project manager Gregor Luft. Schaeffler’s new distribution center will be the main location for its European warehouse network. In the European distribution centers network (EDC), there is currently one warehouse each for Northern Europe in Arlandastad in Sweden and for Southern Europe in Carisio, Italy. The warehouse in Sweden opened in March 2015, and the warehouse in Italy in May 2016. Both warehouses have supplied Schaeffler’s customers reliably and quickly. Excavations and civil engineering work will be completed over the next few months. The topping-out ceremony is scheduled for May 2017 and the official opening for the end of the same year.

October

Ground-breaking ceremony: (from left to right) Andreas Winkler (Max Bögl), Dr. Friedrich Klein, Manager Operations & SCM Industrial (Schaeffler), Jürgen Buchta (Mauss Bau), Gregor Luft, Project Manager European Distribution Centers (EDC; Schaeffler), Oliver Jung, Chief Operating Officer (Schaeffler), Stefan Güntner, Mayor of Kitzingen, Stefan Hantke, Manager Industrial Sales (Schaeffler), Michael Berger, Manager Logistics (Schaeffler), Dr. Guido Herale, Manager Logistics Europe (Schaeffler) and Michael Mücke, Project Manager EDC Central Europe (Schaeffler).

SKF supplies eight-tonne bearing for mining application SKF has manufactured and supplied its largest ever spherical roller bearing (bore diameter 1,25 metres) to be used within the mining industry. The bearing was manufactured at SKF’s factory in Gothenburg, Sweden. “SKF is a world leader in spherical roller bearings, manufacturing bearings of all sizes and series – from the smallest, with a 20 mm bore size, to this large size bearing that weighs close to eight tonnes” says Petra Öberg Gustafsson, Product Line Manager for self-aligning rolling bearings at SKF.

The bearing is equipped with SKF SensorMount, a unique system that measures the actual mounting fit of the bearing onto the shaft. It helps avoid the risk of improper mounting, a major issue for large size bearings. The bearing weighs 7,780 kg. Each roller within it weighs 42 kg. The bearing is of the upgraded SKF Explorer class with improved wear resistance, thanks to the patented material heat treatment process that nearly doubles service life in poor lubrication and contaminated conditions. SKF was chosen to supply the bearing due to its Application Engineering expertise and support, and the knowledge and experience in manufacturing large size industrial bearings. Daniel Ortega, Project Manager at the Gothenburg factory, says: “We have worked in close cooperation with the customer, in order to design an optimum 241/1250 bearing that is particularly suitable for applications in the mining industry. These applications have extreme operating conditions and are very demanding from a bearing service life perspective.” Page: 84

Bearing News • Issue 7

November

Timken acquires EDT Corp., further expanding its portfolio of bearing housed units Timken announced that it has acquired EDT Corp., a manufacturer of polymer housed units and stainless steel ball bearings used widely by the food and beverage industry. “We market a broad range of bearing housed units and are pleased to add the EDT line to our portfolio,” said Chris Coughlin, group president for The Timken Company. “We see this acquisition as an excellent strategic fit, allowing Timken to simultaneously build on the inherent strengths of the EDT team and leverage our expanded marketplace offering, thereby increasing our presence in the food and beverage segment.” EDT Corp. is based in Vancouver, Wash., and serves a well-established customer base primarily through North American distributors with whom Timken has long-standing relationships. EDT® bearings are designed and manufactured to meet the highest level of food safety and sanitation requirements. The line includes a range of non-corrosive, greaseless, wash-down-resistant and extreme temperature bearings and accessories. In 2015, EDT Corp. revenue was less than $10 million.

November

Schaeffler increases production capacities in China and Thailand Schaeffler celebrated the opening of new factory halls in China and a new plant in Thailand in traditional local style. By increasing its production volume, Schaeffler is aligning itself ever closer to its Chinese and Asian customer base and also extending its product portfolio. The Schaeffler Group is continuing its course for growth in China and Asia. By extending its Schaeffler (Nanjing) Co., Ltd. Plant, the location will become a cross-divisional manufacturing site for products ranging from the industrial to the automotive segment. Through the opening of its new plant in Chonburi in Thailand, Schaeffler will also significantly increase Schaeffler celebrated a new workshop in Nanjing, China, with a ribbon-cutting ceremony and a shower of confetti. its production presence in the Asia/Pacific region. In a first phase, automotive components for engine and transmission applications will be produced there. The expansion at both locations will enable a marked extension of the product portfolio. “The new factory hall at Nanjing and the new plant in Thailand are of utmost importance for Schaeffler. Because our manufacturing network of now 74 plants is the backbone of our organization. We will strengthen this backbone even further, laying the basis for future success”, said Georg F. W. Schaeffler, Chairman of the Supervisory Board of Schaeffler AG and shareholder of the Schaeffler Group, who attended both opening ceremonies. The new manufacturing hall as well as a new central logistics warehouse in Nanjing have been constructed on a total area of approx. 46,000 square meters. Around 1,000 employees manufacture camshaft phasing units, hydraulic tappets, chains, tensioners and other engine components. In the presence of the Thai Minister of Industry the first proprietary Schaeffler plant in Southeast Asia was inaugurated. In a first phase 150 employees will be manufacturing clutch disks and clutch pressure plates, mechanical and hydraulic belt tensioners, synchro rings and clutch release systems. The production site has been designed using a modular principle. In the next phase further lines for Schaeffler products and solutions can be added across the entire value added chain of the automotive segment.

November

SKF invests SEK 150 million in Schweinfurt production channels SKF is investing SEK 150 million in modernizing its cylindrical roller bearing (CRB) manufacturing in Schweinfurt, Germany. This is the third significant manufacturing investment announced by SKF in the last 18 months, following the announcement of similar investments in Gothenburg, Sweden and Flowery Branch, USA. The investment in Schweinfurt will involve the implementation of the latest technologies within machining, assembly and packaging and will result in older production channels being replaced by largely automated, worldclass technologies. Luc Graux, President, Bearing Operations, says: “We are very excited to be ramping up our investments in developing world-class manufacturing within SKF. The automated assembly and zero reset-time of the channel will greatly improve our flexibility and lead-times for medium- and small-size lots of standard CRB products. Our ambition is to launch pilot projects such as these across all of our main product lines, before replicating them across other manufacturing sites.” “Together with our projects in Gothenburg and Flowery Branch, we have now announced almost SEK 500 million of investments in upgrading and digitalising our factories during the last 18 months. Ensuring we develop flexible and modern manufacturing processes is essential in supporting SKF’s growth and profitability ambitions.” The investments announced today are expected to be completed by the middle of 2018. Page: 85

What Happened in the

Bearing Industry SecondHalf of

November

2016

Ovako launches Steel Navigator - finds the best steel for customers Ovako launched Steel Navigator, a digital platform that allows customers to search for and identify the best steel for their applications. The investment in Steel Navigator is part of Ovako’s global digitalization strategy and underscores the group’s objective to provide its customers with the best service in the industry. “The steel industry is facing a major transformation with the ongoing wave of digitalization, and we want to be a pioneer in this work,” says Göran Nyström, EVP Group Marketing & Technology. “The launch of Steel Navigator enhances our service offering to the market for engineering steel and will help our customers to quickly identify the right steel for their application, making their processes more efficient.” Steel Navigator allows customers for search for specific steel grades by group, quality, type of process, product and chemical composition, not just among Ovako’s steels but also among steels supplied by its competitors.

November

NSK launches food grade bearings NSK has developed the world’s first grease lubricant that is 100% derived from food grade ingredients. The development represents a breakthrough for any plants where machinery, production equipment or devices come into contact with foods, pharmaceuticals or cosmetics. Furthermore, the new H3G grease is ideal for any application that is suited to the lubricant’s additional strengths of water resistance and low torque. Typical applications range from food machinery such as shakers, fillers, centrifugal separators, bottling machines and conveyors, through to pharmaceutical, cosmetics and medical process devices, including pumps. Importantly, the environmentally friendly grease conforms to the highest international standards for safety regarding products that may come into accidental contact with food. The new NSK eco-friendly grease, which is petroleumfree, exceeds the standards of lubricants currently used widely in such applications. These are generally based on rapeseed oil and other vegetable oils that contain many non-food ingredients. Such greases can also have performance limitations, with lower oxidative stability, resulting in lubricity and durability issues. In contrast, NSK’s grease is made entirely from food-based ingredients including the base oil, thickening agent and additives. For instance, food-grade vegetable oil is used for its excellent heat tolerance as a base oil, while the thickening agent contains food additives with a fine 3D network for good base oil retention. The lubricant is also formulated with food additives that further enhance the durability of the base oil, delivering a grease that offers enhanced oxidative stability and one-third lower friction loss (torque) than existing comparable products. Further advantages are less leakage and longer service live, even where there is exposure to water.

November

Dana to Purchase Power-Transmission, Fluid Power Businesses of Brevini Group Under terms of the agreement, Dana plans to initially purchase an 80 percent share in the Brevini businesses, with an option to purchase the remaining 20 percent by 2020. Dana has valued 100 percent of the Brevini businesses at €325 million, including the assumption of approximately €100 million of net debt. The acquisition will immediately expand Dana’s product portfolio with adjacent technologies and establish Dana as the only off-highway solutions provider that can manage the power to both move the equipment and perform its critical work functions. It adds technologies for tracked vehicles, doubling Dana’s addressable market for off-highway driveline systems. It also provides a platform of proven technologies that can be leveraged in Dana’s light- and commercial-vehicle end markets, helping to accelerate the company’s hybridization and electrification initiatives. The transaction will be funded with cash on hand, with existing Brevini debt to be refinanced in the future. Subject to customary regulatory approvals, the acquisition is expected to close in early 2017. Dana expects the purchase to be accretive to earnings in 2017. The acquisition of Brevini aligns with Dana’s enterprise strategy, which includes leveraging core expertise, strengthening customer centricity, expanding global markets, commercializing new technologies, and accelerating hybridization and electrification.

Page: 86

Bearing News • Issue 7

November

ABF invests in new warehouse equipment and extra personnel In response to a substantial growth in orders, ABF has expanded its warehousing department. Two new colleagues now strengthen our warehouse team. New investments in equipment were also required to accommodate growing demand. “Our warehouse activities continue to grow. We are currently shipping 200 to 400 order lines a day. Our quality monitoring of our huge stock is also a top priority. And we have more than 6.000.000 bearings and electric motors,” explains Niels Boot, Warehouse Manager at ABF. Now with a larger team and a new reach truck and order picker, ABF can guarantee quality same-day shipment for each order received before 17:59 hours.

November

Barden Corporation UK appoints new Managing Director Jon Everett takes over leadership of the Plymouth-based company from former Managing Director, Mr Ian Burnage. Jon’s leadership commences at a critical time as he will steer the company through the next important phase of its ambitious growth plans, which include developing new business in the global aerospace market. As part of the super precision division of leading automotive and industrial supplier Schaeffler, The Barden Corporation (UK) Limited specialises in the design and manufacture of high precision rolling bearings and integrated bearing assemblies for complex or critical applications in industries such as the aerospace, defence, medical and high performance pump sectors. Bearings for this sector have to withstand harsh conditions: extreme temperatures, demanding load profiles and high speeds and can be custom engineered for specific applications. Jon Everett commented: “I am delighted to be appointed Managing Director at Barden UK. We have ambitious strategic growth plans that include a focus on re-engaging with our existing customer base and developing new business in the international aerospace markets, particularly from Europe, China and Asia-Pacific. We’ll also be looking at completely new markets where we believe Barden’s core engineering capabilities and expertise will be required.” Prior to Barden, Jon served in the British Army for 18 years (including service with Commando forces) before working for the UK Foreign Office in the Far East. He served as Managing Director of Ultra Electronics Middle East, and was appointed Managing Director of Ultra Electronics PMES in the UK in 2011.

November

Mr Jon Everett, Managing Director of The Barden Corporation (UK) Ltd.

SKF delivers magnetic bearings to Cryostar for use in turboexpanders in China SKF has secured a contract with Cryostar, a French manufacturer of turbo-expanders, to supply SKF S2M magnetic bearings and the latest generation E300V2 control cabinet. SKF’s solutions will be used in MTC200 oil-free turboexpanders that Cryostar will deliver to Shaanxi Yanchang Petroleum Yanan Energy and Chemical Co., Ltd. The turboexpanders will be installed at an ethylene and propylene plant, located in Shaanxi province, China. The magnetic bearings will be integrated in MTC200 frame turbo-expanders that operate at a design rotation speed of close to 40,000 rpm. MTC200 are magnetic bearing turbines braked by a compressor wheel, with an expander wheel of nominal diameter of 200 mm. SKF magnetic bearings are non-contact, friction-free that allow reaching high tip wheel speed for optimal efficiency and performance of a turboexpander. SKF’s E300V2 control cabinet offers several new features: remote monitoring, on-line data measurement and easy post-processing functionalities providing a high degree of autonomy for plant operators. The magnetic bearing control system has inherent health monitoring and diagnostics possibilities that measure the machine’s critical parameters, such as rotation speed, vibrations and temperatures. Moreover, SKF S2M magnetic bearings are 100 per cent leak-safe preventing oil-ingestion into the process gas. The oil free technology improves the safety of installations in term of risk of process equipment’s contamination by oil. The elimination of lubricating oil is the decisive advantage for low temperature process (-130°C/-150°C)

Page: 87

What Happened in the

Bearing Industry SecondHalf of

December

2016

NBI Bearings opens new Application Engineering Center in Romania NBI Bearings Europe S.A., a company which designs, produces and commercializes bearings of high quality and high performances, has since last September 2016 a new technological center for application engineering based in Bucharest (Romania).

NBI Bearings Romania, AFI Park 4, The new Application Engineering Center of NBI Bearings will provide technical support to clients from Romania.

years of experience in the sector.

In order to guarantee the excellence of its products, the new Application Engineering headquarter will focus its activities on giving a totally customer- oriented service, without neglecting the technical development of its products and the creation of Know-How for the company. The new team is made up of a group of highly qualified engineers with more than 20

This group will work directly in projects together with our clients, with the purpose of offering custom-made technical solutions for each application. This will result in a greater added value to the products and services that NBI provides to the world of industry, as stated by the General Manager Mr. Roberto Martínez. To carry out this important task, the Romanian office will have at its disposal the most modern technologies. The branch will count with the support of two excellent references in the field of applications engineering simulation, and also in the analysis of complex mechanical systems such as Ansys Inc, the world leader in the so-called “Simulation driven development” and Romax Designer, which relies on the leading technology in the NBI’s headquarters and manufacturing plant in Spain precision analysis of bearings and of any other mechanical system component. With the support of such advanced software’s, the team in Romania will be able to perform deep technical studies for each application and also will have the capacity of executing complex calculations that will allow NBI to assist in the choice of the most appropriate bearing in a fast and efficient way. A new challenge come true which, together with the new manufacturing plant in Spain, will allow NBI to become one of the benchmarks in bearing design and manufacture, with a high performance product, and also offering a high added value to its clients.

December

CRAFT Bearings – the new main partner of Antanas Juknevičius’ Dakar team The Lithuanian team of Antanas Juknevičius and Darius Vaičiulis, which is going to compete in the 2017 Dakar during January 2017, made an agreement with its main partner and will have a new name – CRAFT Bearings CRAFT Bearings, an international company established by Lithuanians, is a manufacturer of automotive and industrial bearings with operations in 80 countries around the world, including Central and South America. According to its director, Vygantas Rimgaila, the decision to cooperate together was driven by two main reasons – their similar approach to quality and experience. “Customers around the world choose us because of our well-developed worthwhile products and reliability. For this reason, we place a great amount of emphasis on experience and professionalism when we choose our partners. Antanas is the most knowledgeable Lithuanian in Dakar. His many years of experience and high achievements are the best reflection of these traits”, said V. Rimgaila. “Dakar is a unique challenge and it is not for everyone. Every detail matters, and can often affect the final result in such a lengthy and tough competition. Our actions are based on the same approach, therefore, we are proud to be part of the professional team of Antanas. “First of all, I am very happy that the team is being supplemented by such a strong, internationally known Lithuanian company,” said Antanas Juknevičius in commenting about the new main partner. “While business in our country is often cautious about funding sports, even more than state institutions, there are bold companies that see the benefits of partnership.” The racer says that the choice of partners is primarily based on the values communicated by the company. “I can clearly see that the companies in the list of partners of our company have one thing in common. Whether it is a global brand or a Lithuanian company – all of them are known for professionalism and the high level of services or products in their area, and CRAFT

Page: 88

Bearing News • Issue 7

Bearings is a perfect example. The Dakar challenge is not that overwhelming with this team of professionals.” Before the start of the Dakar rally, the Antanas Juknevičius team of CRAFT Bearings will still have a trip to France, to the city of Le Havre. It is from this port that cars, trucks, motorcycles and quads that will start in the competition, and will be shipped to Argentina after a technical commission. We are unpredictable in a good sense On Friday, Antanas Juknevičius and his new co-driver, Darius Vaičiulis, invited friends and journalists to a press conference in the Energy and Technology Museum of the capital city. Here, the fans of Dakar saw the upgraded Toyota Hilux Overdrive car that will be used in the 2017 Dakar for the first time. The car has already seen a number of races. However, it is continually maintained and its components are renewed. Therefore, it is in great shape and ready for the desert marathon. This, according to Antanas Juknevičius, is the reason for his greatest joy. Speaking of expectations of the place to be taken in the 2017 Dakar, Antanas, who will be driving the desert car for the sixth time, was cautious (it is his 8th start in Dakar). The CRAFT Bearings team will try to achieve the best possible result. However, Antanas admitted that in terms of success, it can be unpredictable. In a good sense. Lessons learned in the 2016 Dakar According to the racer, Antanas Juknevičius, the focus in the preparation cycle for 2017 was on the most vulnerable points of the car in this year’s competition. “Last year, we learned the strengths and weaknesses of this car. This machine only had its debut during the last Dakar marathon, so we collected expertise and information. We had most of our problems with the power steering system, so the main task was to find a solution about how we could improve this system. I am very happy that our team of professionals have found the solution and will only have to test it in the conditions of the next Dakar.” A. Juknevičius, having taken part in the Dakar race for 7 times, is pleased to have the most experienced and resourceful Lithuanian engineers and mechanics on his team, so he is not looking for alternatives. “I think our team has some of the best Lithuanian specialists. All the unique solutions with the power steering and other systems show the highest level of professionalism. It is a pure pleasure to race when you have such technical backing”, said A. Juknevičius in praising the achievements of his technicians. Dakar monster dismantled to its very frame A 330-horsepower Dakar monster before the 2016 Dakar start, the car had been carefully examined by Lithuanian engineers, but there was no time for significant modifications back then. According to the chief engineer of the RaceTech workshop, Marijus Bernotas, in preparing the A. Juknevičius car for 2017, the preparation cycle had perfect timing to rebuild the car to an almost immaculate condition. “This year we had more time, so we reassembled and updated everything, essentially. The car was dismantled down to its bare frame structure. Then it was sandblasted, damaged areas were welded, and everything was reinforced and painted. During the races, the car chassis and body are exposed to huge loads and it is natural that the paint and protective layers are damaged by stones, branches or other objects on the track”, said the engineer. After the 2016 Dakar, the team’s mechanics used factory parts to upgrade the Sadev gearbox and other assemblies. The engine work was minimal: during the trip from South America, the valve seats corroded because of the humid environment, and 4 cylinders became leaky. The engine block was disassembled and the heads were replaced. The Overdrive engine capacity can handle 20,000 to 25,000 kilometres of speed stretches. So far it has travelled about 15,000 kilometres. Thus, according to A. Juknevičius, the engine should be able to withstand the 2017 marathon. New co-driver of A. Juknevičius – a punk Antanas Juknevičius is going to his 8th Dakar with a new co-driver – Darius Vaičiulis. “Including Darius in the team was no surprise to me or the other CRAFT Bearings team members. For many years, we have been joking that we would go together to conquer the Dakar, and this year it has become a reality. Dakar is a huge and daunting project, and ambition and financial resources are not enough alone to overcome it. Inner motivation, along with emotional and physical preparation play a very important role. Darius radiates these traits. In addition, his way of thinking and approach to life are very close to mine. We are both responsible and disciplined, but also what might be called “punks” in our approach to life, said A. Juknevičius in talking about his choice of co-driver.

Page: 89

What Happened in the

Bearing Industry SecondHalf of

2016

Although a Dakar novice, Darius Vaičiulis already has a lot of sand racing experience. He has participated in the rally raid competition, and together with Antanas Juknevičius, he won the Libya Desert Challenge in the Sahara desert in 2008. The new co-driver is not scared of challenges, he is as “punk” as Antanas. Darius has climbed to the peaks of Mount Everest (Asia, 8848 m), Aconcagua (South America, 6960 m), Kilimanjaro (Africa, 5895 m), Mount McKinley (North America, 6194 m) and Elbrus (Europe, 5642 m). Two years ago, Darius Vaičiulis drove more than 5,000 km on a motorcycle along the routes of the future Dakar rally. The rally marathon that will start in January 2017 will be held in Paraguay, Bolivia and Argentina. In the 2016 Dakar, the crew of Antanas Juknevičius and Mindaugas Slapšys ranked 27th in the absolute automobile class standings. A. Juknevičius has already participated in Dakar races 7 times, and achieved his highest ranking, 25th place, in 2009. The 2017 Dakar Rally will start on January 2nd. You can follow CRAFT bearings team results on www.craft-bearings.com.

December

SKF invests SEK 225 million in modernising distribution centres

SKF is investing SEK 225 million in upgrading its distribution centres across Europe and India. The investments will improve customer lead-times and service levels, whilst contributing to reduced stock levels throughout SKF’s logistics chain. Recently completed investments in India and Belgium total SEK 35 million, with a further SEK 190 million to be invested in upgrading existing distribution centres in France, Sweden and Italy during 2017 and 2018. Luc Graux, President, Bearing Operations, says: “These investments complement our efforts in modernising and digitalising our factories. With a more flexible, digitalised manufacturing and logistics base, SKF and its customers will be better able to compete on the market.” SKF’s India Distribution Centre in Pune was inaugurated on 13 December 2016. The purpose-built facility allows for the closure of 15 of 27 previous stocking locations across India, whilst improving product availability for customers and distributors. SKF’s European Distribution Centre in Tongeren, Belgium, was upgraded during the first half of 2016 with a “goods-to-man” workflow, which involves using automated goods retrieval systems and improved handling mechanisms. This results in a more efficient and ergonomically correct working environment and reduces the time needed to pick, pack and ship customer orders. Page: 90

Bearing News • Issue 7

December

Aetna Bearing Company Enters a Strategic Partnership with Elgeti Engineering Aetna Bearing Company, headquartered in Franklin Park, Illinois, entered a strategic partnership with Elgeti Engineering GmbH to be their dedicated bearing and system testing solution provider. Aetna Bearing, founded in 1916, looks to continue advancing their Engineering and Support capabilities to meet the needs of a demanding customer base. With Elgeti Engineering’s unparalleled knowledge and expertise in bearing testing and validation, Aetna Bearing looks to deliver on its commitment of advanced engineering and innovation. Aetna Bearing is a leading manufacturer of Thrust Bearings, Belt and Sprocket Idlers, Clutch Release Bearings, and Custom Bearings and Bearing Assemblies. Elgeti Engineering GmbH is a world-class bearing and gear box engineering solution provider offering bearing and system testing, advanced failure analysis, and condition monitoring. “This partnership is the perfect marriage of resources between two companies with complementary attributes. As we continue to expand our product portfolio and level of engineering support to our customers, we look at Elgeti Engineering as a critical support arm to delivering on our commitment,” said Kal Beidas, Aetna Bearing Company President. Hagen Elgeti, owner and Managing Director of Elgeti Engineering, founded the company in 2009 in Aachen, Germany. With a strong academia and research background in bearings and gear boxes, Mr. Elgeti has built a team of test engineers and bearing experts to support demanding applications ranging from the agriculture to the aerospace industry. “After recently establishing our subsidiary in Valparaiso, Indiana, the Partnership with Aetna Bearing will allow us to showcase our capability and increase our exposure in North America. We offer a unique set of services to bearing and gear manufacturers that provides them with the confidence to propose their solutions in high-demand, critical applications. With Aetna Bearing’s strong commitment to engineering innovation and unparalleled service and support, we believe this partnership will strongly complement its breadth of solutions.” said Hagen Elgeti.

December

Nova/TCB USA Expands Bearing Manufacturing Capabilities Nova/TCB USA Inc., expanded its manufacturing ability over the last year with the installation of screw machines and Swiss turning machines. Additionally, several new lines of automated CNC grinders and turning machines were installed to replace the older more manual operations. Nova can now take care of many products in house that may have been sourced in the past. This change facilitated the streamlining of many processes formerly associated to the older equipment. Capacity and efficiency has been increased while cost is decreased. Nova/TCB USA Inc., a TS16949 Registered company, was founded in 2002 on the commitment to provide quality bearings and machined components for its valued customers. Since it began manufacturing and supplying bearings, components, precision drawn and cut automotive tubing, machined parts and stampings, Nova has grown exponentially. This growth can only be contributed to Nova’s commitment and ability to meet and exceed its customer’s expectations. From the onset, Nova was awarded projects requiring tight tolerances and close clearances. Nova’s ability to satisfy these requirements established them as a premier manufacturer and supplier to their customers. The same ability also propelled Nova to become the largest supplier for many of its customers. With combined resources of over 500,000 ft², design, application and production engineers, quality labs that include metallurgical analysis and automated production lines, Nova has the capacity and capability many customers are looking for and expect. Over the years large investments have been made to enhance capabilities, provide continuous improvements and present new opportunities to customers that allow them to capture and control cost. Nova is recognized by their customers as a partner rather than just another supplier. visit www.novausa.us for more information. Page: 91

What Happened in the

Bearing Industry SecondHalf of

December

2016

Schaeffler sells cylinder head manufacturing unit in Magdeburg The automotive and industrial supplier Schaeffler is to sell its Magdeburg-based subsidiary Schaeffler Motorenelemente AG & Co. AG to the family-run Weber Group. The contract for the sale was signed on December 21, 2016. Schaeffler Motorenelemente AG & Co. KG, an indirectly held 100% subsidiary of Schaeffler AG, specializes in the mechanical processing of cylinder heads and other complex housings for the automotive industry, which are not an integral part of the Schaeffler Group’s core business. During the 2015 financial year, the company generated sales of around 42 million euros. All of the company’s 185 employees will be retained by the new owner. A long-term agreement for the company to supply components to the Schaeffler Group was also concluded as part of the transaction. Klaus Rosenfeld, CEO of Schaeffler AG, said: “We have decided as part of our ‘Mobility for tomorrow’ strategy to concentrate on selected core competencies and future fields of development. The sale of Schaeffler Motorenelemente AG & Co. KG is a further step in this direction. It will allow us to free up resources that we can then invest in future fields of development that are important for us.” In the Weber Group, Schaeffler has found a buyer whose portfolio and expertise in the field of drive components is a perfect match for the expertise of Schaeffler Motorenelemente AG & Co. KG. The Weber Group manufactures drive components for passenger cars, commercial vehicles, and recreation vehicles and is one of the world’s leading suppliers of vehicle components. Prof. Dr. Peter Pleus, CEO Automotive at Schaeffler AG, said: “We are pleased that, with the Weber Group, we have found a buyer who will continue and expand activities at our Magdeburg plant in the interest of our customers and our employees. This is also important for us, since Schaeffler Motorenelemente AG & Co. KG will remain a supplier to the Schaeffler Group in the future, even after it becomes part of the Weber Group.” The closing of the transaction is expected for the 1st quarter of 2017. It has been agreed that the details of the transaction will be kept secret.

January

Huisman produces world’s largest bearings Huisman, the worldwide specialist in lifting, drilling and subsea solutions, is currently producing world’s largest bearings at its production facility in China. These two, 30m diameter, bearings are meant for world’s largest Tub Cranes: the two 10,000mt Huisman designed cranes which are under construction for Heerema’s new semi-submersible crane vessel ‘Sleipnir’. Since 2012, Huisman has been successfully designing and constructing small bearings with a diameter up to 14m. Unlike traditional Tub Cranes, which make use of either bogies or large wheels for their slew system, the Huisman designed cranes make use of large bearings of own design which are manufactured in-house. The benefit of a bearing is that it allows for a substantial weight saving of the crane. in-house production of 30m diameter bearings at Huisman China The two bearings for the 10,000mt ‘Sleipnir’ Tub Cranes are segmented. The design of the bearings allows for inspection of the rollers without disassembly of the bearing. The assembly of the first bearing has been completed at Huisman China, the assembly of the second bearing is scheduled to start in March of this year.

Page: 92

Bearing News • Issue 7

FLURO-Gelenklager GmbH

Celebrating 15 years together! FLURO® Rod Ends and Spherical Plain Bearings are used in multiple industries Worldwide and with the massive stocks that Godiva Bearings holds, these are available for next day delivery anywhere around the world. Since becoming approved FLURO® agents in 1993, we have delivered over over a million items. In the last five years, we’ve supplied over 600,000 items and hold stock of 75,000 items! From the cheaper end of the market which suits Go-Karts right up to the Railway industries and high-end Motorsport, FLURO® have the range covered.

Dudley: +44 (0) 845 345 5955 Newcastle: +44 (0) 845 345 5920 Email: sales@godiva-bearings.co.uk

www.godiva-bearings.co.uk

140 KEY INDUSTRIAL EVENTS IN

COUNTRIES

2017

EVENTS EXHIBITIONS CONFERENCES AGENDA

2017

EVENTS EXHIBITIONS CONFERENCES AGENDA

140

KEY INDUSTRIAL EVENTS IN

COUNTRIES

2017

EVENTS EXHIBITIONS CONFERENCES AGENDA

140

KEY INDUSTRIAL EVENTS IN

COUNTRIES

2ⁿ Edition of

will be held from 10 to 12 October 2017 The Bearing and Reliability Conference & Expo Due to the great success of the BRCE event that ran on 22 – 23 March 2016 and the request of many participants to run it again, the agenda is set for 2017. The first edition of the Bearing Reliability Conference & Expo is held with over 120 participants from 11 different countries, where the industry players found the chance to come together during a two days' knowledge & networking event. All the attendees experienced for two days long 28 powerful speakers from both the bearing & reliability competences, listened to selected experts presenting their strategies to make the bearing and their assets more reliable. There were in total 8 workshops designed to help implementing the best strategies and the chance to visit the key industrial players at the Exhibition center. Aﬅer the mega successful first edition of BRCE2016, the decision is made quickly to continue with this great concept and to run BRCE2017 in the Westfalenhallen Dortmund in Autumn 2017.

The BRCE 2017 event will be a memorable event- consisting of: • 4 Key Note Presentations (1 hour Duration) The Global Experts • 16 Global Bearing and Reliability Presentations (30 Minutes each) The Industrial Experts • 32 Bearing and Reliability Application Presentations (30 Minutes each) The Best Practices in Maintenance (2 corners in the expo area) • A memorable dinner for fun, sharing experiences and networking

Industrial Maintenance and Reliability Other Topics DAY 1 Key Topics

BRCE Agenda 2017 Key Applications and the Maintenance Other Topics DAY 2 Key Topics

08:00 17:15

Vibration Monitoring

Sensors

Bearing Monitoring

13:00 17:15

Maintenance Strategy

RCM and RCA

Asset Reliability

Safety

Planning and Scheduling

KPI’s

Inventory Management

Human Resources

Root Cause Equipment

Consultancy

Tools and Equipment

Lean Manufacturing

IOT - Internet of Things

5S and TPM

Industry 4.0

6 Sigma

Lubrication and Training DAY 3 Key Topics

Other Topics

Lubrication Reliabilty

On Line Trainings

Remote Monitoring

Storage and Handling

Classroom Training

Ultra Sound

Diagnostics

Grease Lubrication

Webinair Communications

Oil Analysis

Skill Development

Oil Lubrication

Skills Certiﬁctaion

Bearing Failure Analysis

Certiﬁcation

Tools and Equipment

Service and Consultancy

08:00 12:00

Maintenance Training

The call for papers is now open

If you have something to contribute read more below and send your paper extract to info@reliabilitylink.com.

Call for Papers!

Are you and expert in any of our conference categories? Then we invite you to be a key contributor to the success of BRCE 2017. All selected presenters will be granted a 50% reduction in the conference fee.

Presentations to ﬁll

• 16 Bearing and Reliability Presentations (30 Minutes each) • 32 Bearing and Reliability Application Presentations (30 Minutes max. and each presentation will be open to all exhibitors, presenters and daily visitors) Please submit an abstract of maximum one A4 size sheet summarizing your presentation. Closing date for submission is end of Apill 2017. You can submit your paper at info@reliabilitylink.com.

Submission of Abstracts to Consider

• Title of the Paper / Presentation • An abstract summarizing your Paper / Presentation content • Information about the lecturer and co-authors: name, title(s), company address, aﬃliation, email, telephone and fax number • In which topic area(s) your presentation should be listed • A statement specifying what is new in your presentation • A bibliography of your previous publications about this subject • All submissions must be either Microsoﬅ WORD (DOC or DOCX) or Portable Document Format (PDF) ﬁles.

Please Note

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Types of Contribution

Your contribution will take the form a full presentation. If your paper is accepted your presentation will be 25 minutes, with additional 5 minutes for discussion and the opportunity to respond to questions and comments from the audience. Based on the abstract, the Conference committee will decide on the acceptance and order of presentation in the program. Please note that the number of co-authors named in the printed program is limited to two.

Submission of the ﬁnal Manuscript

If your paper is accepted you will be invited to submit the ﬁnal manuscript which must be received by May 30th, 2017 latest. If you receive notiﬁcation of acceptance, you will also receive instructions concerning manuscripts and presentation structures.

Submission of the ﬁnal Presentation

Final presentation will need to be submitted latest 30th July 2017

Key Timelines

• Submission of Abstracts to Include • 28th April 2017 • Submission of the ﬁnal Manuscript • 30th May 2017 • Submission of the ﬁnal Presentation • 30th July 2017

Your Contacts Ian Knight

Kenan Özcan

Paper & Presentation Submissions

Conference & Exhibition Participations

P: +31 6 22428425 E: ian.knight@reliabilitylink.com W: www.bearingreliabilityconference.com

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2016

TOP 20 TIPS Bearing Reliability for

by Mr. Per Arnold Elgqvist

BearingTip No. 1: â&#x20AC;&#x153;Bearings are innocent until the contrary has been provenâ&#x20AC;?. Moderns bearings manufactured by recognized quality brands most only in exceptionally cases present defects. These manufacturers apply Zero Defect strategies and defects on their products are measured only in ppm (parts per million).

3. Contamination. 4. Misalignment. 5. Mounting damages. 6. Wrong bearing arrangement. 7. Overloading. 8. Bad quality of bearing seating on shaft and/or in housing. 9. False Brinelling. 10. Electric erosion.

Earlier bearings failed based due to fatigue caused by defects in the material, the design or the manufacturing process.

Thus as the reliability of bearings no longer depends on the manufacturer we now have the opportunity to act in a positive and proactive way:

Today the vast majority of bearings fail due to external causes: 1. Inappropriate lubrication. 2. Wrong bearing (Type and/or Variant).

See each bearing failure as a challenge to identify the cause or causes and to determine and implement the required corrective actions to avoid the recurrence of the same failure.

Page: 104

Bearing News â&#x20AC;˘ Issue 7

BearingTip No. 2: How long should Bearings last? The answer to this question is of utmost importance as it will tell us if the failure of the bearing is natural or premature. If the bearing reached the recommended service life: Congratulations! Just replace it in the most professional way. But if the bearing did not reach the recommended service life the failure was premature and a root cause failure analysis in a must in order to identify the cause or causes and to determine and implement the required corrective actions to avoid the recurrence of the same failure! Be most careful and avoid the Workplace blindness: “This Bearing always fails every 10 months”! The leading bearing manufacturers indicate recommended guidelines for bearing lives for typical applications, like for example: “Machines used for short periods or intermittently where high operational reliability is required………8 000 to 12 000 hours”. “Machines for continuous 24 hours use…………40 000 to 50 000 hours”. This last recommendation means that bearings in electrical motors shall last for 5 years with a reliability of 90% (L10h) and half of the bearings may last up to 5 times the calculated life (L50h). An example for this is that several manufacturers of high efficiency electrical motors extend guarantees for up to 7 years! This means that these motors should only be lubricated and condition monitored and not opened for 7 years.

BearingTip No. 3: The 3 steps to the Reliability of Rolling element bearings. Follow the 3 basic steps to achieve the required reliability of your bearings: 1. The correct bearing for each application. Each and every application must be analyzed in detail in order to determine the optimal bearings and their precise characteristics. The correct bearing must not only take in account the bearing type and size to comply with the loads (Basic designation) but also the variant (complementary suffixes) required for the working conditions. 2. The correct mounting. Use the correct mounting methods and tools to avoid damages to the bearings and other components of the machines.

test methods and required results.

In order to assure the optimal lubricant for each application the analysis must determine at least 5 properties for the lubricant indicating the corresponding ASTM, DIN or ISO

BearingTip No. 4: “Bearings are as good as their lubrication”. This statement is quite easy to confirm as each and every bearing fails as soon as the lubrication fails. No bearing is able to survive metal to metal contacts! See the example below: A 241/900 spherical bearing with a weight of 3,350 kgs in a cement mill failed after only 105 hours in operation due to incorrect lubrication! It should have last for years! In this case commercial EP2 grease was used instead of the recommended special high viscosity calcium sulphonate grease. So be it that several statistics indicate that 55% or even more of bearing premature failures are caused by inappropriate Lubrication. What an opportunity! A totally correct lubrication must include the following: 1. The correct lubricant. 2. The correct Lubrication method/system. 3. Application in the correct place. 4. The correct quantity. 5. The correct re-lubrication. 6. The correct people performing the lubrication,

3. The correct lubrication. Page: 105

with sufficient knowledge and training (= Tribologists).

BearingTip No. 5: “Rolling element bearings must reach their mounting still being virgins”! The best way to avoid new Bearings to be contaminated is very easy: Keep them in their original package until their mounting, unopened as virgins as in the very old days! If new bearings still are in their original packages and the designations are original and complete and are completely in accordance with the required Bearings there is absolutely no need to open the packages until the moment when everything is ready for their mounting. We have always known that contamination “very much” reduces bearing life. But we did not know what “very much” was until year 2000 when the ISO 281 formula included the contamination factor ηc. The effect of contamination exceeded our worst ideas! I use to show 2 examples in my courses: The bearing life calculated utilizing this formula for a deep groove bearing heavily contaminated as it was unpacked exposed to all the usual particle contamination of a repair shop and used for the measurements in the workshop to repair shaft and housing which means exposed to possible handling damages besides the contamination. This bearing is given the contamination factor of 0.1! As comparison an unopened bearing with the cleanliness direct from factory assigned the factor of 0.8. The calculated life was increased 12 times for the second bearing! And what was the cost for this enormous benefit? None at all!

BearingTip No. 6: The costs of rolling element bearings are insignificant compared with the costs caused by their failures. The total costs caused by bearing failures are in most cases enormous. Especially when you as you should take in account the value of the production that was not produced due to downtime caused by the failure. In most reports I have seen the cost only include the costs for the repair when the value of the lost production may be 10 or up to 100 or more times higher. Let’s look at a simple example: The failures of deep groove ball bearings 6210 in felt rolls in a paper machine as shown in the figure below. These bearings should only function as guide to avoid excessive misalignment of the spherical roller bearings during the handling of the roller and all the load should be taken up only by the spherical roller bearing. In this case it was decided to increase the speed of the machine and thus the tension of the felt was also increased accordingly in such a way that the increased misalignment of the roller caused heavy unexpected loads on the deep groove ball bearing causing premature failures. The cost of each bearing was 50 USD. According to the plant manager each failure caused 2 hour downtime with a total cost of 15,000 USD per hour due to the lost production. Thus a relation of 50 to 30,000! This was in an old machine so just imagine the cost in a modern machine, as for example the largest machined manufactured so far that produces 28,000 tons per day. So I’m sure there are even much worse examples! In this case I recommended replacing the bearing by a simple bushing with the diameter big enough to avoid an excessive misalignment of the spherical roller bearing but a clearance enough not to touch the housing during operation. The cost: 20 USD! Conclusion: Always look for the total costs for the failures.

Page: 106

Bearing News • Issue 7

Be a LUBExpert

A COMPLETE ULTRASOUND SOLUTION TO MANAGE YOUR ACOUSTIC LUBRICATION PROGRAM Poor greasing practices are a leading cause of bearing failure.

Grease Bearings Right

Many lube departments re-grease on a wasteful calendar-based schedule. This leads to over and under greased bearings that fail to deliver their engineered value.

Right Lubricant

LUBExpert tells us when to grease... and when to stop. Grease reduces friction in bearings. Less friction means longer life. LUBExpert alerts you when friction levels increase, guides you during re-lubrication, and prevents over and under lubrication.

Ultrasound Solu�ons

Right Location Right Interval Right Quantity Right Indicators sdtultrasound.com/lubexpert

BearingTip No. 7: Wrong Bearings = the 2nd mayor cause for Bearing Premature Failures! My experience on the field has shown wrong bearing to be the second mayor cause for premature failures! Why so?

3. Abrasive wear.

It is clear to me that the lack of knowledge in bearing designation is the reason for most of these mistakes. Just look at the example below: The catastrophic failure of the thrust bearings in an API centrifugal pump in a refinery. The designations of the 2 bearings made evident that these had not been adjusted for mounting in pair which had led to an incorrect thrust preload in between the 2 bearings originating a heavy overload. These bearing should have had the suffix UA indicating the required adjustment made by the manufacturer.

This formula for calculating bearing life takes in account the aISO factor. This factor takes in covers the causes for the 3 types of wear indicated above:

1. Wrong internal clearance. I use to ask what C3 means as I start my training courses and my experience is that most of the participants do not know and a correct internal clearance is most critical for the correct function of bearings.

3. The contamination as regards solid particles expressed as ISO 4406 code, i.e. the quantities of particles larger than 4, 6 and 14 microns per ml. of the lubricant.Before the publication of this formula we talked about the “severe damages” ofsolid particles, but unable to quantify “severe damages”. Now we have an official tool to quantify this type of damage and the fact is that its enormous effects surprised most of us. Just imagine, this factor axyz may have a value from almost 0 (zero) to 50 that is the upper limit. Up to 50 times the previous calculations!

2. Wrong type of integral seals. It is a most common misunderstanding that shielded bearings (-2Z or ZZ) are sealed which they are not: There is a small opening in between the metal shields and the inner ring to avoid contact, which allows the lubricant to leak out and contamination to enter the bearings. Bearings provided with contact seals are almost hermetic and are the indicated to perform correctly in contaminated environments. Just look at the different contamination factors the ISO 281 assign: 0.5 for the capped bearing and 0.85 for the sealed bearing.

1. The relation in between the applied load and the fatigue load limit for the corresponding bearing. 2. The lubrication conditions, mainly the Kappa relation i.e. the relation in between the actual viscosity of the lubricant and the minimum required viscosity to avoid metal to metal contact.

BearingTip No. 8: Utilize the “Tribological Formula” to increase the lives of rolling element bearings! I have called the ISO 281 edition 2000 (and later) formula shown below for calculating bearing life the Tribological Formula. 1. Fatigue or spalling.

As just one example I can mention that the contamination factor for open bearings being re-lubricated is 0.25 and this factor for factory lubricated and sealed bearings is 0.85! Conclusion: Use as many sealed bearings as possible!

2. Adhesive wear.

The latest 2007 edition of the ISO 281 indicates:

As Tribologists we talk about 3 main types of wear:

Page: 108

Bearing News • Issue 7

â&#x20AC;&#x153;Below a certain load, a modern high quality bearing can attain an infinite life, if the lubrication conditions, the cleanliness and other operating conditions are favourableâ&#x20AC;?.

brands. In the following table you can see what I found. The bearing that should have been only one (SKF Ref. 7310 BECBM) was indicated as 12 different SAP numbers and not one single of them was correct! Some missing the suffix indicating the required adjustment for mounting in pair and not one single with the correct machined brass cage as indicated by the API 610/ISO13709.

What an opportunity!

BearingTip No. 9:

In my experience the lack of knowledge in bearing designation is the reason for the 2nd largest cause for bearing failures: Wrong bearings.

Do not systematize the errors in your CMMS Program!

BearingTip No. 10:

The CMMS (Computerized Maintenance Management System) Programs are excellent as long as you guarantee the quality of the information you feed into them. These systems can be outstanding as information sources when you need to repair equipment. If you use it as it is intended you can have all the necessary information in seconds at your finger at the system terminal: All the spare parts needed for the repair (bearings, seals, components, etc.), the required mounting tools and tolerances for the fits, the correct adjustments (axial clearances or preloads) and lubrication data (lubricants and quantities).

The optimum seal, the triple barrier! Deep Groove ball bearings exposed in heavy contaminated areas can be protected in a very efficient way. By heavy contaminated I mean both particles and water.

But the above is only the truth if you take the correct care when you feed the information into the systems. Unfortunately I have seen to many bad examples where wrong bearing information is being fed into the systems. This will cause several problems:

The most usual way to avoid contamination to enter the bearings is by using intensive

- Unnecessary bearing failures.

re-lubrication with grease.

- Excessive stocks in the warehouses.

In several occasions I have recommended so called triple barrier protection: 1. Replacing the open bearing by capped or sealed bearing. 2. Filling the bearing housing100% with grease.

Just to show you an example: A failure of an API centrifugal pump showed to be caused by a wrong bearing so I asked to see the information in the SAP System at the client. The correct bearing should have been a 7310 BECBM in the SKF brand or its correct equivalents in other SAP NO.

Bearing

Actual Bearing Designation

Ref. SKF

100010463