New Product Info
New INA X-life Machined Needle Roller Bearing(Jan 14,2011)
Solutions for Future Trends: From Rolling Bearing for the Highest Level of Energy Efficiency to Mechatronic System.
Rolling and plain bearing solutions, linear and direct drive technology as well as mechatronic components not only for increasing efficiency and conserving resources but also for higher performance and reliability will be Schaeffler Group Industrial’s focus at this year’s Hanover Fair (Hall 22, Booth A12). Robert Schullan, President of Schaeffler Group Industrial, presented the initial highlights at the MDA Press Roundtable for the Hanover Fair 2011. He emphasized Schaeffler Group Industrial’s excellent strategic and operative position that enables the company to gain more than proportional benefit from further growth in the markets worldwide. “With our wide product range, innovative strength and position in the growth markets, we are able to shape the big future trends in our sectors – energy and energy efficiency, mechatronics, and electric mobility – and to expand the Schaeffler Group’s market position.
Needle roller bearings: Downsizing and reduced friction
Schaeffler Group Industrial’s efficient rolling bearings with optimized friction are a key component for the entire industry. Rolling bearings make an important contribution to saving energy and conserving resources and, at the same time, increase the performance and competitiveness of machines and plants. An example of the high efficiency potential of rolling bearings is the consistent further development of needle roller bearings in the form of downsizing and friction reduction. Schaeffler Group Industrial will be presenting three new INA needle roller bearing designs at the Hanover Fair 2011: the X-life machined needle roller bearing -D with higher performance for downsizing, the X-life machined needle roller bearing with the Twin Cage and reduced friction, and the slimline drawn cup needle roller bearing with a radial section height of only 1.5 mm.
The newly developed, profiled steel cage of the new X-life machined needle roller bearing -D produced by optimized forming methods gives a significantly higher load carrying capacity. The cage is designed such that both the number of needle rollers and their load-bearing length can be increased with identical bearing dimensions. As a result, the new X-life machined needle roller bearing NK 55/25-D-XL, for example, achieves a load rating that is 25% higher. This opens up new design options for downsizing. A bearing of the above size can thus achieve a load carrying capacity that previously required an X-life needle roller bearing of size NK 75/25-XL.
The new machined needle roller bearing with the Twin Cage made of plastic provides higher efficiency as a result of increased friction. Two short needle rollers can be inserted next to each other in one cage pocket instead of the otherwise usual single long needle roller. This completely new combination of cage and rolling elements achieves a significantly lower frictional torque in comparison with conventional needle roller bearings. The power loss due to friction of X-life machined needle roller bearing NK 45/20 with the new Twin Cage at 4,000 revolutions per minute is between 25 and 30 watts lower than with a conventional plastic cage. This means using only one needle roller bearing with the Twin Cage saves as much energy as is required for operating a light bulb.
The new slimline drawn cup needle roller bearings also make a significant contribution to lower friction and higher efficiency. They are the first needle roller bearings in the diameter range from 15 to 50 mm that have a radial section height of only 1.5 mm and are therefore particularly suitable for replacing plain bearings in automatic transmissions. Compared to conventional plain bearing supports, slimline drawn cup needle roller bearings reduce friction by up to 60% and simplify the adjacent construction noticeably. At the same time, the oil supply requirement in the transmission is reduced, which enables the use of a smaller oil pump, for example. This leads to a higher accuracy since the clearance is reduced and start-stop applications, for example, have a higher reliability.
Renewable energies: Water, sun and wind
Renewable energies are a strategic growth area where Schaeffler Group Industrial is positioning itself early on in order to secure and expand its market capability and competitiveness in the long term. In addition to wind power, this particularly includes solar power plants as well as wave and tidal power plants. Schaeffler Group Industrial is development partner for various projects in this area and creates the prerequisites for advancing the development and economical use of regenerative energies with application-specific expertise and innovative products.
Schaeffler Group Industrial was one of the strategic partners from the onset for one of the most promising projects in wave power technology. This enabled the British firm Pelamis Wave Power to make a decisive breakthrough in the development of wave energy converters. This breakthrough was possible due to extended performance limits in the bearing and seal technology. The Pelamis wave energy converter floats on the surface of the water like a sea serpent and is anchored to the sea bed. Gigantic steel tubes are linked together using joints and are located transverse to the crests of the waves. The upward and downward motion of the waves drives hydraulic motors that are linked to generators via hydraulic cylinders and pressure accumulators. The main steel tube structures are connected by bearing units which use a combination of different Schaeffler bearings. The working forces generated across each joint can be several hundred tons, which must be supported by the bearings.
The reliability and precision of rolling and plain bearing supports in the tracking systems of solar power plants play a decisive role in facilitating the maximum efficiency and high cost-effectiveness of these plants. Series AXS angular contact roller bearings are particularly suitable for this application. They have cylindrical rollers as rolling elements and raceways that are arranged at an angle to the bearing axis. The conical bearing rings that are reminiscent of thin disc springs are a special feature of series AXS. These special rolling bearing rings are manufactured using forming methods, which enables designs to be manufactured that are extremely lightweight and have a very high load carrying capacity. Bearing rings one millimeter thick and low radial bearing section heights facilitate especially compact types. Lightweight steel cages formed of strip material are used for bearing dimensions with a diameter of more than 250 mm. This means high load ratings are achieved and, at the same time, the bearing preload ensures high system rigidity.
Mechatronic systems in rolling bearings: Electric mobility and optimized condition monitoring
Mechatronics are becoming increasingly important for the development of innovative rolling bearing solutions. They enable the productivity, cost-effectiveness and reliability of machines to be further improved by means of increased functionality. With the newly developed rolling bearings with integrated sensors and an integrated or adjacent power supply, Schaeffler Group Industrial is offering new solutions for numerous industrial sectors. Examples are e-bikes, rail vehicles, machine tools, or condition monitoring systems for rolling bearings.
Electric mobility is becoming increasingly important not only in the automotive industry. In the two-wheel vehicle sector, electric bikes or so-called pedelecs are enjoying growing popularity. Schaeffler Group Industrial offers a torque sensor bottom bracket that, for the first time, determines the total torque from the sum of the pedal force from the left and right pedals for the comfortable control of the drive. This enables correct detection of the rider’s requirement for motor assistance depending on the riding situation and corresponding control of the power output. The new FAG torque sensor bottom bracket is characterized by the high-resolution speed signal and the accuracy of the torque sensor system. These characteristics are a prerequisite for the quality of the output signal and rapid response of the motor control system. The rider is thus provided with optimum assistance in every situation. This is associated not only with increased comfort, but also with maximum efficiency, which results in an increase of the range.
In conjunction with sealing specialist Freudenberg and lubrication expert Klüber-Lubrication, the Schaeffler Group has now developed a grease sensor incorporating an electronic evaluation system that enables the condition of the grease in the bearing to be analyzed during operation. By using this new system, it is now possible to detect any changes in the condition of the grease before any damage to the rolling bearing occurs. This means the time the grease is replaced can be precisely planned, whereby the user can decide when relubrication or replacement can occur, depending on the condition of the grease (100 percent for new to theoretically 0 percent for unusable). For this purpose, the grease sensor can be connected to an automatic lubrication system using an interface. The new grease sensor enables the switch from scheduled relubrication to relubrication according to requirements and thus to a more cost-effective use of the grease that is more beneficial to the environment.
Solutions for Future Trends: From Rolling Bearing for the Highest Level of Energy Efficiency to Mechatronic System.
Rolling and plain bearing solutions, linear and direct drive technology as well as mechatronic components not only for increasing efficiency and conserving resources but also for higher performance and reliability will be Schaeffler Group Industrial’s focus at this year’s Hanover Fair (Hall 22, Booth A12). Robert Schullan, President of Schaeffler Group Industrial, presented the initial highlights at the MDA Press Roundtable for the Hanover Fair 2011. He emphasized Schaeffler Group Industrial’s excellent strategic and operative position that enables the company to gain more than proportional benefit from further growth in the markets worldwide. “With our wide product range, innovative strength and position in the growth markets, we are able to shape the big future trends in our sectors – energy and energy efficiency, mechatronics, and electric mobility – and to expand the Schaeffler Group’s market position.
Needle roller bearings: Downsizing and reduced friction
Schaeffler Group Industrial’s efficient rolling bearings with optimized friction are a key component for the entire industry. Rolling bearings make an important contribution to saving energy and conserving resources and, at the same time, increase the performance and competitiveness of machines and plants. An example of the high efficiency potential of rolling bearings is the consistent further development of needle roller bearings in the form of downsizing and friction reduction. Schaeffler Group Industrial will be presenting three new INA needle roller bearing designs at the Hanover Fair 2011: the X-life machined needle roller bearing -D with higher performance for downsizing, the X-life machined needle roller bearing with the Twin Cage and reduced friction, and the slimline drawn cup needle roller bearing with a radial section height of only 1.5 mm.
The newly developed, profiled steel cage of the new X-life machined needle roller bearing -D produced by optimized forming methods gives a significantly higher load carrying capacity. The cage is designed such that both the number of needle rollers and their load-bearing length can be increased with identical bearing dimensions. As a result, the new X-life machined needle roller bearing NK 55/25-D-XL, for example, achieves a load rating that is 25% higher. This opens up new design options for downsizing. A bearing of the above size can thus achieve a load carrying capacity that previously required an X-life needle roller bearing of size NK 75/25-XL.
The new machined needle roller bearing with the Twin Cage made of plastic provides higher efficiency as a result of increased friction. Two short needle rollers can be inserted next to each other in one cage pocket instead of the otherwise usual single long needle roller. This completely new combination of cage and rolling elements achieves a significantly lower frictional torque in comparison with conventional needle roller bearings. The power loss due to friction of X-life machined needle roller bearing NK 45/20 with the new Twin Cage at 4,000 revolutions per minute is between 25 and 30 watts lower than with a conventional plastic cage. This means using only one needle roller bearing with the Twin Cage saves as much energy as is required for operating a light bulb.
The new slimline drawn cup needle roller bearings also make a significant contribution to lower friction and higher efficiency. They are the first needle roller bearings in the diameter range from 15 to 50 mm that have a radial section height of only 1.5 mm and are therefore particularly suitable for replacing plain bearings in automatic transmissions. Compared to conventional plain bearing supports, slimline drawn cup needle roller bearings reduce friction by up to 60% and simplify the adjacent construction noticeably. At the same time, the oil supply requirement in the transmission is reduced, which enables the use of a smaller oil pump, for example. This leads to a higher accuracy since the clearance is reduced and start-stop applications, for example, have a higher reliability.
Renewable energies: Water, sun and wind
Renewable energies are a strategic growth area where Schaeffler Group Industrial is positioning itself early on in order to secure and expand its market capability and competitiveness in the long term. In addition to wind power, this particularly includes solar power plants as well as wave and tidal power plants. Schaeffler Group Industrial is development partner for various projects in this area and creates the prerequisites for advancing the development and economical use of regenerative energies with application-specific expertise and innovative products.
Schaeffler Group Industrial was one of the strategic partners from the onset for one of the most promising projects in wave power technology. This enabled the British firm Pelamis Wave Power to make a decisive breakthrough in the development of wave energy converters. This breakthrough was possible due to extended performance limits in the bearing and seal technology. The Pelamis wave energy converter floats on the surface of the water like a sea serpent and is anchored to the sea bed. Gigantic steel tubes are linked together using joints and are located transverse to the crests of the waves. The upward and downward motion of the waves drives hydraulic motors that are linked to generators via hydraulic cylinders and pressure accumulators. The main steel tube structures are connected by bearing units which use a combination of different Schaeffler bearings. The working forces generated across each joint can be several hundred tons, which must be supported by the bearings.
The reliability and precision of rolling and plain bearing supports in the tracking systems of solar power plants play a decisive role in facilitating the maximum efficiency and high cost-effectiveness of these plants. Series AXS angular contact roller bearings are particularly suitable for this application. They have cylindrical rollers as rolling elements and raceways that are arranged at an angle to the bearing axis. The conical bearing rings that are reminiscent of thin disc springs are a special feature of series AXS. These special rolling bearing rings are manufactured using forming methods, which enables designs to be manufactured that are extremely lightweight and have a very high load carrying capacity. Bearing rings one millimeter thick and low radial bearing section heights facilitate especially compact types. Lightweight steel cages formed of strip material are used for bearing dimensions with a diameter of more than 250 mm. This means high load ratings are achieved and, at the same time, the bearing preload ensures high system rigidity.
Mechatronic systems in rolling bearings: Electric mobility and optimized condition monitoring
Mechatronics are becoming increasingly important for the development of innovative rolling bearing solutions. They enable the productivity, cost-effectiveness and reliability of machines to be further improved by means of increased functionality. With the newly developed rolling bearings with integrated sensors and an integrated or adjacent power supply, Schaeffler Group Industrial is offering new solutions for numerous industrial sectors. Examples are e-bikes, rail vehicles, machine tools, or condition monitoring systems for rolling bearings.
Electric mobility is becoming increasingly important not only in the automotive industry. In the two-wheel vehicle sector, electric bikes or so-called pedelecs are enjoying growing popularity. Schaeffler Group Industrial offers a torque sensor bottom bracket that, for the first time, determines the total torque from the sum of the pedal force from the left and right pedals for the comfortable control of the drive. This enables correct detection of the rider’s requirement for motor assistance depending on the riding situation and corresponding control of the power output. The new FAG torque sensor bottom bracket is characterized by the high-resolution speed signal and the accuracy of the torque sensor system. These characteristics are a prerequisite for the quality of the output signal and rapid response of the motor control system. The rider is thus provided with optimum assistance in every situation. This is associated not only with increased comfort, but also with maximum efficiency, which results in an increase of the range.
In conjunction with sealing specialist Freudenberg and lubrication expert Klüber-Lubrication, the Schaeffler Group has now developed a grease sensor incorporating an electronic evaluation system that enables the condition of the grease in the bearing to be analyzed during operation. By using this new system, it is now possible to detect any changes in the condition of the grease before any damage to the rolling bearing occurs. This means the time the grease is replaced can be precisely planned, whereby the user can decide when relubrication or replacement can occur, depending on the condition of the grease (100 percent for new to theoretically 0 percent for unusable). For this purpose, the grease sensor can be connected to an automatic lubrication system using an interface. The new grease sensor enables the switch from scheduled relubrication to relubrication according to requirements and thus to a more cost-effective use of the grease that is more beneficial to the environment.
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