5 years ago

MDA Technologies 4/2015

MDA Technologies 4/2015


MACHINE ELEMENTS Bearing solutions with increased efficiency and high performance Wolfgang Czarnach To meet the specific technical and economical demands of its customers, Schaeffler offers a one-stop service for electrical, mechanical and hydraulic drive technology, from bearing design and product development to manufacturing and mounting. Author: Wolfgang Czarnach Vice President, Power Transmission Sector Management, Schaeffler Technologies AG & Co. KG, Herzogenaurach, Germany Schaeffler, using the most up-to-date simulation and calculation programs developed in-house, such as Bearinx or CABA3D, enables its customers to predict the behavior of the bearings. This ability to predict and analyse the bearing behaviour, right at the design stage helps improve the performance of the bearing. The reliability gained during bearing design reduces the development time and thus the development costs. Finding solutions using calculation and simulation “Bearinx”, developed by Schaeffler, can be used to model and calculate all types of bearings, shaft systems, and even complete gearboxes. It maps the complete power flow in a gearbox, taking loads and speeds into consideration along with many other influencing factors. To provide the customer with optimum support during development various versions of Bearinx are avaialble for the customers. Long-term development partners with a license agreement can use Bearinx- VIP. The “Easy versions” are freely available online: For example, Schaeffler customers can now use the “Easy EMachine” module to calculate electric motors and generators based on their field loads. The simulation program CABA3D, also developed by Schaeffler assesses external factors like vibrations, shocks or speed ramps. This means that the movement patterns of the bearing components, the forces acting between them and the frictional power that is generated can be determined. These results allow statements to be made regarding, for example, minimum load, the risk of smearing and cage strength. 24 MDA Technologies 4/2015

MACHINE ELEMENTS Higher efficiency for mobile drives Higher efficiency simply means, improving the performance levels with increasing driving and operating speeds while at the same time reducing the fuel consumptions and CO 2 emissions. There must not be any negetive effect on the operational safety and longevity of the machine. When specifying bearing solutions for mobile drives high performance density, reduced friction and heat, exceptional wear behavior and low negative noise levels are the key points. Schaeffler provides solutions for applications in both mechanical and hydraulic transmissions units. Optimization of hydraulic units With respect to hydraulic units in mobile machines, improved efficiency can be achieved by reducing the fuel consumption. This can be done if the adjustable hydraulic units are controlled in an optimum manner and are equipped with low-friction, energysaving sliding and rolling contacts. For good controllability of excavators or road construction equipment, a bearing support is required, which allows low actuating forces and breakaway torques as well as high actuator accelerations. The LSGS matched bearing/cage system has been developed specifically for hydraulic units and provides precision, highly dynamic adjustment of the volume flow, even under high pressures, irrespective of high vibrations. In axial piston motors, the tapered roller bearing is the central bearing. It must support very high radial and axial forces in small spaces. The frictional torque of conventional tapered roller bearings increases sharply, particularly with increasing axial loads. The basic dynamic load rating of FAG tapered roller bearings in X-life quality is up to 20 % higher, the nominal operating life up to 70 % longer and the frictional torque is up to 50 % less than standard products. Optimization of mechanical transmission units In mechanical transmission units, it is important not just to focus on increasing the efficiency, but also on reducing the overall space requirement of the system. This requires early collaboration with customers in order to assess the whole system. For example: Cage bearings are used for high speeds and radial accelerations, while full complement planetary bearings are used for high loads and low speeds. The rolling elements run directly in the bore of the planet gears, which means the bearings only require a small radial design envelope. Since these bearings have the largest possible number of rolling elements, they have extremely high radial load carrying capacity, high rigidity and are suitable for compact designs. Higher efficiency for stationary drives: Small electric motors are very common in all sorts of industries. Significant reductions in energy costs can be made with FAG Generation C deep groove ball bearings. The internal friction in this type of bearing is reduced by 35 % compared to conventional deep groove ball bearings. As Worldwide success story in two words: Turkish Machinery Do you know Turkishmachinery sector exports its products to 200 different countries worldwide? Do you know more than 60% of the machinery export made by Turkey goes to EU andthe US? Do you know more than 5.000 establishments in Turkey operate in machinery sector? Do you know Turkey is the 6th largest machinery manufacturer of the entire Europe? 01 02 FAG cylindrical roller bearing with cage 02 Do you know R&D investments of Turkish machinery sector has doubled in the last 10 years? Hall 18 -Stand A08 01 Double row, full complement INA cylindrical roller with black-oxide coating Stand 2035 MDA Technologies 4/2015 25 Turkish-Machinery-Englisch.indd 1 27.08.2015 08:49:05