www.zen.biz ISO 9001 certification awarded by TUV Rheinland the global benchmark that guarantees a total focus on customer service and continual improvement
NEW LRG SERIE :
GOTHIC ARC PROFILE TRACK ROLLER
Steel or Stainless Steel
Double Row Angular Contact Bearing
Gothic Arc Profile High Performance Shield and Seal
HIGH PERFORMANCE GUIDE WHEELS As a result of Swiss quality, precision and innovation, JESA is a world leader in manufacturing high-quality and high-performance profile track rollers. JESA track rollers are perfect smooth in operation and provide a long service life time. In addition JESA offer a wide variety of ball bearing assemblies, customized bearing solutions, overmolded rollers, and standard ball bearings. www.jesa.com
Rte du Petit-Moncor 9 I 1752 Villars-sur-Glâne I Switzerland I +41 26 408 47 00 I www.jesa.com
Page: 4
Bearing News • Issue 2
What’s Rolling...Rolling What’s ahr Federal Introduces M Next Generation μMaxμm®
Digital Indicators and Economical Indicator to Measures IDs/ODs on the Shop Floor
onitoring Plain Bearings M With Ultrasound F riction: friend or foe? The answer all depends on your particular situation.
NKE Rolling Bearings for Industrial Gearboxes Digital Indicators and Economical Indicator to Measures IDs/ODs on the Shop Floor
An insight into the effect of Precision Class in Thin Section Bearings
Interview: A Look Inside the importance of Bearing Components with NN Inc.
page
8 page
10 page
16 page
18 page
22
What Happened in the
Bearing Industry First Half of
page
28
2014 Interview: Inside The BearingStockShop & BearingStocks
Page: 6
page
54 Bearing News • Issue 2
g... Research: earing Performance under Contaminated B Lubrication Conditions
Tailored Bearings: Profile Rollers for Linear Guidance System
Interview: Reality Revealed: The Bearing Silent Killer
KL’s Breakthrough into Z Railway and Urban Track Transport Segment
page
60 page
70 page
72 page
78
Case Study: atastrophic Failure Avoid on a Cement C Crusher Planetary Gearbox
OP 20 Bearing T Manufacturers of China
page
82 page
86
Machine Status at a Glance eal-time machine status information on PCs R and mobile devices with ONLINE VIEW 4.0
page
90 Page: 7
Mahr Federal Introduces
Next Generation µMaxµm® Digital Indicators and Economical Indicator to Measures IDs/ODs on the Shop Floor Mahr Federal has introduced the next generation of its well-established µMaxµm® line of digital indicators. In addition to the many existing features of µMaxum indicators, the enhanced µMaxum II line offers a wide range of new features, including: Dynamic Max, Min, TIR; two point difference measurement; Multiplier Factor for ratio measurements; indicator serial number identification; resolution to 10 µin; selectable continuous output; and longer battery life. “µMaxum Indicators have been standard equipment for QC operations for nearly a generation,” said Paul Mailloux, Manager of Precision Gages for Mahr Federal. “Now, based on new transducer technology with increased 10 µin resolution, µMaxum II indicators approach the accuracy of higher end amplifier systems. These are by far the most versatile and complete digital indicators ever.” Versatility of the new µMaxum II indicators is enhanced in a number of ways. Resolution is selectable in increments from 0.001 in/0.02 mm down to 0.00001 in/0.0002 mm to accommodate differing application requirements. Two point difference measurement allows comparison of different readings or calculation of measured values. The addition of Multiple Factors for ratio measurements allows chordaltype measurements, useful for making ID/OD measurements using a V plate, or for gage fixtures using lever-type non-direct contacts. Data output with indicator serial number identification is an excellent gage management Page: 8
Bearing News • Issue 2
feature. It can be used to improve ISO tracking, where a number of indicators are networked on a production line, or to identify which gages need to be pulled for recalibration. Other useful µMaxum II features include: Normal/ Reverse Sensing; a high resolution digital output with analog bar graph or Go/No-Go display; selectable MarConnect data output via USB, OPTO ES232C, or Digimatic; application of Unilateral Tolerances; and an auto power-down feature which conserves power and helps assure long life from readily available commercial batteries. The new µMaxum II line of Digital Indicators is available in two models, the µMaxum II and the µMaxum II XL which provides longer measuring ranges. Weighing as little as 6 oz, all µMaxum units are lightweight and ruggedly built to withstand hard use. The gasketed case, crystal, and stem assemblies resist fluid contamination. A versatile bench-mounting indicator gage available from Mahr Federal provides a handy and economical way to measure IDs and ODs right on the shop floor. Available in both T-Plate and V-Plate styles and in two sizes, the 36 B ID/ OD Indicator Gage can measure inside diameters from 0.75” to 9” and outside diameters from 0.25” to 9.5”. The 36 B comes with either a dial indicator, Maxum® III, or µMaxum indicator, and a number of different jaw sets and contacts.
The 36 B ID/OD indicator gage features adjustable contact retraction which allows for the measurement of grooves and races. Frictionless reed-spring motion transfer facilitates repeatability, and gaging pressure is adjustable from 0-35 N/ 0-8 lb. The gage can be positioned at any angle from horizontal to vertical, and simply reversing the topplates changes the measurement from ID to OD. The 36 B ID/OD Indicator is supplied with JW-9 jaws, but special spherical contacts are available in steel and tungsten carbide. Doughnut shaped contacts as well as TC Ball and Pie Plate contacts are also available. Mahr Federal Inc., a member of the Mahr Group, is known worldwide for its expertise in providing dimensional measurement solutions. The ISO 9001:2000-certified company manufactures and markets a wide variety of dimensional metrology products, and is headquartered in Providence, RI. Visit www.mahr.com for more information.
“The 36 B is a real work horse,” said George Schuetz, Director of Precision Gages for Mahr Federal. “Fast, accurate and easy to operate, the basic design has been proven in many shops over many years, and with a Maxum III or µMaxum indicator, digital measurement data can be output directly to any computer.” The T-Plate configuration gives a diameter reading directly across the diameter (a third contact may be used as a side-stop or centralizer), while the V-Plate configuration is self-centralizing. Frequently used to inspect parts with odd number lobing conditions, the three “V” jaws measure the distance between the sensitive contact and the chord formed by the two reference contacts. This measurement bears a direct relationship to the diameter, and compensation is made by a special ratio indicator so diameter is read directly.
Page: 9
Monitoring Plain Bearings With Ultrasound Friction: friend or foe? The answer all depends on your particular situation. When driving your car aggressively over wet or icy roads, friction, as well as a good set of tires, is your friend and will save you from some stressful moments. If you’re in the reliability game and are tasked with extending the life of your bearings, then friction is the enemy. While zero friction is neither practical nor even possible, you search for the best ways to minimize these forces between the elements of your bearings. For rotating machines, it is necessary to reduce friction most of the time to increase efficiency, decrease power losses and support loads. The element of choice is the well-known team of bearing and lubricant. Bearings, in their different configurations, are one of the most efficient ways to reduce friction between a stationary and a rotational part of a mechanism. Two broad classes of bearings exist: plain bearings and rolling contact bearings. Which type of bearing is used depends on several factors related to the design of the machine and its process. Sometimes both types are used in the same machine doing different jobs. For this article, the focus is on plain bearings. Choosing the best technology to monitor friction and condition in plain bearings is a challenge. Due to the physical characteristics of plain bearings, using vibration analysis (VA) is more effective for rolling contact bearings and less so for plain bearings. Ultrasound (US) is trending more frequently for condition monitoring of rolling contact bearings and it also shows promise for plain bearings. Understanding the physical differences
Page: 10
between the two bearing categories is critical for developing condition monitoring strategies for plain bearings using ultrasound. Rolling contact bearings consist of several elements (e.g., cage, inner and outer race, and roller elements among the important ones). This category of bearings relies on rolling instead of sliding to decrease friction. Plain bearings have a more simple design. In their most basic form, plain bearings consist of two surfaces, one stationary and one rotating. The rotating part slides over a lubricant film to reduce friction. Plain bearings have some advantages, the most relevant being the following: • As long as the lubricant film is maintained, there is separation between the stationary and moving part, thereby keeping the friction low. • A very high load carrying capability. • A better capacity than rolling contact bearings to withstand shocks and vibration. • The lubricant film dampens vibration and noise,
Bearing News • Issue 2
making plain bearings quieter than rolling contact bearings. • Less sensitive than rolling contact bearings to contaminants in the lubricant.
Types Of Plain Bearings There are four types of plain bearings: 1. Journal (sleeve bearings) – They are cylindrical and the inner surface can be lined with Babbitt metal, bronze, or other material softer than the rotating journal. 2. Segment Journal - Similar to journal bearings, with the difference being the stationary bearing consists of segments or bearing shoes. 3. Thrust – These bearings are used to support axial loading. 4. Self-Lubricated – These are journal bearings with a solid lubricant deposited over the internal bearing surface. The lubricant is activated by friction.
Plain Bearing Lubrication Plain bearings rely on a fluid film lubrication to keep the stationary and rotational parts separated with very low friction between them. When an external high pressure lubricant supply is used, the journal is lifted and the lubricant film keeps the surfaces separated. This is known as hydrostatic lubrication and special care is needed to maintain a steady lubricant flow. This type of lubrication is used mainly for big machines, such as turbines, where heavy journals need to be floating in oil at start-up to avoid rubbing and wear. For medium and small size plain bearings, the film is achieved by a rotating action of the shaft, which forces an oil wedge between the shaft and the bearing, thus developing hydrostatic pressure that lifts the shaft. This type of lubrication is known as hydrodynamic and the oil wedge is maintained as long as the shaft rotates. Oil or grease is suitable for lubricating plain bearings. But using one or the other depends on the
Page: 11
shaft speed, load and temperature. In general, it is better to use grease for low speed and oil for high speed.
Plain Bearings Failure Modes Plain bearings have some advantages over rolling contact bearings, but also some disadvantages. One of them is a sudden loss of fluid film will cause an almost instantaneous metal-to-metal contact with serious consequences, like wear and temperature increase. Loss of lubricant isn’t the only error that can cause problems. Contaminants in the lubricant, incorrect assembly, poor workmanship, corrosion, oil whip and oil whirl between the elements all can damage the bearing. Problems related to the absorption of hard contaminants range from a light wear of the inner liner surface to scoring of the journal. Good housekeeping practices and filters in the breathers help to avoid contamination. Mistakes in the assembly cause excessive fretting damage and flexing in the outer diameter (OD) of the shell and housing. Other problems related to the assembly are excessive interference and misalignment. Corrosion is caused by a chemical attack to the inner liner from chemical components in the oil. These originate from certain additives or oil degradation itself. Oil whirl and whip happens when the oil can’t form a stable oil wedge.
Using Ultrasound For Monitoring Plain Bearings In recent years, improvements to instrumentation and software have challenged the concept of ultrasound applications as ONLY a simple inspection tool for leak detection. Many successful reliability teams have adopted ultrasound as an important tool for condition monitoring and predictive maintenance. Monitoring rolling contact bearings and acoustic assisted lubrication are performed daily using ultrasound. This has freed up valuable time for vibration analysts to focus on assessing critical assets first identified by ultrasound as being in a problematic state. Plain bearings are widely used in turbo machinery and many other types of machines in the plant. Different to rolling contact bearings that enter a starved lubrication condition slowly and, therefore, Page: 12
are easier to trend, plain bearing lubrication requires a steady fluid film to work. Any situation that alters this oil flow leads to almost instantaneous contact-to-contact metal. Therefore, the window to failure for plain bearings is much smaller than it is for rolling contact bearings. The data gleaned from monitoring plain bearings with ultrasound has some differences compared to rolling contact bearings. These differences are shown in Table 1.
Contition
Rolling Contact Bearing
Ultrasonic signal intensity
Strong
Materials impedance effect
Negligible
Low (Depends on the inner metal layer)
One
More than one (One point for every two square inches of project journal area)
Measurement points
Type of sensor preffered
Sampling time
Problems Detected
Window to action
Plain Bearing
Weak
Needle
Magnetic foot
Short
Short to medium (According to journal speed, 1 minute, 3-5 rotations) Lost lubrication Hard contaminantsMisalinment
Starving Lubrication Contaminants
Medium to long
(Larger plain bearings need several measurement points due to low energy generated by faults. Draw a profile of the static values along the projected journal area.)
Short
Table 1
Health Assessment Based On Static Ultrasonic Data There are three primary failure modes that are identifiable by trending static ultrasound data and analyzing dynamic ultrasound data. In order to easily visualize the different positions of the journal inside the bearing, imagine the bearing as a clock with a clockwise rotation (see Figure 2). With a well lubricated, normal plain bearing, as the journal rotates, the pressure effect of the oil wedge moves the journal towards 7 o’clock. The highest static
Bearing News • Issue 2
ultrasound data should be expected at this point.
predominantly seen at 6 o’clock and 7 o’clock positions because clearance between the shell liner and the journal are smallest there.
Oil Starvation A low supply of oil causes problems in lifting the journal and consequently, metal-to-metal contact is possible. Static signals at the 5 o’clock, 6 o’clock and 7 o’clock positions increase against the normal values and readings at the 9 o’clock, 12 o’clock and 3 o’clock positions likely remain the same or decrease a little bit. Temperature also increases, so it is necessary for the ultrasonic data collector to capture a non-contact temperature value in the trend. The time waveform shows a general increase. The CF should remain low without the presence of impulses. Inspectors have to think in two dimensions now. Following a line at the 7 o’clock point position, several static readings are taken across the face of the bearing. All should be similar. An ultrasonic data collector with very good sensitivity is required because friction levels are low. The acoustic impedance of the shell and inner liner affect the acoustic energy reaching the contact sensor. The ultrasonic crest factor (CF) should be low. Crest factor is a numerical value that describes the ratio between the root mean square (RMS) value and peak decibel micro volt (dBuV). This is a condition indicator that provides insight for inspectors. CF allows them to differentiate between friction and impacting as the cause for high static values. Readings taken at 12 o’clock and 3 o’clock positions should be lower than seven. The time wave trace should be uniform without many spikes of energy.
Misalignment
Hard Contamination
comparing static ultrasound readings across several points, it is possible to uncover a misalignment situation. To illustrate this, Figure 5 shows an analysis of a hypothetical bearing that has nine measurement points over the journal’s projected area.
A steady supply of lubricant keeps friction levels low. Soft contaminants are embedded in the soft metal liner, but hard contaminants scratch the journal surfaces and are revealed by random, high static peaks (RMS peaks) and increasing crest factor values. The time waveform shows random peaks if the contaminants are floating. If the hard contaminants remain in the same position, the time trace will show sinusoidal peaks. The presence of contaminants will be
In mid- and large-size plain bearings, when
Points 1, 4 and 7 are located axially on the left side of the bearing, at the 9 o’clock position. Points 2, 5 and 8 are at the 12 o’clock position, while points 3, 6 and 9 are at the 3 o’clock position. Under normal operation, the maximum load (friction) should be at the 7 o’clock position (points 1, 4 and 7) and lower friction at the 12 o’clock position
Page: 13
capturing dynamic signals with sample time sets that are long enough to reflect three to five shaft rotations, you will see a clear variation in signal along the time axis.
(points 2, 5 and 8). If the journal is aligned, these values should remain stable over time. For points 1, 4 and 7, the readings should be similar (highest in the bearing) and points 3, 6 and 9 also should have similar readings between them, but be a little higher than points 2, 5 and 8. If points 1 and 9 increase and 7 and 3 decrease, or 7 and 3 increase and 1 and 9 decrease, it is a clear indication of an uneven journal rotation. By
Testing plain bearings has proven challenging using traditional condition monitoring techniques. Oil analysis remains an important technology here. Advancements in ultrasound technology made by manufacturers are providing additional tools for assessing conditions in plain bearings. Follow the techniques here and use both static and dynamic data to observe changes. Always remember that the window to failure is a little bit smaller with plain bearings than it is with roller bearings and plan your uptime with the precision of ultrasound. by Gus Velasquez Gus Velasquez is the Latin America Account Manager for SDT Ultrasound Solutions and Corporative trainer for Spanish speakers. Gus is a Chemical Engineer and has more than 30 years field experience helping a wide variety of industries in lubrication and ultrasound inspection. www.sdthearmore.com
RELIABLE, EFFICIENT AND VERSATILE
NKE ROLLING BEARINGS
FOR INDUSTRIAL GEARBOXES Page: 16 Page: 16
Bearing News • Issue 2
NKE Austria offers rolling bearings for industrial gearboxes that meet the efficiency and reliability requirements of a wide range of sectors, such as general machinery, mining, material handling systems and heavy machinery. “Suitable bearings play a vital role in industrial gearboxes. Speeds, loads and available space are just some of the many factors that must be taken into account when designing a drive system capable of reliably meeting the demands placed on it, during long term operation.” explains Daniel Thalmann, Application Engineering Manager at NKE. One of the major strengths of the Steyr-based rolling bearing manufacturer is its range of single row cylindrical roller bearings. NKE manufactures over 3,000 different variants, which enable an enormous variety of application possibilities. The bearings are suitable for high radial loads and moderate to high speeds. Made from pure rolling bearing steel, they have an exceptional lifespan, while the raceways’ high surface quality reduces the operating temperature down and wear. The inner and outer rings of the cylindrical roller bearings can be fitted separately, simplifying installation. Notable for their outstanding economy and operating reliability, they can be produced at the Steyr factory with short lead times. In addition to cylindrical roller bearings, NKE’s standard portfolio of industrial gearbox bearings comprises spherical and taper roller bearings as well as angular contact and deep groove ball bearings. Of particular interest are the company’s special bearings for gearboxes, which are developed in close cooperation with the customer and ensure optimum balance of space and performance. NKE offers gearbox manufacturers a comprehensive service including consulting, assistance with design, calculations and training courses. All bearings made by NKE are subject to stringent quality requirements and are tested using modern inspection and measurement procedures. NKE produces standard and special bearings for all industrial applications. Engineering, product development, production and final processing of components, modular assembly, quality assurance,
Calculation model for a two-stage cylindrical-gear pair with helical gear teeth (Source: NKE Austria GmbH/Romax).
logistics, sales and marketing are centralised at NKE’s headquarters in Steyr, Austria. A wide range of standard bearings is available from stock or at short production lead-times. NKE also provides tailored products and solutions. NKE’s products are distributed through 15 international representative offices and more than 240 distribution outlets in 60 countries. Company Information: NKE is a bearing manufacturer with headquarters in Steyr, Austria. The company with about 150 employees was founded in 1996 by a group of senior staff members of former company Steyr Wälzlager. NKE produces standard and special bearings for all industrial applications. Engineering, product development, production and final processing of components, modular assembly, quality assurance, logistics, sales and marketing – are centralised at NKE’s headquarters in Steyr, Austria. The factory in Steyr is certified to ISO 9001:2008, ISO 14001:2004 and OHSAS 18001. Its wide range of standard bearings is available from stock or at short production lead-times. NKE also provides tailored products and solutions. In addition to product development and application engineering NKE provides a full range of technical, consulting, documentation and training services. NKE’s products are distributed through 15 international representative offices and more than 240 distribution outlets in 60 countries. Visit www.nke.at for more information
Page: 17
An insight into the effect of Precision Class in Thin Section Bearings What are ABEC / ISO and DIN grades? ABEC stands for Annular Bearing Engineering Committee. ABEC is part of the American Bearing Manufacturers Association, which acts as the official governing body of the bearing industry in the United States. The bearing grades and tolerance specifications come in five classifications; 1, 3, 5, 7, and 9. European bearing precision classes are normally categorised under the ISO or DIN standards and follow a similar format to the American ABEC classes. Normal / P0, Class 6 / P6, Class 5 / P5, Class 4 / P4 and Class 2 / P2. As the ABEC grades increase the tolerances tighten from least to the most precise. The ISO and Din systems work in reverse so that the tolerances tighten from most precise to least. The grades control tolerances from boundary dimensions such as bore and OD, to tolerances like axial run-out that impact rotating accuracy, and values like the dimension measured from the centre point of the raceway to the side faces of the bearing. Classification does not govern all aspects of bearing quality. There are many critical design features of bearings that are not covered by classification classes, including: material, cage, retainer type, surface finish (smoothness) of the rolling elements and raceways, clearance, preload, ball precision grade, or anything to do with the ancillary components like seals, snap rings and lubricants. Classification also does not directly control noise level or torque. The table below provides a useful reference to help interchange between the various classification Page: 18
systems. The exact tolerance bands are not identical but they offer a very good reference point.
Why aren’t all bearings made to ABEC 9, Class 2 or P2? As with most things in the manufacturing world, higher precision means higher cost, and the term “precision” is relative – one designer’s need for “precision” may actually require the higher end of the precision class and another may be satisfied with the lower end. There are also many cases where a problem with a bearing system cannot be solved simply by increasing the level of precision. Deciding on a precision class boils down to a cost / benefit decision for the designer. A bearing made to mid-range P5 will have tolerances that are approximately half those of a P0 bearing, but it could cost two or three times as much.
Bearing News • Issue 2
Not your average distrubutor Hybrid and Ceramic Bearings Thin Section Bearings Aerospace Bearings Super Precision Bearings Custom and Special Bearings Cross Roller Bearings
Air Bearings Cam Follower Bearings Slewing Rings High Temperature Bearings Linear Guide Systems Wire Guide Bearings
Which precision class should I design into my application? The grade specified for an application depends on the type of equipment and its function. A mechanical inspection system for a silicon platter may require a reader head located very close to the surface of the wafer. It is critical to control the movement of the inspection system in the horizontal axis, which has direct correlation to the axial run-out of the bearing in the system. A bearing of at least ABEC-5 / Class 5 or P5 grade would be required to provide the necessary precision in this application.
A turntable is an application where higher rotating accuracy may not be critical, but the assembly steps of the unit are very important to the function of the system as a whole. Using an ABEC-5 / Class 5 or P5 bearing will result in consistent fit with the shaft, helping standardize the mounting forces and installation time for every assembly. A hybrid that has an ABEC-5 / Class 5 or P5 bore tolerance and ABEC-1 / Normal / P0 class for all other tolerances will prove to be cost effective and meet the requirements of the application. Silverthin is able to provide a flexible solution producing a hybrid bearing that only has tighter control of the specifically required dimension at a much lower cost point.
Turning “Revolutionary Ideas into Motion” A gun mount would require far less dimensional control or rotational accuracy. Preloading will impact the bearing’s performance far more as the bearing experiences heavy shock loads and external forces. Tolerances like axial run-out will have less impact on the accuracy of the system than the movements of the operator. Bearings in this application should be preloaded to increase system stiffness, but tolerances would be sufficient at an ABEC-1 / Normal / P0 level.
Carter Manufacturing Limited is the Silverthin European Master Distributor. The partnership between Carter and Silverthin allow flexibility and capacity to customize products to meet customers challenging and often demanding requirements with accuracy, value, and performance. The Silverthin standard catalogue options are only the beginning of what can be provided for diverse applications. From standard thin section bearings and high precision specials, to hybrid combinations of both precise and cost effective components.
To determine the best precision classes for your design, talk with a Carter Bearing engineer.
Why not let Carter Manufacturing Limited help you specify the most appropriate thin section bearing for your application and then let Silverthin customize your Precision Thin Section Bearing product to your requirements of accuracy, optimal value, and performance. Precision Thin Section Bearings in the standard Silverthin catalogue are only the beginning of what we can provide for diverse solutions. Contact Carter today to get a helping hand in turning your revolutionary ideas into motion. Tel: +44 (0)1865 821 720 www.carterbearings.co.uk.
Page: 20
Bearing News • Issue 2
We keep your world rotating PRĂœFTECHNIK specializes in measurement technology for rotating machinery We offer innovative solutions including products, services, training and support for industrial maintenance across all industries and around the world: condition monitoring, vibration analysis, laser shaft alignment, geometrical measurements, roll alignment, and more.
Find out how we boost uptime
PRĂœFTECHNIK AG Oskar-Messter-Str. 19-21 85737 Ismaning Germany PROVEN QUALITY
Made in Germany Global Presence Qualified Support Quality Service
Tel.: +49 89 99616-0 Fax: +49 89 99616-100 info@pruftechnik.com www.pruftechnik.com
Richard Holder President & Chief Executive Officer
Page: 22
A Look Inside the importance of Bearing Components with
“Any machine shop can make a ball or roller, but only a sophisticated company can produce billions of perfect balls and rollers every year.�
Page: 23
A Look Inside
the importance of Bearing Components with
NN, Inc. The term “bearing” is derived from the verb “to bear,” a bearing being a machine element that allows one part to bear or support another. The precision of bearing components is crucial in order to fulfill the most demanding applications. The process of manufacturing bearing components requires some of the highest standards of current technology. In an interview with NN’s Chief Executive Officer, Richard Holder, we discussed the importance of precision bearing components. What is your role in the company? President and CEO
Why were you chosen for this function? The company engaged in a retained search process specifically to find a replacement for the retiring CEO. Like me, most of the candidates were from larger companies and all had successful growth records and a lot of experience in acquisitions in addition to running domestic and international operations.
When did NN, Inc. start production, and what was the evolution of the company? NN was formed in 1980 by Dick Ennen—hence the name “NN.” Dick was a divisional manager of Hoover Universal, which had a precision ball division. He took key managers and employees with him from Hoover to start NN from scratch. Within 10 years, he had built a $50 million company with multiple plants in the U.S. and Ireland. When Dick stepped back from daily operations, he hired Roderick “Rock” Baty to serve as president. Rock continued the growth of the Page: 24
Richard Holder / President & Chief Executive Officer
company with many significant acquisitions from $50 million to $400 million in sales by 2011. In 2013, Rock retired and I took over.
Can you give us a short description of the bearing components you produce? Starting with just balls for bearings, the company now produces balls, cylindrical rollers, tapered rollers, spherical rollers, plastic retainers, metal cages and bearing seals.
Which other market solutions do you have? In addition to bearing components, we also manufacture high-precision metal components and custom-engineered plastic and rubber solutions which serve a variety of markets and customers around the world.
What is your difference with the competitors on the market? We have an unmatched breadth of components for bearing manufacturers. We are a one-stop shop for components, which allows the bearing Bearing News • Issue 2
manufacturers to focus on their biggest valueadd: designing and marketing better and more sophisticated bearing solutions. We worry about the basic parts, and they focus on using them in lower and lower friction reducing bearings. This leads to better gas mileage for cars and lower energy use in industrial equipment.
and roller bearings are also used in the same applications. However, a roller carries more weight because the weight is distributed along the entire length of the roller, whereas all of the weight on a
What is the quality/precision level of your products? Our products are truly high precision, meaning that we measure roundness and surface finishes in fractions of a micron. Any machine shop can make a ball or roller, but only a sophisticated company can produce billions of perfect balls and rollers every year. That is what our customers count on us to do, and there are only a small handful of companies in the world that can deliver quality on that scale.
Can you explain the importance of a precision roller for a bearing? A roller carries the weight of the machinery in which the bearing is installed. It is the same with a ball. Ball bearings are used in many applications, Page: 25
ball is carried only along the diameter.
Do you have any research or case studies of your bearing components? We have done many complex process improvements which improve the characteristics of our bearing products. Right now we are engaged in developing a new generation of low-noise balls and rollers. Lower friction and lower noise are the holy grail of bearings, and we are leaders in the industry.
How do you see the developments in Asia? Do you undergo any competition from there? Yes, we have production facilities in China, and we sell throughout Asia and in India. Most of the competition is not yet able to produce at the same quality level of NN. Our goal is to continue to leap ahead of the competition so that as the local Asian producers get better, we will still be well ahead of them in terms of quality and manufacturing technology.
What is your latest product development? Page: 26
As I mentioned, we are working on lower noise and lower friction Class 1 rolling elements. In addition, we are designing a new generation of manufacturing cells which can significantly lower the cost of production. The development of the Class 1 Roller is a breakthrough to improve bearing perfor-mance resulting in Low heat generation; very low noise and friction. We achieved this through the development of high precision roller end face geometry with super finished raceway and a unique packaging method into a plastic foil.
What are some of the biggest challenges you have faced at NN and how have you dealt with them? As with any change comes challenge, and I have faced a few challenges so far during my time at NN. We are focused on educating the investment community on the true value of our current and future business. As we attend investor conferences and present our strategic plan to potential investors, shareholders, and stakeholders, we are spreading the word about NN, who we are, what we do, and why you should choose us. We are also working Bearing News • Issue 2
diligently to convince the bearing customer that NN can execute their primary operations in a more efficient, cost effective manner than their current internal operations. Furthermore, we are reorienting the overall corporation toward growth and how we can realize a truly bright future.
Is there any project you truly enjoyed or a customer experience you are most proud of? One of our greatest successes has been convincing our customers to sell their component production plants to us so that they can focus on bearing design. In the case of our tapered roller plant that we bought from the world’s largest bearing company, we improved quality and delivery and lowered the price of the rollers sold back to them year after year. This was a win-win scenario and a huge success for us.
How do you motivate and convince potential customers to choose NN to be their solution provider?
This is easier than you think. We offer high quality products in plants located near our customers. We offer the broadest line of components in the industry. Our customers design us into their products, and we deliver quality every day. We have made ourselves an indispensable part of their supply chain. This is how you build a sustainable business model.
How do you see the future of bearing production? There is no substitute for bearings in heavy products that must move. Cars are full of bearings and so are the mars rovers and MRI machines. The key is making the bearing as nearly frictionless as possible. Bearings are here to stay until someone develops the anti-gravity machine like on the Jetsons. Maybe someday this will be a reality. Until then, we’ll be making better balls and rollers and the major bearing manufactures will be putting them into everything that moves. www.nninc.com Page: 27
Page: 28
What Happened in the
Bearing Industry First Half of
2014
Page: 29
What Happened in the
What Happened 2014 Bearing Industry First Half of
in the
Bearing Industry First Half of
Jan
03
2014
Richard Hall promoted to President Industrial and Deputy Managing Director at Schaeffler UK Richard effectively takes over Kate Hartigan’s President Industrial responsibilities following her retirement in 2013. Richard, who held the position of Vice President Automotive at Schaeffler UK from 2007 to 2013, is now also promoted to Deputy Managing Director, Schaeffler (UK) Ltd.
Jan
04
Igus launch lubricant free linear solutions, combined with motor and ready to fit For the first time, linear drive technology specialist igus® is offering its linear actuators with polymer bearings, complete with motor, from stock.
From its beginnings with lubricant and maintenance-free basic linear bearings, the linear technology department at igus has progressed to linear guides, lead screws, and fully assembled units. Up until now, the main focus has been on manual operation in format adjustments. Now, the company is expanding its low price, quick delivery, complete solutions promise by adding a motor to their ready-to-fit linear units.
Currently, the small motor range covers stepper motors in sizes NEMA17 and NEMA23. The motors are optionally available with encoder and/or brake. Stepper motors are a good accessory to the DryLin® linear drives due to their outstanding costeffectiveness, precision, and simple operation. The units work reliably in a wide range of environmental conditions (depending on the IP protection class chosen). The NEMA standard also guarantees global availability. Alternatively, igus has designed the drive units for lubricantfree linear movements in such a way that they can also be driven by competitor stepper motors. To achieve this, igus offers customers who already have a motor a quick-fit connection by means of an aluminum
The new compact, light and quiet DryLin® E SAW-0630 from igus® now available with stepper motor.
Lubricant – free means the drive system is suitable for rough environments.
Lubricant free linear solutions, combined with motor and ready to fit For the first time, linear drive technology specialist igus® is offering its linear actuators with polymer bearings, complete with motor, from stock
Page: 30
Bearing News • Issue 2
Are failures like these happening in your plant? Lubrication Reliability By implementing a lubrication reliability strategy in your plant will have the effect of eliminating bearing failures and reducing equipment wear - with the effect of improving your equipment reliability. Enluse BV has the knowledge and the product lines to help you implement a lubrication reliability strategy in your plant.
Identify and Label it!
Statistics reveal that more than 60% of bearing damage is lubrication related!
Managing Your Strategy
Store it, clean it, keep it clean!
Air Sentry Breathers
Oil Safe
Enluse Labeling Chart
www.enluse.com +31 (0) 76 57 81 280
feed movements, and the handling of components. The new driven axis is available from stock within a few days, in the exact length specified, and including the motor. Tribologically optimized polymer gliding film
Ready-to-fit DryLin® E drives with a motor cable in a plastic Energy Chain® on a handling gantry.
spacer and motor flange to fit the NEMA motor. New: extremely light axis with NEMA17 motor The new linear axis DryLin E SAW0630 with NEMA 17 motor is driven via a trapezoidal or high-helix thread lead screw. Numerous pitches from .06 to .6 inch (1.5 – 15 mm) are available. The drive lead screws are supported by ball bearings. The lead screw nuts are made of tribologically optimized iglide® high-performance polymers, and guarantee freedom from lubrication over the entire stroke length, and entire life of the bearing. Almost all the components used for the ready-to-fit linear unit are made from plastic and aluminum, meaning the system is extremely light weight. The SAW-0630 is ideal for simple lubricant-free format adjustments,
Jan
07
The linear guide itself is based on the maintenance free DryLin W system, is comprised of a bearing housing and tribologically optimized polymer gliding film for very low friction and wear. The design makes a flexible and modular structure possible, making assembly easy. There a numerous design possibilities to choose from, with 12 rail profiles available, single and double rail options, and the choice between individual bearings or complete slides. These guides are also available as linear axes with a toothed belt drive. About igus® igus® develops industry-leading Energy Chain® cable carriers, Chainflex® continuous-flex cables, DryLin® linear bearings and linear guides, iglide® plastic bushings, and igubal® spherical bearings. These seemingly unrelated products are linked together through a belief in making functionally advanced, yet affordable plastic components and assemblies. With plastic bearing experience since 1964, cable carrier experience since 1971 and continuous-flex cable since 1989, igus provides the right solution from over 80,000 products available from stock. No minimum order required. For more information, contact igus at 1-800-521-2747 or visit www.igus.com.
NSK Develops an Advanced EPS for Modularization NSK announced that it has developed an electric power steering (EPS) system that is optimized for modularization for application to multiple types of global vehicle models.
Jan
08
Federal-Mogul to acquire Honeywell’s brake friction business for $155 million The Honeywell unit makes disc brake pads and braking system components for automakers and the aftermarket.
Jan
09
Development of “Long-life Needle Roller Bearing Unit” for Reduction Gearbox by NTN The new bearing unit improves operating life more than 10-fold by applying a special heat treatment to the “rollers” of the bearing rolling element and changing the design of parts, and combining a grooved thrust washer and shaft with optimized surface roughness and hardness. Page: 33
What Happened in the
Bearing Industry First Half of
Jan
10
2014
SKF CARB® Toroidal Roller Bearings Engineered to Withstand Tough Operating Conditions at Steel Mills Offered in wide range of sizes, CARB® Toroidal Roller Bearings are non-locating solutions engineered to withstand operating conditions encountered in rotating machinery in steel mills, including casters, electric motors, and gearboxes.
SKF CARB® toroidal roller bearings introduce robust non-locating bearing solutions engineered to withstand the tough operating conditions encountered in a wide range of rotating machinery applications in steel mills. These self-aligning bearings designed for radial loads exhibit very high loadcarrying capacity, high running accuracy, low friction, and resistance to wear resulting in reduced noise and vibration and promoting improved reliability and longer service life. Typical steel industry applications for these bearings include casters, large electric motors, gearboxes, fans, and others where non-locating bearings must be specified. A CARB bearing (for radial loads only) in the non-locating, or “float,” position in combination with a spherical roller bearing (for combined axial and radial loads) in the locating, or “held,” position ultimately can deliver a highly efficient bearing arrangement to eliminate the influence of shaft contraction or expansion due to temperature fluctuations often associated with steel mill applications. CARB bearings integrate design features from several conventional bearing types to realize optimized capabilities and performance. They can accommodate misalignment (similar to a spherical roller bearing), adjust for axial expansion of a shaft (similar to a cylindrical roller bearing), and maximize load capacity due to long self-guiding rollers (similar to needle roller bearings). Page: 34
All CARB bearings have further been upgraded to the SKF Explorer performance class characterized by high-quality steel and an improved heat treatment process to impart superior hardness and toughness for operation in the most difficult conditions. CARB bearings are offered in a wide range of sizes and can be supplied with specialized seals and cages. Custom designs can be engineered. Contact for more information: Ken FosterMetals Industry Specialist SKF USA Inc. Phone: 219-865-2693 Email: Ken.R.Foster@skf.com
Bearing News • Issue 2
Jan
11
One-millionth Barden bearing for dry vacuum pumps Super precision bearings manufacturer Barden has celebrated the production of its one-millionth deep groove ball bearing for dry vacuum pumps at is plant in Plymouth - See more at: http://www.plantengineer.org.uk/plant-engineer-news/ one-millionth-barden-bearing-for-dry-vacuum-pumps/58824#sthash.m4Hz5CpA.dpuf.
Jan
13
Kingsbury Breaks Ground to Build New Western USA Repair Facilitypumps Turbine bearings manufacturer Kingsbury Inc. has broken ground on a new 33,000-square-foot repair and service facility in Yuba City, California
Jan
15
United Utilities Oldham waste water plant turns to Revolvo SRB bearings United Utilities is reporting that split roller bearings are now providing heavy-duty support for the crankshaft of a large sludge pump at its Oldham waste water treatment plant, following operational problems that resulted in damage to the original equipment
Jan
16
ArcelorMittal Bremen places order for SKF customised electromechanical actuators ArcelorMittal Bremen GmbH has chosen SKF to customise and supply 30 electromechanical actuators for use in the continuous casting of steel. The order is one of the biggest for a mechatronics solution that SKF Germany has ever received from a customer in the metals industry.
Jan
19
New Barcode System: Proactive method to identify defects NSK continues to invest in improved manufacturing techniques, which allows customers to benefit from new technologies and improved reliability.
Jan
20
SKF to invest in two new Global Technical Centres in Europe S part of the commitment to further increase its investment in Research and Development, SKF has announced plans to build two new Global Technical Centres - one in Gothenburg, Sweden and one in Nieuwegein, The Netherlands.
Jan
21
FRANTZ Launches New Line of Alum Conveyor Wheels FRANTZ Manufacturing Launches New Line of Aluminum Conveyor / Skate Wheels – Now Offered in Standard and Tortoise ShellŽ Versions
FRANTZ Manufacturing Company, the respected name in Made in USA rolling components for the material handling industry, announces the introduction of a new line-up of aluminum conveyor wheels to support
Page: 35
What Happened in the
Bearing Industry First Half of
2014
the varied application requirements in today’s material handling industry. Aluminum wheels provide reduction in weight along with corrosion resistance benefits. The new offering provides an entry-level price point option as well as a Tortoise Shell® version for applications where enhanced impact resistance and heavier load ratings are required. FRANTZ entered the conveyor or skate wheel business in the 1930’s with the introduction of a line of roller skates branded “Hustler Speed King”, hence the term skate wheels. Later, conveyor wheels were mass produced for the war effort during WWII and then for use in the material handling industry. Today, FRANTZ sets the standard of excellence in the conveyor component and steel ball market segments where it competes. Consultative working relationships with its customers, engineer to engineer, enables FRANTZ to innovate solutions that solve customer problems and deliver value, rather than just sell product. Domestic manufacturing and testing facilities provide the quality assurance that
Jan
22
Both the Standard aluminum wheel and the Tortoise Shell® aluminum wheel utilize the same internal components. The steel balls and raceways are heat treated and hardened under stringent processes to assure years of satisfactory product usefulness. In fact, FRANTZ Sterling® Steel balls manufactured in Sterling, Illinois are produced to meet strict automotive quality standards TS16949. Most FRANTZ aluminum wheels are engineered with a labyrinth shield designed to keep dirt and dust out of the wheel ball complement to assure long product life. To address unique application issues, other options are available such as polyurethane tires, special lubrication oils for cold temperature applications and wheels with no lubrication. For further information on FRANTZ Manufacturing Company, 3201 West LeFevre Road, Sterling Illinois 61081 please visit: www.frantz-mfg.com.
Napoleon Engineering Expands Bearing Manufacturing Capabilities Napoleon Engineering Services (NES Bearings) have announced the expansion of their bearing manufacturing capabilities to now include back-up bearings for use with active magnetic bearings (AMB), where they serve as secondary failsafe systems. AMB are used in electrical power generation, petroleum refining,
Page: 36
gives its customers peace of mind regarding the products delivered.
machine tooling, and natural gas pipelines. Their design incorporates the use of electromagnets, which magnetically levitate rotating shafts or other moving parts. The lack of contact between the bearings and the loads they support removes
Bearing News • Issue 2
the need for lubricating systems and increases the speed at which the moving parts can operate. To ensure the success of AMB systems, a backup or auxiliary bearing must be in place to enable controlled shutdown, in case of a power or control systems failure. When using AMB to support a rotating shaft, any reduction or loss of power could cause the shaft to drop. With NES Bearings AMB back-up bearings in place, the shaft will drop 2 to 3 thousandths of an inch onto the back-up bearing system, allowing it to coast to a stop without damage to the shaft or surrounding machinery. The design of NES Bearings AMB back-up bearings incorporates specialty heat treatments, wear resistant material combinations, conventional or dry film lubricants and a variety of cage and internal design characteristics, all of which help to effectively manage the safe coast down of the rotating shaft. Notes Chris Napoleon, NES Bearings president and chief engineer, “Understanding the magnitude and distribution of radial and axial loads, rotational speeds and lubrication
Jan
23
constraints allow us to determine whether a full ball complement or caged bearing design is warranted. In some cases, standard bearings can be highly modified to meet specific application needs, resulting in manufactured AMB back-up bearings with very short lead times. Other applications require more extreme design considerations, including special heat treatment processes, yielding very stable parts with extremely low residual stress. At NES Bearings, we’ve developed and manufactured many different AMB back-up bearing solutions, in sizes ranging from 1” to 14” OD, to meet a variety of needs.” Napoleon Engineering Services is a provider of engineered bearing products, specializing in bearing inspection, bearing testing, custom bearing manufacturing and bearing test rig manufacturing. Visit www.nesbearings.com for more information.
The Gates Corporation to Introduce New 48” FlatClean™ Food Grade Belts Gates Corporation, today announced it will introduce a new version of its 48” FlatClean™ food conveying belt in 2mm and 3mm thicknesses at the 2014 International Production & Processing Expo (IPPE) in Atlanta .
Jan
27
Service Life of ACHE Fan Bearings Doubled With Innovative Composite Assembly After more than three years since the first installation, Greene, Tweed’s AFB assembly for ACHE (aircooled heat exchanger) fans remains successfully running in the field. The AFB assembly is a turn-key upgrade for the upper roller bearing on ACHE fans in refineries, chemical plants, and power generation facilities.
Historically, MTBF (mean time between failure) for these bearings is 12-20 months. Since installation of the first AFB assembly in June 2010, service life has been extended Page: 37
What Happened in the
Bearing Industry First Half of
2014
to 42 months delivering a projected
a longer service life. The result is
plant-wide savings of $3.4 million over
an overall reduction in the life cycle
five years.
cost of ACHE fans through reduced
ACHEs are a common fixture in hydrocarbon and chemical processing
maintenance, faster repair, and fewer plant shutdowns.
plants. By forcing air through a heat
Greene, Tweed installed its first AFB
exchanger with a fan, they function to
assembly in June 2010 at a major
cool essential process fluids. The roller
refinery in Texas. As of December
bearing supporting the fan shaft of
2013, it has been in service for 42
the ACHE has typically experienced
months. Subsequent installations in
a very short service life due to the
Texas and Louisiana are experiencing
harsh operating environment. And
the same success; all have been
when a bearing fails, it can cause a
running for over two years. Shafts
plant shutdown with potential losses
have varied from 2 7/16’’ to 2
of up to 25% of refining capacity. In
15/16’’, but the company states it
addition, repair requires that the fan
can accommodate any size. It can
unit be disassembled, taking two to
also fulfill rush orders in emergency
three days and costing up to $20,000
situations, with a turnaround of
per incident. Repair also poses a safety
approximately one week.
risk to personnel as they must operate heavy equipment at great heights and in high heat. Greene, Tweed’s AFB assembly was designed with the goals of simplifying the repair process and extending service life once installed. Featuring a patent-pending split design, the assembly consists of a WR®600 thermoplastic composite sleeve contained in a universal metallic housing. The split design eliminates the need to disassemble the fan unit during replacement, reducing repair time from two to three days to less than four hours. In addition,
Greene, Tweed leverages expertise in a variety of markets and products to give customers the most innovative solutions to meet performance challenges and reduce total cost of operation. With fully qualified engineering, sales and support personnel located throughout the Americas, Europe and Asia, Greene, Tweed delivers solutions to individual customer applications on a global scope. Greene, Tweed products are sold and distributed worldwide. For additional information, contact Greene, Tweed at +1.215.256.9521 or visit our website at www.gtweed.com.
the WR600 sleeve enables dry-run capability, while the non-contact bearing design minimizes wear for Page: 38
Bearing News • Issue 2
Feb
02
GGB Names Prema S.A. Distributor for Poland GGB Bearing Technology, the world’s largest producer of metal-polymer plain bearings, has appointed Prema S.A. as its authorized distributor for Poland.
Feb
05
NTN started construction of a New Plant at NTN Fukuroi Corp. NTN has been reorganizing its global production system as part of the two-year mid-term management plan “Revival 2014” that began in April 2013. Based on the ‘on local site with local materials by local personnel’ concept, NTN is expanding production overseas that are experiencing increased demand with the aim of establishing a production system that is not easily affected by exchange rates.
Feb
08
Klüber Lubrication Introduces Synthetic Rolling and Plain Bearing Greases Klüber has introduced ISOFLEX TOPAS NB 52 and ISOFLEX TOPAS NB 152, two rolling and plain bearing greases based on a synthetic hydrocarbon oil and a barium complex soap. The products are ideally suited for amusement industry applications, such as roller coaster wheel bearings, in order to optimize operational reliability, cut servicing costs, conserve energy and extend maintenance intervals.system that is not easily affected by exchange rates.
Klüber Lubrication Introduces Synthetic Rolling and Plain Bearing Greases
to water and ambient media. Both products protect against corrosion, as well as oxidation and ageing.
Klüber Lubrication, a worldwide manufacturer of specialty lubricants, has introduced ISOFLEX TOPAS NB 52 and ISOFLEX TOPAS NB 152, two rolling and plain bearing greases based on a synthetic hydrocarbon oil and a barium complex soap. The products are ideally suited for amusement industry applications, such as roller coaster wheel bearings, in order to optimize operational reliability, cut servicing costs, conserve energy and extend maintenance intervals.
ISOFLEX TOPAS NB 52 is suitable for temperatures ranging from -60°F to 250°F and short peak temperatures up to 300°F depending on the application. ISOFLEX TOPAS NB 152 can be used in a wide service temperature range of -40°F to 300°F.
The special barium-soap thickener used in the ISOFLEX TOPAS NB 52 and 152 greases offers good loadcarrying capacity, as well as resistance
ISOFLEX TOPAS NB 52 is a versatile grease for many applications, including: rolling and plain bearings subject to high speeds and loads, as well as low temperatures – ideal for road, sideguide, and up-stop wheels tooth flanks in precision gears, such as Page: 39
What Happened in the
Bearing Industry First Half of
2014
bevel gears in milling machines and electromechanical actuators for valves electric contacts and components to reduce insertion forces ISOFLEX TOPAS NB 152 is compatible with many plastics and is used primarily for medium speed rolling and plain bearings, such as coaster wheels, wheel bearings in racing cars, fan bearings and pump bearings. The grease is also suitable for plastic/ plastic or steel/plastic friction points. “Using ISOFLEX TOPAS NB 52 and ISOFLEX TOPAS NB 152 greases leads to more consistent torque over a wide temperature range as well as longer component life when exposed to water or aqueous media,” said Stephen Mazzola, director of engineering & technical services for Klüber Lubrication North America L.P. Mazzola recently conducted two training seminars on lubrication fundamentals and advanced lubrication of gears, bearings, chains at the Amusement Industry Manufacturers and Suppliers (AIMS) International Safety Seminar, Jan. 1217 in Orlando. The AIMS International Safety Seminar is a comprehensive safety-training experience for
Feb
10
individuals responsible for the care and safety of the amusement industry’s guests. About Klüber Lubrication Klüber Lubrication is one of the world’s leading manufacturers of specialty lubricants, offering high-end tribological solutions to virtually all industries and markets worldwide. Most products are developed and made to specific customer requirements. During its more than 80 years of existence, Klüber Lubrication has provided high-quality lubricants, thorough consultation and extensive services, which has earned it an excellent reputation in the market. The company holds all common industrial certifications and operates a test bay hardly rivalled in the lubricants industry. Klüber Lubrication, set up as a retail company for mineral oil products in Munich in 1929, is today part of Freudenberg Chemical Specialities KG, a Business Unit of the Freudenberg Group, Weinheim. In 2013, Klüber Lubrication has approximately 1900 employees in more than 30 countries. For further information, please visit www.klueber.com.
NTN Establishes New Company for CVJ in Hubei, China NTN Corporation has decided to establish the “Xiangyang NTN-Yulon Drivetrain Co., Ltd. ” joint venture in Xiangyang, Hubei Province, China, with the Yulon Group in Taiwan, as the third plant for the production of CVJ.
Feb
11
NES Announces Custom Bearing Services Napoleon Engineering Services recently announced their newly expanded custom bearing manufacturing services, in support of oscillating, wear and corrosive applications.
Page: 40
Bearing News • Issue 2
Feb
12
Schaeffler expands its range of innovations for all-electric and hybrid vehicles Schaeffler has developed a series of innovations that are contributing to the further development of engine start-stop systems. These include the optimisation of components in order to accommodate the significant increase in the number of start procedures, as well as solutions for start-stop systems such as non-contact sensors, optimised bearings, specially-coated components, electro-mechanical camshaft phasing units, latching valves, and components for beltdriven starter generators and permanently-engaged starters.
Feb
13
Explosion at NH ball bearings plant injures 15 people The plant, in the southwest New Hampshire town that was the inspiration for Thornton Wilder’s play “Our Town,” manufactures high-tech parts for the aerospace industry and employs 700 people.
Feb
14
Rolman World Reports 8% Market Share in the Ball Bearing Market in the MEA Region According to recent studies by Freedonia, the imports of ball bearings in the Middle East are worth a total of $240 million. As a result, and based on Rolman World’s profits, Rolman World accounts for 8% of the total market share of the ball bearing market in the Middle East.
Feb
15
Timken Company Raises Dividend by 9 Percent The Timken Company (NYSE: TKR) board of directors today declared a quarterly cash dividend of 25 cents per share, an increase of 9 percent over the previous quarterly amount.
Feb
16
Roller Bearings Tested @ NASA The crawler-transporter that will carry NASA’s Space Launch System (SLS) and Orion spacecraft to Launch Pad 39B for launch on Exploration Mission-1 in 2017 recently passed the first phase of an important milestone test at Kennedy Space Center in Florida. Another test is scheduled for November, after installation of the second set of bearings has been completed.
Feb
17
Minebea starts to provide miniature & small sized ball bearings The CAD data of miniature & small sized ball bearings are provided through Minbea online catalogue “eMinebea” with a view to respond to the needs of customers, as well as offering them further improved design efficiency.
Feb
21
Lubrication Engineers Introduce Monocal GP Grease LE Introduces Grease with Calcium Sulfonate Complex Thickener Versatile Monocal™ GP Grease Protects Equipment from Heat, Moisture & Heavy Loads Lubrication Engineers, Inc. introduces Monocal™ GP Grease (1499), a versatile general purpose lubricant for use in severe conditions such as high temperatures, heavy loads and water. It provides long-lasting reliable protection and is the right solution for industrial and mobile equipment used in a wide variety of industries, especially those in which moisture
problems are caused by high humidity, elevated operating temperatures, and severe environmental contamination. An NLGI 2 grease, Monocal GP Grease is especially effective when used on bearings operating in a warm, moist environment or in operations where a lot of water is needed to keep Page: 41
What Happened in the
Bearing Industry First Half of
2014
equipment cool. Without effective, reliable lubrication, these conditions can lead to costly downtime and repairs. Monocal GP Grease is a highperformance formula featuring highviscosity base fluid, calcium sulfonate complex thickener and Monolec®, LE’s proprietary wear-reducing additive. This premium combination imparts a very high dropping point, exceptional inherent extreme pressure characteristics, superior mechanical stability, low oil bleed, and water resistance – everything necessary to protect and extend the life of valuable equipment. LE chose to use a calcium sulfonate thickener because of its inherent ability to prevent rust and corrosion – even in sea water. It also has a very high dropping point as compared to conventional thickeners and ensures excellent mechanical stability for longlasting use. Calcium sulfonate imparts outstanding EP properties without the Page: 42
addition of heavy metals, providing protection even when pound-out conditions occur. In addition to protecting against wear, metal-to-metal contact and scoring, LE’s Monolec additive gives the grease exceptional film strength and the ability to resist oxidation and water contamination. It also helps the grease maintain consistency after repeated heating and cooling. Typical industrial applications for which LE recommends using Monocal GP Grease include many types of bearings (anti-friction, conveyor, fan, heavily loaded ball, high-speed, plain, roller element, slow-speed), forging equipment, machine tools, presses, rolling mills and rotary aerators. Automotive applications include ball joints, chassis, front axle arrangements, U-joints, and wheel bearings. Visit www.le-inc.com for more information.
Bearing News • Issue 2
Mar
09
NTN develops Low Torque Seal Ring for Automotive Transmissions NTN has developed seal rings for automotive transmissions that deliver low torque, low wear and fewer oil leaks by optimizing the plastic composite material composition, as well as incorporating a specially-shaped lubrication groove on the surface of the seal rings.
Mar
11
FEA and optimizer find the best design for a turbine bearing seal Freudenberg’s systematic approach to exploring design concepts yielded good results.The company finalized a gasket with characteristics superior to those achieved with more standard methods.
Mar
12
igus launches new Bearings Catalogue igus has launched its new Bearings Catalogue for 2014. The catalogue features more than 7,000 self-lubricating and highly wear-resistant iglidur parts and provides comprehensive details, including application examples and design specifications.
Mar
16
MTK+ expands the production range for big size spherical roller bearings MTK+ Bearing Factory have announced the expansion of the range for big size spherical roller bearings manufacturing capabilities from 1200 mm OD up to 3000 mm OD, with her recently developed design and production unit. The new design and production unit is enforcing the spherical roller bearing production line of MTK+ with the latest advanced technical capabilities and tools in order to meet the customized needs from customers; operational in the heavy industry. The achievement was developed in the recent years, by expanding the organization in East-Asia with specialized engineers and further investments in production tools in order to accelerate growth and further strengthen the organization’s ability to capture strategic opportunities. As an result for this effort, MTK+ produced recently the spherical roller bearing 240/1320CAF3/W33X.01 with the following specs:
d: 1320 mm • D: 1850 mm • B: 530 mm • Cr: 23200 kn • Cor: 63500 kn • Weight: 4420 kg MTK+ Bearings are used in many applications in a wide range of industries such as general engineering, general machinery, crane industry, steel industry, offshore industry, food industry, agriculture and mining as well as in the replacement market. The full list of the application area’s and key industries as well as the production video of the 240/1320CAF3/ W33X.01 can be seen on the website www.mtk-bearings.com
Page: 43
What Happened in the
Bearing Industry First Half of
Mar
18
2014
New plummer block housing from Schaeffler increases bearing operating life by up to 50% Schaeffler has developed a new plummer block housing for spherical rolling bearings, which increases the operating life of the bearings by up to 50% compared to conventional plummer block housings.
Mar
19
European Bearing Corporation (EPK) and Timken Sign Joint Venture Agreement The Timken Company has established a joint venture (JV) with European Bearing Corporation (EPK) aimed at serving industrial markets in Russia and the broader Commonwealth of Independent States (CIS).
Mar
21
Bearings manufacturer Lignum Vitae partners with Apex Energy Technologies Lignum Vitae North America has partnered with Apex Energy Technologies to supply and support the hydroelectric power industry with water-lubricated bearings.
Mar
22
Double ACCOLADE for Acorn Industrial Services ltd. Rotherham-based Acorn Industrial Services, one of the UK’s leading distributors of bearings, power transmission components and linear systems, has achieved two prestigious national accolades for its impressive sales growth. Firstly, the company has secured a place in the prestigious London Stock Exchange Group’s ‘1,000 companies to inspire Britain’ – one of only three companies to do so from the Rotherham area and secondly, Acorn has been recognised as an ‘Outstanding Company’ by Plimsoll Publishing, the world leading provider of market reports and company analysis. Acorn Industrial Services was selected to appear in the ‘1,000 companies to inspire Britain’ guide, as it has demonstrated positive growth in revenue over the last four years, as well as an increase in employee numbers, workspace and contract wins. The ‘1,000 companies to inspire Britain’ is produced as a reference book to highlight the importance of SMEs to the future of the UK economy.
Page: 44
The Plimsoll Publishing ‘Outstanding Company’ accolade is awarded to businesses, like Acorn Industrial, which have significantly improved their financial health, based on Plimsoll’s assessment of their overall performance and achieved continuous sales growth. Acorn Industrial Services has achieved a 50 per cent increase in turnover in the last four years and has created 25 new jobs. Martin Povey, managing director of Acorn Industrial Services Ltd, said: “It is fantastic to receive these two Bearing News • Issue 2
accolades. It has been an amazing couple of years for us, with major growth in our UK and international sales, the move to our purpose-built premises at Hellaby and the creation of a number of new jobs. To achieve national recognition from these two high profile national organisations is fantastic and is testament to the hard work and efforts of our team here in Rotherham.” (local version) Acorn Industrial Services Ltd has achieved these two prestigious accolades in the year that it completed a £1.25m investment in new 40,000 sq ft premises at Hellaby Industrial Estate. This includes relocating to premises twice the size of its previous
Mar
26
premises in order to house its £4m worth of stock, plus its head office functions. Acorn Industrial holds the most extensive stockholding in the country, with over one million items in stock, stored on eight miles of shelving. The company has 30 years’ experience in the supply of bearings, linear systems and power transmission products, delivering a fast response for local, national and international customers. For more information, visit the website at: www.acorn-ind.co.uk or call 0845 602 9946.
Shell opens first lubricant research centre in China This facility is dedicated to the research and development of lubricants and oils and applicationfor China and the wider Asia region covering countries such as India, Indonesia, South Korea, Thailand and Vietnam.Shell (Shanghai) Technology Limited will join a global network of 10 Shell R&D centres.
Mar
28
Trans-Pacific Aerospace Announces its First Sale of Spherical Bearings Trans-Pacific Aerospace is in the business of designing, engineering and manufacturing self-lubricating spherical bearings for commercial aircraft, with planned product extensions using similar proprietary technology into maritime, power plant and space applications.
Mar
29
C&U Americas Receives 2013 Quality Award from Remy International C&U Americas, LLC, the North American subsidiary of The C&U Group, one of the world’s top 10 bearing manufacturers and China’s largest bearing producer, has received the “2013 Quality Award for Excellence” from Remy International, Inc. The award was given to C&U Americas in appreciation and recognition for consistently providing superior quality parts to Remy Mexico during the 2013 business year. Remy International, Inc. presented the award to Matt Unsworth, C&U Americas Director of Sales, and Victor Lopez Navarrete, C&U Americas Regional Sales Manager, during their 2014 Annual Supplier Conference, Page: 45
What Happened in the
Bearing Industry First Half of
2014
which was held in San Luis Potosi, SLP, Mexico on February 20, 2014. “We are very excited about this prestigious award, and grateful for the opportunity to partner with Remy International, Inc.,” states Matt Unsworth. “It takes a great effort and commitment to become a valued supplier, so when you are recognized for excellence by a world leading manufacturer such as Remy, it says a lot about you and the way you do business. We are very proud of our people and their dedication in serving Remy International, Inc.” Remy International, Inc. (NASDAQ:REMY) is a leading manufacturer and remanufacturer in the automotive, heavy duty, and transportation industry. The company produces starters and alternators for light vehicle and commercial vehicle applications, locomotive products and hybrid electric motors for North America, Europe, Latin America and Asian markets. C&U Americas offers a full line of bearing types and styles for use in original equipment manufacturing, aftermarket replacement, and MRO operations. The C&U portfolio includes over 3,000 types of bearings in a wide range of specifications
Apr
01
and sizes ranging from 1.5mm inner diameter to 4000mm outer diameter. As China’s largest bearing producer, and one of the world’s top 10 bearing manufacturers, C&U utilizes the formidable production capabilities of its nine manufacturing centers, 34 bearing plants, and 22 vertically integrated component plants to produce over 2.8 million bearings per day. C&U relies on state-of-theart manufacturing and stringent QC in order to maintain its leadership position in the bearing market. C&U Bearings are precision made in advanced manufacturing facilities that are independently certified for ISO9001 Quality Management System, QS9000/VDA6.1 Quality Management System, ISO14001 Environmental Management System and SO/TS16949: 2002 Quality Management Systems. From its North American headquarters in Plymouth, Michigan, C&U Americas is able to offer its NAFTA customers exceptional value along with complete application engineering and customer service support. For more information, visit: cubearing.com or contact David Marek, C&U Americas, 45901 Five Mile Road, Plymouth, MI 48170, Tel: 734-656-0260 ex 228
Jamaica Bearings Group (JBG) Appoints Mike Matrazzo as Director of Quality Prior to his appointment at Jamaica Bearings Group (JBG), Mike Matrazzo served in the U.S. Navy as an Aviation Fuels Operations Technician, where he supervised all fuels going on board a U.S. Navy aircraft carrier. Soon after, he obtained certification as Quality Control Sentry. Other positions since filled by Matrazzo have included Manager of the Quality Department for CPI Aero, Director of Quality for Testing Machines, and Director of Quality for Seal Dynamics.
Page: 46
Bearing News • Issue 2
Apr
02
Maintenance-free bearings provide support for suspension bridge Federal-Mogul has developed maintenance-free bearings for one of the world’s longest suspension bridges. Upon completion, the Hardanger Fjord Bridge in southwest Norway will be one of the largest in the world, spanning 1,310 m (4,297 ft) between pylons.
Apr
03
Waukesha Bearings has launched its multi-lobe semi-floating (MLSF) bearings Waukesha Bearings claims that its MLSF technology improves stability and reliability compared to conventional floating ring bearings and can extend the life of host equipment and surrounding parts.
Apr
04
SKF receives 2013 Excellent Quality Supplier award from Hino Motors, a Toyota Group company SKF has received the Excellent Quality Supplier award from Hino Motors, a Toyota Group company, in recognition for zero customer complaints as a result of outstanding performance in quality in 2013. SKF has been in partnership with Hino, the leading truck manufacturer in Japan, since 2011.
Apr
07
NSK Expands Creep-Free™ Bearing Series Lineup NSK announced that it has expanded its Creep-Free™ bearing series lineup. These bearings are widely used in fan and pump motors to prevent creep.
Apr
09
Action Bearing Announces Senior Marketing Specialist Action Bearing, a Boston based bearing company catering to OEM and MRO markets throughout the world, recently promoted Bob Piracini to senior marketing specialist for its Machine Tools division.
Apr
12
Carter Manufacturing exhibits at Drives and Controls exhibition 2014 Another successful show for Carter Manufacturing at Drives and Controls exhibition 2014 held recently at the National Exhibition Centre in Birmingham. The Drives and Controls Show 2014 at Birmingham’s NEC hosted a total of 12,793 visitors, and increase of almost 15% on the previous year. Show visitors were interested by the comprehensive range of specialist bearing products on show at the Carter Manufacturing Stand. The products generated an unprecedented level of enquiries and enthusiasm, especially the newer technologies such as the OAV Air Bearings and ISISZ Split Thin Section Bearings. OAV Air Bearings have further developed a technology enabling the practical use of frictionless air bearings, an innovation displayed to great effect on the stand. No
friction means no heat so with just a bit of technological imagination the applications are almost endless. Air bearings are available as: Air Bushings, Flat Rectangular Air Page: 47
What Happened in the
Bearing Industry First Half of
2014
Bearings, Roller Air Bearings, Flat Rectangular Air Bearings, Thrust Air Bearings and Bushings, Vacuum Preloaded Air Bearings, Air Bearing Assemblies and Custom Air Bearings. Carter has to date received a large number of requests for further information as a result of the show, with air bearings, ISISZ ceramic and hybrid bearings and Silverthin thin section bearings generating the greatest interest. ISISZ ceramic and hybrid bearings are used in a multitude of applications including Ultra-low temperature, Ultra high vacuum and Cryogenic applications. This coupled with Carter’s unsurpassed technical capability in understanding severe environment applications breaks technological ground and further demonstrates Carter’s place at the forefront of research and development, sourcing and manufacture of specialist bearing products. Silverthin Precision Thin Section Bearings are often used in HiTech equipment and machinery where compact designs and ease of maintenance is key such as rotary polishing equipment, X-ray – MRI, rotary pipe cutting equipment, rotary welding equipment etc. For The Page: 48
bearing width and section (distance from bore to outside diameter) in each series remain constant regardless of the change in bore diameter. Carter Manufacturing Limited is the European Master Distributor for the Silverthin product range and carry a comprehensive stock locally in our UK warehouse. The 4 time World Record holding Drayson Racing Technology electric race-car was also a very popular attraction to the Carter stand. Inspiring both admiring glances and curiosity about the upcoming Formula E race series of 2015. As sponsor, supporter & supplier of hybrid bearings that are included in the drivetrain of the Drayson Racing car, Carter Bearings demonstrates its’ commitment to pushing the boundaries and continue to turn revolutionary ideas into motion. Carter Manufacturing Limited is reflecting on a highly successful show at the NEC with plans already afoot to exhibit at the Hannover Messe Drives and Controls Show in 2016 and the NEC Drives and Controls Exhibition in 2017. Visit www.carterbearings.co.uk for more information!
Bearing News • Issue 2
Apr
14
X-life bearings for screw drives provide 33% increase in operating life Precision bearing manufacturer Schaeffler has launched an X-life range of double row axial angular contact ball bearings for screw drives. The new optimised bearings benefit from a 10% increase in basic dynamic load rating, resulting in a 33% increase in nominal operating life.
Apr
15
Global Automotive Needle Roller Bearing Market 2014-2018 Research and Markets has announced the addition of the “Global Automotive Needle Roller Bearing Market 2014-2018” report to their offering.
Apr
19
Ceramic and Ceramic Hybrid Bearings For The Semiconductor Industry The Boca Bearing Company announces the expansion of their line of Full Ceramic and Ceramic Hybrid bearings suited for the semiconductor manufacturing industry.
Apr
25
Hepcomotion’s bearings can create linear and rotary guides for extreme temperatures Hepcomotion has introduced its off-the-shelf stainless steel linear and rotary guide solutions, which are aimed at design engineers looking to design systems for vacuum and extreme temperature environments.
May
04
NTN Develops ULTAGE Large Size Tapered Roller Bearing SKF Blohm + Voss Industries launches the Turbulo BlueMon emission monitoring system, that can record all relevant emissions on board ships in only one system. Additionally, Turbulo BlueMon couple these values with the vessel’s position data, based on GPS signals.
May
07
Emerson Bearing Expands Food Processing Division to Include Fryer Equipment Offerings Emerson Bearing, a Boston based bearing company catering to OEM (Original Equipment Manufacturers) and MRO (Maintenance, Repair and Operations) markets throughout the world, recently expanded its food processing division to include offerings for businesses that employ frying equipment.
May
11
Universal Bearings Invests $39.1 Million To Expand Its Bremen, Indiana, Manufacturing Center Universal Bearings, a manufacturer of loose needles and needle bearings, will invest $39.1 million to expand its operations in Bremen, Indiana, creating up to 78 new jobs by 2017.
May
14
PKB Receives Quality and Performance Award Pacamor Kubar Bearings (PKB) is a regular recipient of the Gold Metal for excellent quality and on-time delivery for U.S. Military Defense Programs.
May
17
Timken to Increase Prices on All Special Bar Quality Products The Timken Company announced that it will increase base prices on all special bar quality (SBQ) products by $30 per ton.
May
19
NTN Begins Mass-production of Automotive Products in Mexico NTN Corporation announces that it has decided to begin mass-production of automotive products at its new company in Mexico, “NTN MANUFACTURING DE MEXICO, S.A.DE C.V.
May
19
Winkel bearing systems from Hepcomotion are used in WTC Transportation Hub The Winkel range of high-load combined bearing systems from Hepcomotion has an ability to withstand very high radial and axial loads: a quality that has resulted in the series’ use in a project at the World Trade Center Transportation Hub. Mexico, “NTN MANUFACTURING DE MEXICO, S.A.DE C.V.
Page: 49
What Happened in the
Bearing Industry First Half of
May
22
2014
7th International NKE Distributor Conference Bearing manufacturer NKE Austria GmbH held its seventh Distributors’ Conference from the 22nd to 24th of May 2014. The conference was held in Linz, Austria and attended by 110 participants from 42 companies, 25 countries and four continents.
May
23
Trans-Pacific Aerospace Signs Letter of Intent with AVIC Harbin Bearing Company Trans-Pacific Aerospace Company, Inc., a manufacturer of spherical bearings for the commercial aerospace industry through its China-based subsidiary, is pleased to announce that it has signed a Letter of Intent with AVIC Harbin Bearing Corporation, Ltd. to form a joint venture to produce plain spherical bearings and to improve manufacturing methodology for all bearings.
May
24
Kaman to Celebrate Grand Opening of New Tooling Facility in UK With the technologically advanced facility, Kaman Tooling’s customers will benefit from quick turnaround time, efficient operations, from large size machining and inspection equipment, and an overall significantly improved process.
Jun
01
Kingsbury Announces Plans for German Manufacturing Plant Following the opening of the Kingsbury GmbH sales office in Göttingen Germany in 2012, officials at Kingsbury have announced plans to expand into manufacturing.
Jun
02
JESA exhibits at AUTOMATICA in Münich As a solution specialist in tailored bearings, often in combination with engineering polymers, JESA is exhibiting at AUTOMATICA from the 3rd to 6th June 2014, which is at the heart of technical innovations and solutions for the future.
Jun
03
Rulon Materials: New Report Reveals Consequences of Counterfeit Bearings TriStar Plastics, the leader in engineered plastic solutions, announces a free white paper to help manufacturers identify genuine Rulon® materials and avoid costly equipment failures associated with counterfeit bearings.
Jun
04
SKF Blohm + Voss Industries introduces the Turbulo BlueMon emission monitoring system SKF Blohm + Voss Industries launches the Turbulo BlueMon emission monitoring system, that can record all relevant emissions on board ships in only one system. Additionally, Turbulo BlueMon couple these values with the vessel’s position data, based on GPS signals.
Jun
05
NTN-SNR Exhibits at “UGOL ROSSII & MINING 2014
Jun
06
Change in the Executive Board of Schaeffler AG Georg F. W. Schaeffler und Maria-Elisabeth Schaeffler, sole shareholders of Schaeffler Group, have decided to appoint Klaus Rosenfeld (48) for a five-year term as Chief Executive Officer of Schaeffler AG.
Jun
09
Igus develops press-fitting tool for plain bearings with an internal diameter of 6–20mm Igus has developed a simple-to-use press-fitting tool for Iglidur plain bearings. The PT-0620, which is smaller than the original PT-1350 press-fit tool, is suitable for fitting bearings with an internal diameter of 6–20mm.
Page: 50
Bearing News • Issue 2
Jun
16
Rodriguez at the Eurosatory 2014 The Eschweiler-based drive specialist presented its product portfolio – first and foremost the Kaydon Reali-Slim® bearings at the biggest international ‘Defence and Security Exhibition’.
Jun
21
NACHI-Fujikoshi Expands Precision Bearings Product Lineup To meet the diverse needs of customers in the industrial machinery market at home and abroad, NACHI-Fujikoshi is adding two new products to its precision bearings product lineup. 1.”XY Type” Bearings for Small Ball Screws 2.”AC Type Angular Contact Ball” Bearings for Machine Tools
Expansion of Nachi Precision Bearings Product Lineup To meet t he diverse needs of customers in the industrial machinery market at home and abroad, NACHIFujikoshi is adding two new products to its precision bearings product lineup. 1. “XY Type” Bearings for Small Ball Screws (1) Market needs Small ball screws, which are used in positioning applications and conveyors for manufacturing
equipment and analysis equipment, are expected to meet a wide range of needs, from high loads to light loads, all while maintaining the accuracy of conventional bearings. As such, the performance needs of bearings that support small ball screws, such as bearings that ensure high rigidity and improved load bearing, are increasing. (2) Features of XY Type Bearings a. Improved load-bearing capabilities and longer life compared to conventional products through adoption of a large-diameter ball and optimization of the track surface.
Page: 51
What Happened in the
Bearing Industry First Half of
2014
XY Type
b. Adoption of a high-strength resin in the cage ensuring high precision and rigidity, and contributing to low-noise operation. c. Easy replacement with existing products by using the same size as standard angular contact ball bearings. 2. “AC Type Angular Contact Ball” Bearings for Machine Tools (1) Market needs With the increased demand for machine tools geared toward heavy cutting, particularly in Europe, bearings that offer a higher processing load while maintaining the highspeed performance with respect to spindle bearings for machine tools are required. (2) Features of AC Type Angular Contact Ball Bearings
Jun
23
a. Optimized contact angle of the ball and the track surface achieving approx. twice the stiffness when compared with conventional angular contact ball bearings. b. Energy-savings realized through significant reduction in frictional resistance thanks to a highly rigid design and by adopting polyamide resin material boasting excellent sliding properties. c. Ceramic ball type with a non-contact seal meets a wide variety of customer needs. 3. Sales Target The annual sales goal of precision bearings in FY2016 is set at 6 billion yen. Visit www.nachi.de for more information.
NSK will Exhibit at Hillhead 2014 in UK NSK Europe will be featuring AIP Program (Added Value Program) which uses the expertise of NSK engineers to help customers improve efficiency, reduce breakdowns and improve profitability at Hillhead 2014
Jun
25
NN, Inc. Acquires Tapered Roller Bearing Company NN, Inc. (Nasdaq: NNBR) today announced that it has acquired 79.2% of the outstanding shares of RFK Valjcici Konjic. RFK is a manufacturer of tapered roller bearings with operations in Konjic, Bosnia & Herzegovina.
Page: 52
Bearing News • Issue 2
MANAGING YOUR STRATEGY Enluse provides a full range of tools and equipment to help you manage your lubrication activities. These range from innovative solutions like 3-D bull’s-eyes and oil sight glasses to check your oil levels, to filtering systems and breather dryers to stop airborne contaminants from entering the oil. Enluse is also an authorised distributor for the Reliability Institute providing a range of online training courses.
Desiccant breathers to protect the oil
Reduce airborne contaminants
Oil Sight glasses for level control
Online Training Programs
Mobile Filtering
Reliability Institute On-line Training Courses
www.enluse.com +31 (0) 76 57 81 280
For further clarification, information or proposal for global collaboration you can contact us at: www.bearingstocks.com Just for distributors Contact : Eduardo San MartĂn Email : support@bearingstocks.com Tel : +34 948 248 303 Fax : +34 948 244 317
Page: 54
www.bearingstockshop.com Just for end consumers Contact : Gabriel Uriarte Email : support@bearingstockshop.com Tel : +34 948 248 303 Fax : +34 948 244 317
Inside The
BearingStockShop & BearingStocks
Page: 55
“In BearingStockShop industries find the bearings they need and they can choose among different quotations to reduce costs. In BearingStocks distributors are connected to a practically limitless market.� Interview with their co-founders in Pamplona, Spain
Page: 56
Inside The
BearingStockShop & BearingStocks We journeyed to Pamplona (Spain) -a small but charming city that is internationally known for its Sanfermines festivities- headquarter of BearingStocks, to interview their core team: Gabriel Uriarte (Ph.D. in Telecommunications awarded in the Stafford University) and Eduardo San Martin (Graduated in Business Administration and Management, at the Public University of Navarra and with more than 20 years of experience in the bearing industry), both of them came on board as co-founders, each bringing different talents to the organization.
What is BearingStock.com? BearingStocks (BS) is an online marketplace for bearings distributors. BS does not intervene in buying or selling. It is just a meeting place for bearings distributors who want to buy and sell.
How does BS work? ESM: Sellers register in the platform uploading their stock for free and buyers can ask for a price quote of the same reference to different sellers with just one click. This makes it easier for buyers to compare prices between sellers. Distributors receive requests for quotations by mail and they can respond on the web or using their usual channel (fax, mail, etc.).
When buying or selling through the platform, we assure our customers a professional management with each purchase because they will always have access to all the information of their inquiries, quotations and orders, photos and files they sent or received, remarks and prices used in previous quotations, etc... At the end, they can evaluate the purchase or sale; file a complaint, etc…
In addition to BearingStocks, there is another platform BearingStockShop (Bss). What is BearingStockShop.com? GU: Following the successful launch of BearingStocks, where more than 1.100 distributors from all round the World are already working, we started to receive requests from industries so we decided offering them the right channel (Bss) where they can send their inquiries and orders to BS distributors. BearingStockShop is the professional platform where industries can find the bearing they need in the stock of BS distributors.
What are the main differences with the competitors? ESM: There are two relevant differences. The first one is to give the distributors the opportunity to access to the industries’ demands. The second
Gabriel
Eduardo
“Industries do not have to pay anything to find the bearings they need and send requests for quotation to several distributors at the same time”
“Buying in BS is totally free. To sell, you can pay an annual fee or choose a flexible option and pay according to the number of inquiries you would like to open and respond” Page: 57
one is that we rate the service provided by the distributor (time used to respond, level of activity in the platform, others distributor valuation on each order, etc.) This allows us to improve the service provided in BS and give priority to the best distributors’ stock on search results.
Bearing Industries must pay to receive quotations? GU: No, they can register for free in Bss and send up to 50 requests for quotation monthly with no cost. If additional requests for quotation are required they can buy them at a very low cost. Furthermore, bearing industries have a cross references search engine with more than 115.000 entries, 570 manufacturer brochures and an Express service for emergency cases when is needed to find a bearing as quickly as possible.
How much should a Distributor pay to work in BS? ESM: Buying in BS is totally free of charge. Distributors can register and buy for free. If they also want to sell, there is an option to pay a yearly subscription which allows them working without limitations, opening all inquiries and demands of industries and other distributors; or they can choose the flexible option, and pay according to the request they want to open and respond. In both cases, uploading their inventory is free. It does not matter the stock number of lines.
You have now begun to make satisfaction surveys to evaluate orders formalized via the Platform. Could you please explain what exactly the Survey consists of? GU: I would say that, for us, the primary factor is to continually improve the quality of the service we provide, and we therefore consider very important to know the opinion and experience of users.
Page: 58
In these surveys users can rate the treatment received by their supplier or customer. Just fulfilling the satisfaction Survey they receive important benefits, i.e. discounts or free promotions for the company or for the inventory. Other members of the team are Alfonso Martinez de Lizarrondo, the analyst of computerized management systems and consultant in the information technology sector, and Cristina Barragán, the Head of Corporate Marketing.
We have seen that there are more than 2.200.000 lines of stock. We assume that being in the top will be important for Distributors. How is the result searches categorized? AM: Those companies which offer a better service and are highly valued by the rest of companies are at the top in the Ranking, and, as a result, their bearings are first on search results; and therefore they receive more inquiries and orders. Distributors who have registered recently or have not achieved good position, they can use other methods to promote their stock and appear on the top of search results.
Where do your users come from? CB: With both platforms, we have over two thousand users from nearly a hundred different countries. We are the leader online bearing platform in Latin America and also in other emergent countries like India or Turkey; and we also have a strong presence in Europe, America, Asia, Africa and Oceania. We have just started a collaboration program based on the identification of a local representative in each country who helps us improving the provided service and increasing the number of industries and distributors in both platforms.
Alfonso
Cristina
“Bearings of those companies who provide the best service are placed at the top on search results. There are also different options to promote your stock”
“We are the leading platform within the emerging countries and we are engaged in a process of international expansion looking for a suitable representative for each country” Bearing News • Issue 2
BEARING PERFORMANCE Page: 60
under Contaminated Lubrication Conditions Page: 61
Experimental and Analytical Methods for Assessing
BEARING PERFORMANCE
under Debris Contaminated Lubrication Conditions by Harvey Nixon, Thomas Springer, Michael Hoeprich, Douglas Clouse, The TIMKEN COMPANY
Debris particle contamination in lubricants has been identified as a major cause of premature bearing and gear failure, with accompanying costs in equipment downtime, warranty, and lost productivity. Various experimental and predictive methods have been developed to assist the design engineer in analysis and development of equipment that is less sensitive to such contamination. This paper provides an overview and new data comparing bearing life test results and predictive analysis methods for various tapered roller bearings operating under debris-contaminated conditions. Recent work has refined one analytical method (using a surface characterization technique), correlated this method with bearing test lives in debris conditions, and pointed to design and manufacturing modifcations in the bearings themselves, making the bearings live longer in debris-contaminated environments.
Contamination Characterization Equipment design engineers have many contaminated lubricant analysis tools to help them assess the detrimental effects of debris particles on machinery wear and by their use can monitor the resulting loss in performance [1, 2, 3, 4]. Others are aimed at understanding the material make-up and characteristics of the lubricant contamination [5]. Most of the analysis tools just mentioned are used in monitoring and understanding the evolution of Page: 62
equipment failure, as well as the level of lubricant contamination for predicative and preventative maintenance. But t hey do little in helping to evaluate the impact debris damage has on finished gear and bearing surfaces as it relates to fatigue life of their materials.
Surface Characterization Method Nixon and Cogdell developed a method for assessing the detrimental effect of debris contaminated lubrication environments [6] which is appropriately labeled Debris Sig-nature AnalysisSM. The following field study, conducted in cooperation with an equipment manufacturer, is an example of the advantage that such a surface characterization method might provide in evaluating equipment systems. The standard method for determining particle size distributions and concentration levels was used to monitor contamination levels in an actual customer field application. Bearings from these field units were then removed from service after an extended period of time and examined for debris damage both visually and by the surface characterization method in order to quantify the damage levels. Table 1 shows a few typical particle size distributions and concentrations observed through the period of service by the equipment. Figure 1 shows a typical visual appearance of some of the bearing load carrying surface after the same period of service. Bearing News • Issue 2
Page: 63Page: 63
It was quite evident in just these visual comparisons alone that the lubricant analysis did not illustrate the level of surface damage that FIGURE 1 – Micrograph of typical bearing might be expected. load carrying surface with extremely large By a comparison of dent the data in Table 1 to the damage evident by the visual appearance, it is certain that the lubricant sampling did not predict any particles much greater than 300 um in size. However, the visual comparison of dents, some on the order of 6 mm in diameter, indicates the presence of huge particles on the order of 100 times larger than the 300 um size particle from the lubricant sample. The Debris Signature AnalysisSM method was used to more accurately characterize the surface damage and indicated a 42% life reduction would be predicted. This example serves to illustrate the need for surface characterization in linking performance to contamination damage.
Product Performance Comparisons As part of the evaluation process for assessing and predicting bearing performance under conditions of debris contamination, numerous bearing life tests have been run and a standardized method to apply debris damage was used [7]. Tested bearings were predented and no additional debris was added during these tests. In Figure 2, the performance comparison for five major tapered roller bearing manufacturers Page: 64
FIGURE 2 – Life test comparison, bearing outer diameter 73 mm
is shown. This testing was previously reported [8] and was performed on what is considered to be standard product, manufactured with the conventional process common to each given manufacturer. The results within this group varied by a factor of about three with Brg A having the highest relative performance. Brg B and Brg E used through hardened material and processing, the other bearings C & D were manufactured in part or completely of case carburized components. For statistical comparison purposes, the life test results are shown bracketed with 65% confidence bands. The width of these bands is calculated based on the sample size and scatter of testing failures and is a function of the Weibull slope. When such bands overlap between test groups, no statistically significant difference in performance can be claimed at the 90% confidence level.
Testing Of Conventional Versus Special Debris Resistant Bearings Bearing News • Issue 2
Testing has also been performed with a conventional product from one manufacturer (Brg A) and special “debris resistant” products from two other manufacturers. Here the special debris resistant products were claiming up to ten times life improvement over conventional processes. Figure 3 shows the normalized results for debris damage testing with conditions identical to Figure 2. In this Brg A had life test results that slightly exceeded the results of the special bearing.
Brg A, and predicted only threshold life reduction due to debris. Under these conditions, Brg A had performance results that were equal to the results of the special bearing. Figure 5 shows the normalized results with a large, 318 mm outer diameter bearing. A different set of life testing conditions was applied (caused in part by the use of the larger test bearing) as well as new debris media and new method to apply the debris media. This resulted in moderate-to-severe debris damage. Debris Signature Analysis was ap-plied to conventional Brg A and predicted up to a 3 times life reduction. Under these conditions, Brg A had life test results that significantly exceeded the results of the special bearings.
FIGURE 3 – Life test comparison of conventional versus special “debris resistant” bearing (outer diameter 83 mm)
Figure 4 shows the normalized life test results with conditions similar to that of Figure 2, except the debris media was changed. This resulted in only light debris damage being incurred. Here Debris Signature Analysis was applied to conventional
FIGURE 5 – Life test comparison of conventional versus special “debris resistant” bearing (outer diameter 318 mm)
One conclusion from this testing is that differences in the manufacturing process, materials and metallurgical practices used in bearings produced by different manu-facturers impacts fatigue life of bearings operating in high debris environments.
Raising The Performance Level
FIGURE 4 – Life test comparison of conventional versus special “debris resistant” bearing (outer diameter 68 mm)
By studying the unique metallurgical design and processing parameters used to produce Brg A, an improved debris resistant approach was developed. The goal was to enhance the bearing mechanical properties of strength, ductility and toughness, particularly at the functional contact (raceway) surfaces. The approach included change to key design specifications and the tightening of process control limits for select parameters particularly Page: 65
during heat treat. The proprietary specification involves select parameters including material chemistry, retained austenite, microstructure, and post heat treat control of near surface properties. The performance results of this new debris resistant design and processing approach are shown in Figure 6. In this particular testing scheme the lives of two debris dented conventional baseline groups were approximately 2 to 3 times less than the predicted life with no denting. Debris Signature Analysis was applied and predicted a debris life reduction factor between 0.4 to 0.5. for these
baseline bearings. The debris resistant bearing performance was shown to be much higher than the baseline groups with its upper 65% confidence band crossing the line for predicted life with no debris damage. Thus the new debris resistant bearing negated the effects of the given debris damage and increased mean population bearing life by up to 2.3 times over the two baseline bearing groups made with conventional processing. This debris resistant bearing is currently being offered as providing up to 2 times life improvement in debris environments.
Life Prediction Model The theoretical basis for the debris life prediction tool was presented by Ai [12] wherein the effects of debris dents on raceway contact stresses and fatigue life are determined. The model was verified with controlled debris dent bearing tests using bearings with the performance characteristics represented by Brg A.
FIGURE 6 – Life test comparison of special “debris resistant” versus conventional bearing (outer diameter 248 mm)
Page: 66
Since debris in applications covers a large range of particle sizes, a program was put together to determine the effect of lubricant contamination composed of realistic particle size distributions. Two approaches were used. The first approach simulated debris particle size distributions that correlate to ISO 4406 code distributions. 52100 steel debris particle distributions for ISO 13/10, Bearing News • Issue 2
15/12, 17/14, 18/16, and 21/18 were mixed with lu-bricant and used to dent bearings as explained by Nixon [7]. As an example, Figure 7 shows the particle distributions used for the ISO 4406 21/18 and 15/12 cleanness levels. These distributions were developed from the analyses and ISO 4406 characterization of debris contaminated used oil. The dented bearing surfaces were then optically mapped to obtain dent size and surface density distributions. Thus obtaining a Debris Signature AnalysisSM profile for each of these debris conditions. Data files containing dent sizes and surface densities were stored for use by application engineers in analyzing the life of bearings which might be operating in these environments.
To determine a life reduction factor, the dent Debris Signature AnalysisSM data files are then used in the following manner. The rolling element contact loads are determined for application conditions so as to determine contact stresses and contact area. The effect of the size and number of dents on the life of the bearing in this environment can then be determined. Figure 8 shows a plot of debris life factors (a3D) for a 33 mm bore tapered roller bearing for different lubricant cleanness levels and radial loads in terms of percent C(90) rating. It can be seen that at heavy loads the effect of varying debris levels is re-duced because the net effect on the general stress level is reduced as opposed to the greater effect on modifying the general stress level at light loads. In Figure 2, it is shown that bearings made of through hardened steel can be more sensitive to debris dents than bearings made of case carburized steel. Figure 6 shows that case carburized bearings can be made even more debris resistant. Figure 9 shows the difference in model debris life factors for bearings made of these materials relative to case carburized bearings for a moderately contaminated environment. Bearings made of through hardened steel will have a somewhat lower life than case carburized bearings. As might be expected, the debris resistant bearing microstructure is seen to be more ef-fective in improving bearing life in the more contaminated environments.
FIGURE 7 – Particle size distributions for two specific ISO codes
The second approach was to obtain bearings from actual applications in the field and optically characterize the sizes and surface density of dents on these bearings for future life analyses. These were larger bearings that generally operate in more heavily contaminated conditions and cannot be adequately described by ISO 4406. Photographs of these dented surfaces can then be used by engineers to select a level of raceway surface damage typically seen in their applications. The analysis of typical life test lubricant taken from standard life test machines have shown that the base cleanness level is ISO 15/12. The debris life factor has a value of 1.0 at this cleanness level. Cleaner lubricant would provide enhanced life and lubricant with more debris would give a reduced life.
FIGURE 8 – Debris life adjustment as a function of load and various ISO codes
A significant number of debris dented bearings have been life tested in the authors’ life test machines. The correlation between the
Page: 67
Page: 68
conventional and debris resistant bearings from various manufacturers perform at significantly different levels. These differences should be considered when making comparisons concerning the relative hierarchy of product debris resistance and when applying performance prediction tools. 4) The direct measurement of damage method encompassed by Debris Signature AnalysisSM is expected to provide more precision over other approaches involving lubricant contamination analysis in quantifying damage differences.
FIGURE 9 – Relative debris life factor for bearing materials
experimentally determined reduction in life due to debris dents and the life reduction predicted by this approach is shown in Figure 10. [15] For the authors’ bearing product, this model has been shown to provide a practical connection between actual debris dents and subsequent fatigue damage.
5) Debris Signature AnalysisSM should provide a tool for comparing, in a quantifiable way, the contamination environments of successful equipment performance to those that are not successful. 6) The new life prediction model provides a practical connection between actual debris dents and subsequent fatigue damage. References 1 Anderson, D. P., “Wear Particle Atlas (Revised),” Predict/DLI, Cleveland, OH, 1995. 2 Anonymous, “Standard Test Method for Insoluble Contamination of Hydraulic Fluids by Gravimetric Analysis,” ASTM D4898-90, ASTM, W. Conshohocken, PA, 1996 3 Glaeser, W. A., “Use of Surface Analysis Techniques in the Study of Wear,” Wear, Vol. 100, No. 1-3, pp. 477-487, December 1984 4 Ives, L. K., “Electron Microscopy,” ASM Handbook, Vol. 18, Friction, Lubrication and Wear Technology, ASM International, 1995 5 Poley, J., “Oil Analysis for Monitoring Hydraulic Oil Systems, A Step-Stage Approach,” Lubrication Engineering, Vol. 46, No. 1, 1990 pp 41-47 6 Nixon, H.P., Cogdell, J. D., “Debris Signature AnalysisSM: A Method for Assessing the Detrimental Effect of Specific Debris Contaminated Lubrication Environments”, SAE Paper
Conclusions The following conclusions and observations are provided as a result of the analysis experience and experimental test results. 1) For heavily contaminated systems, lubricant analysis methods alone might not be a reliable method for linking bearing damage and the resulting field service. 2) Fatigue life testing of bearings to evaluate debris damage sensitivity, can be a useful tool to differentiate performance of products.
9814781998 7 Nixon, H.P., Zantopulos, H., Cogdell,J.D.,“A Standardized Method for Evaluating Debris Resistance of Rolling Element Bearings,” SAE Tech. Paper Series 940728, (1994) 8 Nixon, H.P., Ai, Xiaolan, Cogdell, J.D., Fox, G.P., “Assessing and Predicting the Performance of Bearings in Debris Contaminated Lubrication Environment”, SAE Paper 1999-01-2791 9 Ai, Xiaolan and Nixon, Harvey P., “Fatigue Life Reduction of Roller Bearings Due to Debris Denting: Part I – Theoretical Modeling,” Tribology Transactions, Vol. 43 (2000),2, pp. 197204 10 Ai, X., “Effects of Debris Contamination on the Fatigue Life of Roller Bearings”, 2001 All images: The Timken Company
3) Standardized life testing with debris showed that Page: 69
PROFILE ROLLERS FOR LINEAR GUIDANCE SYSTEM A specialist in tailored precision ball bearing solutions and units containing engineering polymers, JESA has been developing and manufacturing rollers for many years. Over the years, the company has consolidated its expertise and experience, and is now one of the world’s leading manufacturers of bearings. Responding to strong market demand, JESA is now launching a standard version of its roller, until now custom produced. Each parameter was analysed, redesigned and optimised, both from a geometric standpoint and at design level in order to be able to offer a standard “LRG” product line, exclusively Swiss Made and with maximum efficiency.
Page: 70
Bearing News • Issue 2
Advantages of “LRG” profile rollers Increased lifetime: When calculating the lifetime, the deformation of the outer ring is taken into account to make sure it remains as rigid as possible. The heat treatment is selected based on the end application. This treatment improves impact resistance and thus increases the lifetime of the product.
effectively from dust, with a very low friction torque. The guide rollers can be used in temperatures ranging from -35°C to +120°C. JESA rollers contain a synthetic grease with additives for high pressure (EP). The grease viscosity is suitable for a broad speed range. Hybrid bearings with Si3N4 ceramic balls can be used up to 270°C. FPM seals with other types of sealing, or even lubrication solutions for vacuum environments are also available on request. Running noise: As a result of low friction, optimized lubrication and very high precision, the “LRG” roller presents very low running noise.
Diagram of ring load distribution with two levels of rigidity [Tedric A. Harris, 2007, Advanced Concepts of Bearing Technology, CRC Taylor&Francis Group, 140]
Diagram of “Finite Element Analysis” (FEA) [Programme de simulation FEM : Ansys Workbench v15.0]
Guidance accuracy and low noise: The accuracy achieved as a result of state-of-the-art manufacturing processes leads to a significant reduction in the noise generated by the contact between the rail and the outer ring. JESA offers a suitable solution, by applying an ABEC3 tolerance class (KEA striking 0.009 mm) on the outer profile. (For comparison, the current industry standard is ABEC1 (KEA striking 0.020 mm)). This makes sure the roughness of the profile in contact is at maximum Ra: 0.3 µm. The resulting drop in the magnitude of harmonics delivers optimum guidance accuracy, low noise and the most negligible vibrations possible. Materials and sealing: JESA’S “LRG” rollers are available in steel 100Cr6 or stainless steel 1.4125. These high quality materials are manufactured in Europe. Thorough quality controls are performed on the macro- and microstructures, as well as on the inclusion cleanliness. Selected by JESA, the cage is suited to the temperature range of the polyamide family. The sealing by NBR labyrinth seal protects
Direct contact: JESA offers direct contact between its customer and the producer/designer. Moreover, all the rollers are Swiss Made. Sources: 1. Tedric A. Harris, 2007, Advanced Concepts of Bearing Technology, CRC Taylor&Francis Group, 140 2. Programme de simulation FEM : Ansys Workbench v15.0 3. Credit photo: JESA SA
About JESA JESA, founded in 1969 by Mr. Joseph Egger in Villars-sur-Glâne in the Swiss Canton of Fribourg, is currently a limited company of the POLYGENA group and employs a workforce of approximately 200 people. A specialist in bespoke precision ball bearing solutions and units containing engineering polymers, JESA has been a leading player in this market for over 40 years. With a worldwide presence through sales offices in Germany, the USA, France, Great Britain and also in China, its turnover is around 50 million Swiss francs. In 2010, JESA invested about 5 million Swiss francs in cutting-edge technology production equipment in order to continue its journey towards operational excellence. To contact JESA: Marcel Dubey Sales & Marketing Director Tel: 026/408 47 13 E-mail: marcel.dubey@jesa.com
Page: 71
BearingNews Interview with Ian Knight
Reality Revealed:
THE BEARING SILENT KILLER
The term “Bearing Reliability” is starting to become a term used in industry today, however it is generally referred to as a sub set of the term “Equipment Reliability”. It can be argued that because the bearing is the rotating core of all equipment then any cost reducing initiatives should be focused on reliability of the bearing – in other words get the bearing performance right and the equipment reliability will follow. Bottom line - the bearing starts to fail from the first minute it is put into service and in 90% of cases the damage process is not known until it is too late. In an interview with Ian Knight, Director /Owner of Enluse BV, we discused what he refers to as “The Bearing Silent Killer”.
Page: 72
Bearing News • Issue 2
1. What is your background? You could answer this in 3 words bearings, bearings and bearings. I spent over 35 years working in the bearings industry, starting at the age of 21 as a machine setter on automatic lathes at the Timken factory in Ballarat in Australia. Timken gave me the opportunity to enter the sales and marketing sphere, which is where I developed a passion for bearing service and reliability; I joined SKF in the early eighties which culminated in moving to Europe in 1989, where I joined the newly formed SKF Condition Monitoring group. This European and Global experience gave me a wide knowledge working in Marketing, Service, Reliability and Training, again with a dominant focus on bearing maintenance and reliability. In 2004 I started my own company, based out of the Netherlands, focusing on the lubrication aspect of Bearing Reliability.
2. You stated Enluse BV in 2004, what drove you to do this? A number of things - a passion for creativity, being tarred with the Entrepreneur brush and an interest in effective bearing lubrication. In 1995 whilst working as the Marketing Manager of SKF Maintenance Products, I met an Australian with great marketing foresight, called Michael Killian. Michael had developed the Oil Safe line of lubrication dispensing products. In 2003 we came into contact once again and Michael asked me if I would consider developing the Oil Safe distribution network in Europe. I loved the fully sealed concept of the Oil Safe can, not to mention the 10 different colours for effective lube identification, so it was really a no brainer to say yes. Today we are still busy with the Oil Safe distribution business as the can is a pillar of foundation in the Lubrication Reliability concept.
3. Were there events of significance in your career that drove the concept of Lubrication Reliability? Absolutely, there were 3 things of significance. First was the fact that industry – the bearing end user, had little appreciation of the effect poor lubrication practices had on bearing life and hence the thinking was why pay money for the Oil Safe system. The understanding at the end users was low, but it was
even lower with the bearing distribution network. So I needed to technically show the benefits of Oil Safe in order to succeed with Enluse. The second was an understanding of the SKF New Life Theory. In 1994 I was on a Pulp and Paper tour in Canada with three other SKF Colleagues, one of which was Professor Bo Jacobson, who presented at each of our seminars, the SKF New Life Theory. It was from Bo that I learnt about the importance of clean oil for long bearing life. And the third point was my own study or examination of over 100 replaced bearings. This I did in the period of 2008 and 2009, where the results confirmed what I knew from SKF and that was that over 60% of bearing failures or damages are lubrication related.
4. If the New Life Theory was well defined, why was the importance of lubrication slow to take hold in Industry? It did take hold very well within the OEM market sector and you can see the results of that today with cleanliness standards established by large OEM companies, Caterpillar for example. However, it has been a different story in the end user market place. In the 90’s and early 2000’s the reliability focus on plant and equipment was more the exception, rather than the rule and as the need for improved equipment reliability gained momentum, so did the understanding of the benefits of only having clean oil operating in our equipment. Companies specializing in areas of reliability and lubrication management have been pushing the concept. Organizations like filtration suppliers, oil analysis companies, hydraulic system suppliers, reliability consulting companies and lubrication and predictive maintenance service suppliers, have all played a role in promoting the concept of lubrication reliability, but we still have a long way to go. I believe if bearing supplier representatives were trained on the how clean oil effects bearing life, then the concept would have been more widely accepted.
5. Can you explain what you mean by the term, the silent killer? It has been stated that if all contaminants greater the lubrication film thickness can be removed, then the bearing can boarder on life infinity. Additionally, always maintaining a good separation of the rolling elements can have a similar Page: 73
effect. Clean oil and a correct and well maintained lubrication viscosity, will reduce the two main bearing killers - three body abrasive wear and adhesive wear. Unfortunately, this is not always the case and when it isn’t the case, the bearing starts its wearing process from day one. If a company is not applying the Lubrication Reliability principles, then this wear continues to the point where it can be then be detected by traditional predictive means and technologies, such as heat and vibration measurements and visual inspections. However, at this point it is too late to save the bearing, because it has reached the point of no return, caused by the Silent Killer – inappropriate lubrication. Refer to graphic.
6. What can be done to stop the killing process? pply the Lubrication Reliability principles. Short A of going into the details of our defined Enluse 10 Steps to Lubrication Reliability, the best answer I can give is one must ensure the application of the 6 lubrication rights. Ensuring that the Right lube is added, to the Right machine, at the Right time, in the Right quantity, in the Right condition and Page: 74
maintained in the Right condition.
7. This seems like an expensive process, can it be cost justified? Yes there is no doubt a “Best Practice” lubrication program will cost end users money, so will any other Reliability initiative for that matter, however unlike other reliability actions, eliminating the silent killing process is not something where short term results can be easily seen. The benefits are certainly there, however it needs engineers or company management to take a very pragmatic view of the processes needed to get the ROI, return on investment, results. There are case studies available showing the benefits, however I always like to show the graphic from the work Doctor MacPherson from Westland Helicopters did, relating millions of cycles to bearing fatigue failure compared to the filter rating. The bottom line of this graphic, is that the finer the filter or the cleaner the oil, the longer the bearing life. Refer to graphic.
8. How does industry start implementing a Lubrication Reliability strategy? Bearing News • Issue 2
The first step is recognizing the need and once this is agreed then it is a case of making a plan, assuming of course that management is convinced and is making the funds available for the investment. There is information available via the internet, however most companies ask a qualified supplier to assist them with their needs. These can be Lube Suppliers, Lube Service Companies, Reliability and Lubrication Consultants and in some instance MRO suppliers if they have the knowledge. The information can also come from attending a lubrication training course.
9. What are the most important milestones in starting a Lubrication Reliability strategy? There are for sure a number of milestones that any company has to pass in order to start a lubrication reliability strategy. The first is recognition of the need, followed by the plan and the plan always users as the benchmark , the six maintenance rights. These are using the right lube, in the right quantity, at the right time, in the right way, in the right condition and kept in the right condition. Certainly such things as colour coding for effective
identification, cleanliness management processes and staff knowledge are important, however consistently one asks if ingredients of the plan ensure that the six maintenance rights are catered for.
10. What does Enluse offer to help industry get started? We offer assessments. Over the years we have developed a lot of knowledge about the lubrication reliability process and it only takes us about one day working inside a plant to define what is needed to move the process to a best practice standard. Generally, when we conduct an assessment we always like to run a best practice workshop with the maintenance staff, because this not only sets the scene for what they’re about to experience, but it is also a source to gain a lot of knowledge about how the current lubrication practices are employed and managed.
11. How can the Bearing community help industry with their lubrication activities? Good question and this is one that I am often Page: 75
asked. The answer is clear, the industry can do lot. Assuming of course that the bearing community we are referring to, have the objective to make the products they sell last longer, or in other words, help customers maximize the life of the bearings they consume. I come back to the base point and that is that the bearing is the rotating core of all equipment and the majority of bearings fail because of lubrication issues, so the bearing community can directly help customers improve their equipment reliability by focusing on the lubrication reliability processes.
12. How do you see this lubrication awareness growth affecting the bearing industry? It could quite possibly be a lubrication knowledge and competence evolution. Those companies involved directly with industry and their requirements for improved reliability of their equipment, will develop a portfolio of products and confidences within the lubrication sphere. They will be seen as a logical competence partner within the lubrication sphere. Today this knowledge Page: 76
exists with specialized organizations, companies like service suppliers, consultants and lubrication suppliers, however I believe over time they will be a shift to the bearing supplier to provide this competence.
13. What can bearing organizations do to get started in this competence area? Be well trained on bearing failure analysis. A very important point is that all bearing representatives should be trained on recognizing lubrication related bearing failures. My experience is that many bearing representatives do not have this knowledge, but those that do have it, are a valuable resource in the eyes of the customer. When a representative enters the maintenance workshop he or she should be on the lookout for opportunities to evaluate component failure as this will build credibility very quickly. Recognizing bearing failure modes is now an ISO standard and our own organization have made an online failure analysis training course, based on the ISO standard. Information about this course can be accessed by following the link www.reliabilityinstitute.com
Bearing News • Issue 2
STORE IT, CLEAN IT, KEEP IT CLEAN! New oil is not necessarily clean. With our modular bulk system your oil can be both stored and cleaned to a the standard you require All systems come in the standard 10 OilSafe colours and there are many storage volumes and combinations available to meet all needs. The OilSafe dispensing system is the ideal partner of the Bulk System to achieve a Best Practice standard in Lubrication Reliability.
Coloured and Modular Bulk Storage System
An Instant Lube room
A coloured lid for every point
Retro Fitted Lube Rooms
The New Premium Pump
www.enluse.com +31 (0) 76 57 81 280
Page: 78
ZKL’S
BREAKTROUGH INTO
RAILWAY AND URBAN TRACK
TRANSPORT SEGMENT Page: 79
ZKL SUCCESFULLY BREAKS
INTO RAILWAY AN URBAN TRACK TRANSPORT SEGMENT All products are the result of a valued know-how gained through field work during the bearings´ operation or on basis of long-term tests especially in cooperation with the Railway Research Institute. Despite the demanding development process including detailed analysis of service criteria and the fulfillment of many European regulations regarding technical specification, testing conditions or lubricants selection, ZKL successfully breaks into this segment. Amongst the novelties in ZKL´s portfolio we can find the roller bearings with a new plastic cage, which meet high international standards and are suitable for regular railway service. This execution is more resistant to mechanical damage during manipulation as well as it simplifies the assemblage of a bearing on a wheelset. Another interesting item is the sealed roller bearing with plastic lubricant filling produced for RegioPartner train axles. We cannot omit the tapered roller bearings unit TBU. These axle bearings have never been produced in ZKL before. This is why ZKL had to cope not only with the product´s construction but also with the technological production process. The first in this type range was a bearing developed for a two level electrical wagon of Ceské dráhy named City Elephant which could reach a maximum speed of 140 Km/h. During the testing of the bearings an extremely high durability of at least 1 000 000 kilometers was proved. During the test the total distance covered exceeded 1 200 000 kilometers, and this without any need for service or re-
Page: 80
lubrication. With a regular maintenance, common for every track vehicle, we can count on a durability of several millions of kilometers. These bearings with a labyrinth seal and permanent plastic lubricant filling were successfully tested even for a speed up to 200 kilometers per hour. The successful milestone in the field of the urban mass transportation is the implementation of new ZKL bearings in the trolleys produced by Škoda Transportation. Within this cooperation several construction variations of the tapered roller PLC 810-15 bearing have been developed and proposed. These bearings were mounted on the trolley prototype 26T, designated for the Hungarian city of Miskolc. Deliveries of adapted type of this bearing have been realized also for the 28T trolley project for Konya, Turkey. Visit www.zkl.eu for more information.
Bearing News • Issue 2
Two websites that connect bearing Distributors & Consumers
1. Distributors Inquiries from industries (bearingstockshop) and other distributors
Bearing Stocks
bearingstocks.com
Buying is totally free! 2. Consumers Quotations from best distributors in bearingstocks.com
Bearing Stocks Shop
bearingstockshop.com
Wi-Care
Wireless Vibration and Temperature Contidion Monitoring System Case Study: Catastrophic failure avoid on a cement crusher planetary gearbox Introduction Introduction In a perfect world, the easiest solution to ensure maximum production uptime is for all industry experts to live onsite around the clock! With the aim of ensuring that dedicated experts are always in the neighborhood, I-care has developed its own condition monitoring remote diagnosis solution. Wi-care wireless condition monitoring system performs online, real-time analysis of a particular machine to predict eventual failure. The system performs the onsite data collection while certified analysts analyze your data to deliver comprehensive recommendations 24/7. This wireless and remote strategy offers cost savings over routine-based maintenance and very flexible solution for troubleshooting and monitoring. The following case study represents a typical remote analysis application of a gear defect. Default was detected in a very comfortable way for both customer and analyst: * For customer, continuous surveillance of its critical asset with low upfront investment and lower cost than manual/classic online monitoring *For analyst, continuous data (historic and change follow-up) from office without any travel or measurement time spent The world Page: 82
turns to wireless, condition monitoring too. Equipment, plant overview, Context The plant is a cement industry producing close to full capacity, established for many years in Western Europe. The Equipment is a huge cement ball mill. The suspected mechanical assembly is the gearbox and its electrical drive 1MW. Customer requests I-Care support after a suspected increase in vibration level. In order to do a close monitoring and diagnostic of the vibration on the complete assembly, the analyst decide to install Wi-care wireless system.
Analyst diagnosis and spectrum justification: Gear frequency Wi-care system is set on the gearbox and the electrical drive in a minute using magnet to cover classical vibration directions, vertical, horizontal and axial. Note on the right side of the picture the Wi-care speed sensor directly measuring with a keyphasor on
Bearing News • Issue 2
the shaft. Standard spectrum collected via Wi-care in vertical direction. Display in speed units. The dominant frequency appear at 373,9 Hz and its harmonics On a closer zoom on 373,9 Hz appears modulation at 5Hz. The amplitude is close to 4mm/sec RMS. Looking in the drawings and data sheet, we can find the gearbox specifications and calculate theoretical fault frequencies Calculate Gear mesh frequency of 373,71 Hz and its harmonics match the measured frequency of 373,9 Hz. Detected 5Hz modulation are linked to a ring defect (5.01 calculated). Amplitude trend indicate a 100% growth in a few days. Decision was taken by customer based on analyst recommendations via Wi-care measurement to start the maintenance process. Root cause of gear defect is an excessive
looseness in the gear assembly due to structural cracks. The measurements performed with Wi-care helped to plan and implement targeted maintenance successfully. Consequential damages and many month of lost production could be prevented. Wi-care product and remote diagnosis overview What it is? The Wi-care™ system is the latest wireless condition monitoring system from I-Care. The system has been designed to detect, measure and analyze the root causes of excessive levels of vibration and temperature. The Wi-care system is a cost-effective tool used to report any vibration or temperature deviation in a short time. The I-CARE team of engineers using the data from Wi-care is able to give you a condition monitoring remote diagnosis at any time 24 hours a day/7 days a week. The condition based maintenance partnership has been created to give you the chance to correct a potential problem before it occurs. The solution developed in the Wi-care system is based on a receiver connected on the internet and able to manage up to 144 transmitters, each transmitter sending vibration and temperature Page: 83
data. In order to reach long distance data transfer
installation. Wireless vibration added values result
and remote locations, the WI-care involves a range
in a more flexible system, cutting expense and labor
extender in its network. Using a web-based portal
costs on installation and maintenance of the old
to manage the system avoids any extra cost and any
wired vibration and temperature sensors. Consider
difficulties linked to software. We all know how
that you fix the sensors using extra-strong magnets
frustrating it is when you are waiting for your data
where you need them and in minutes they create
analysis and you can’t take any quick condition
a large network of real time data transmission to
based maintenance decision due to software issues.
the gateway data manger in accordance with the
www.wirelessvibration.eu
range extender. The solution created by Wi-care is
Added values? Online monitoring based on permanent wired sensors can be expensive in many applications.
very flexible and cost effective because it allows the reuse of existing piezoelectric vibration sensors and turns them into wireless vibration sensors with one action – plugging the transmitter.
Wireless monitoring with wireless vibration
Visit www.wirelessvibration.eu/added-
sensors improves the reliability of difficult-to-
values-wireless-vibration-sensor.html for more
monitor assets with quick and cost effective
information.
Page: 84
Bearing News • Issue 2
IDENTIFY AND LABEL IT! The key to ensure that the right oil and grease gets into the right machine, is to allocate for each oil and grease it’s own distinct colour. Enluse can start you on the way to implement an effective Lubrication Reliability program by making your wall mounted colour-coded lube chart. We also supply a wide range of labels to identify any lube points in your entire plant.
10 coloured labelling convention wall chart
Dispensing Labels
Fill Point Labels
Coloured and Transparent Grease Guns
Coloured Grease Nipple Protectors
www.enluse.com +31 (0) 76 57 81 280
Page: 86
TOP 20 CHINA BEARING MANUFACTURERS OF
Page: 87 Page: 87
TOP 20 Association of Chinese Bearing Industry (CBIA) announced the leading bearing manufacturers, based on statistics from 2013 of 96 major manufacturers.
Page: 88
Bearing News • Issue 2
CHINA BEARING MANUFACTURERS OF
Despite the financial crisis of 2008-2009, when there was a slowdown in the production of bearings in
China, now the Chinese bearing industry income is recovering consistently and keeps his place amongst the top three regions of the world. The production in China covers more than 70 000 types of bearings with a diameter of 0.207 mm up to 6.2 m.
Analysts believe that the turnover of bearing manufacturers in China is expected to be around 200 billion yuan in 2014. The main part will be standard bearings for general applications. At the same time, there will be a growth for high-margin and high-precision bearings, for which demand is growing. A significant part of these high-precision bearings will continue to be imported from outside China.
Page: 89
MACHINE STATUS AT A GLANCESIMPLE, STRAIGHTFORWARD AND FROM ANY LOCATION Real-time machine status information on PCs and mobile devices with ONLINE VIEW 4.0 With ONLINE VIEW 4.0, PRÜFTECHNIK Condition Monitoring presents a new server-based visualization software that provides a simple, clearly structured and live display of current machine conditions on PCs, smart phones and tablets via a dynamic web interface. ONLINE VIEW 4.0 supports all PRÜFTECHNIK online condition monitoring systems: VIBGUARD, VIBROWEB XP, VIBNODE, VIBRONET Signalmaster, VIBCONNECT RF as well as the WEARSCANNER online particle distribution counter. The software communicates via Modbus TCP. Consequently, machine condition information from the online system and data from the process control system can be recorded and displayed simultaneously. The live data is accessed via a browser-based client. All that is needed to obtain real-time data via the server is an up-to-date browser as well as a user name and a password. The server can either be installed locally on a company computer or run as a cloud application. The dynamic web interface of ONLINE VIEW 4.0 makes it possible to display machine conditions not only on a PC, but also comfortably on tablets or smart phones. The user interface features a clearly structured design. A traffic light function gives a quick overview of the current condition of the monitored assets. In case of a warning or alert, trend data is available from recent days or weeks, depending on customizable settings. This helps the user identify the rate of condition deterioration at a glance. Threshold violations can be Page: 90
acknowledged and documented on the interactive machine sitemap. These records may then be used as an alarm log. Thus, this software is an ideal tool for managers and machine operators. If used in combination with the VIBGUARD Viewer diagnosis software, in-depth analyses are also possible. Now the question of whether the machine may be operated until the next shutdown can be answered more easily. With ONLINE VIEW 4.0, PRÜFTECHNIK Condition Monitoring has broadened its extensive portfolio of condition monitoring solutions for rotating equipment. Together with its well-established portable measurement instruments, PRÜFTECHNIK provides plant operators and service providers with a large supply of measuring equipment to effectively optimize machine availability.
About PRÜFTECHNIK: The PRÜFTECHNIK group, with subsidiaries and partners in more than 70 countries worldwide, is continuing to set new standards with innovative technical developments in the sectors of laser alignment and vibration measurement technology to maximize and optimize machine and plant availability Visit www.pruftechnik.com for more information
Bearing News • Issue 2
You need to subscribe to www.bearing-news.com
BEARING INDUSTRY MAGAZINE
to read the complete digital or printed version
SUBSCRIBE HERE
FOLLOW US SOCIAL MEDIA: