schaeffler group: press kit hanover fair 2011 · press release page 1 schaeffler group industrial...

Hanover Fair 2011

Press Kit

Content

Needle roller bearings: More efficiency due to downsizing and less friction ____________________________________________________________________

Pure efficiency in premium quality: New FAG tapered roller bearing X-life combines lower friction with improved performance ____________________________________________________________________

Calculating energy efficiency: BEARINX®-online Easy Friction for calculating the friction of rolling bearings ____________________________________________________________________

Online monitoring of greases in rolling bearings ____________________________________________________________________

Innovative Solutions for Reducing Life Cycle Cost ____________________________________________________________________

System know-how and solutions for all bearing positions ____________________________________________________________________

Challenging engineering for the rotor bearing supports of multi-megawatt wind turbines ____________________________________________________________________

Tracking the sun with precision ____________________________________________________________________

Plain bearings – no maintenance and high load carrying capacity, even under extreme conditions ____________________________________________________________________

Schaeffler’s solutions expertise enables major engineering breakthrough in wave power technology ____________________________________________________________________

Train Support System with Generator Sensor Bearing ____________________________________________________________________

Assistance on demand: Precise control makes e-bikes more attractive ____________________________________________________________________

Axial Angular Contact Roller Bearings with Integrated Electromechanical Brake ____________________________________________________________________

Handling and Gantry Robot Systems from INA Linear Technology Save Time and Costs

Press Release

Page 1

Schaeffler Group Industrial at the HMI 2011 (Hall 22, Booth A12)

Needle roller bearings: More efficiency due to downsizing and

less friction

HANOVER/SCHWEINFURT, April 5, 2011. Efficient rolling bearings with optimized

friction characteristics from Schaeffler Group Industrial 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 INA 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.

X-life needle roller bearings -D: Efficiency due to downsizing

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 the number of needle rollers and

the needle roller length can be increased with identical bearing dimensions. The

larger number of rolling elements and the extension of their load-bearing length

result in a load rating increase of up to 25 percent for new X-life needle roller

bearings -D. This means that bearings installed in the same mounting space can be

subjected to significantly higher loads. Viewed another way, the new X-life needle

roller bearings -D open up new design options for downsizing, i.e. a reduction in the

size of machines and units while maintaining the same performance. For example:

The new X-life needle roller bearing NK20/16-D-XL with a bore diameter of 20 mm

and a width of 16 mm surpasses the load carrying capacity of the X-life needle roller

bearing NK26/16-XL with a bore diameter of 26 mm. If the new bearing is used for

downsizing, the section height of the bearing is reduced by 15 %, the weight by

20 % and the friction by 30 % while maintaining the same load carrying capacity.

In addition to presenting the needle roller bearing NK20/16-D-XL, Schaeffler Group

Industrial will present the NK55/25-D-XL at the Hanover Fair 2011. Three further

sizes will follow during the course of 2011: NK14/16-D-XL, NK28/16-D-XL and

NK37/20-D-XL. A large number of radial needle roller bearings are covered by

downsizing alternatives with these five X-life-types, i.e. the enveloping circle

diameter range from 14 to 70 mm.

X-life needle roller bearing TWin Cage: 25 % less friction

The new machined needle roller bearing with the TWin Cage made of plastic

provides higher efficiency as a result of lower 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 reduces the friction by up to 25 percent in comparison with conventional

needle roller bearings. For example: The power loss due to friction of X-life

machined needle roller bearing NK45/20-TV-XL 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. This is also

associated with reduced heat generation in the bearing which results in a longer

grease operating life and therefore longer lubrication intervals. In addition, the

accuracy of the application is improved due to reduced differences in temperature.

The kinematic characteristics of the bearing are also improved due to the optimum

load distribution on both rows of needle rollers. Test series have shown that

bearings with the TWin Cage have a significantly increased operating life.

Slimline drawn cup needle roller bearings: Less friction and simpler design

The new slimline drawn cup needle roller bearings also make a significant

contribution to lower friction and higher efficiency. Their radial section height is only

1.5 mm. This is an absolute peak value in the diameter range between 15 and 50

mm. This means that slimline drawn cup needle roller bearings are identical to plain

bearings in terms of their outside dimensions and are particularly suitable for

replacing plain bearings in automotive automatic transmissions. Slimline drawn cup

needle roller bearings are also advantageous because they reduce friction by up to

60 % compared to conventional plain bearing supports. In addition, slimline drawn

cup needle roller bearings simplify the adjacent construction and increase accuracy

and reliability.

Plain bearings in automatic transmissions must always receive a direct and

adequate supply of oil from inside the transmission for reliable operation. This

causes significant outlay during machining of the shaft because this must be

provided with horizontal and vertical holes for the oil feed. In contrast, a fine oil mist

is absolutely sufficient for reliable operation of slimline drawn cup needle roller

bearings. Complex oil feed systems are no longer required and the oil pump can be

designed smaller at the same time. A load-bearing lubricant film is no longer

necessary for reliable operation of the bearing. The reduced frictional torque of a

rolling bearing compared to a sliding layer also results in reduced breakaway torque

during starting. This means that slimline drawn cup needle roller bearings offer

higher operational reliability, for example, in start-stop applications. In addition, the

transmission oil is not contaminated by fine wear debris from the sliding layer of the

plain bearing. The oil therefore remains cleaner if slimline drawn cup needle roller

bearings are used. However, the accuracy also increases at the same time because

the bearing clearance on the shaft also increases due to abrasion in the plain

bearing. The constant high accuracy of a drawn cup needle roller bearing also

contributes to reduced clearance of the gear teeth and therefore to increased

reliability and a longer operating life of the transmission.

Photos: Schaeffler Group

Schaeffler Group Industrial will be presenting three new INA needle roller bearing

designs for higher performance and lower friction at the Hanover Fair 2011:

The X-life machined needle roller bearing -D for downsizing with more and longer

needle rollers and higher performance,

the X-life machined needle roller bearing with the TWin Cage and reduced friction,

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and the slimline drawn cup needle roller bearing with a radial section height of only

1.5 mm.

Downsizing: The new X-life needle roller bearing NK20/16-D-XL with a bore

diameter of 20 mm and a width of 16 mm surpasses the load carrying capacity of the

X-life needle roller bearing NK26/16-XL with a bore diameter of 26 mm. If the new

bearing is used for downsizing, the section height of the bearing is reduced by 15 %,

the weight by 20 % and the friction by 30 % while maintaining the same load

carrying capacity.

Contact/s: Martin Adelhardt Schaeffler Technologies GmbH & Co. KG Director of Communication Schaeffler Group Industrial Georg-Schaefer-Strasse 30 97421 Schweinfurt, Germany Phone: +49 9721 91-3400 Cell phone: +49 172 8820421 [email protected] Please send a specimen copy.

Press Release

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Pure efficiencyin premium quality: New FAG tapered roller

bearing X-life combines lower friction with improved

performance

HANOVER/SCHWEINFURT, April 5, 2011. Schaeffler Group Industrial is now

offering the world’s widest range of high-performance tapered roller bearings with its

FAG tapered roller bearing series in X-life quality. This product range includes sizes

previously not available on the market in this premium quality. FAG tapered roller

bearings in X-life quality achieve a reduction in frictional torque of up to 75 %

compared with conventional standard products. The dynamic load rating, which is

the load carrying capacity of the bearing, has been increased by 20 % and thus the

basic rating life has been increased by up to 70 %. This means these new tapered

roller bearings provide a significant improvement in energy efficiency. They can also

be used for improving performance and therefore for downsizing, which offers

further advantages in terms of design envelope, mass, and friction. Furthermore,

they make a considerable contribution towards reducing outlay and operating,

servicing and maintenance costs when considering the total cost of ownership

(TCO). Schaeffler Group Industrial is presenting these new X-life tapered roller

bearing series at the Hannover Messe 2011 for the first time (hall 22, booth A12).

Particular attention was paid during the further development of this bearing type to

the highest-possible level of reliability and minimal friction in applications that place

high demands in terms of load and accuracy. Thus, manufacturers of hydraulic units

or gearboxes (pinion bearing supports) such as those found in wind turbines,

agricultural and construction machinery or stationary machines can now surpass

previous performance limits and significantly improve operational safety at the same

time. These new X-life tapered roller bearings are currently available in sizes with an

outside diameter of up to 635 mm. Bearing sizes of 1600 mm and above will be

available at the end of 2011. The majority of applications are covered by this range

of sizes. Bearing types for wind turbine gearboxes and rotor bearing supports in

particular are incorporated into this portfolio that will offer X-life products in future

that set the benchmark in the sector in terms of performance capacity, operating life

and friction.

The geometry, surfaces, materials and dimensional and running accuracy of these

new X-life tapered roller bearings has been revised. This has resulted in an increase

in basic dynamic load ratings of up to 20 percent and thus the basic rating life of

around 70 percent. The alloy of the premium material, which has been specially

adapted to meet the requirements of the rolling bearings, is an important factor for

these increases. The fine grain of the structure of this material leads to high

toughness and therefore to high resistance to solid particles. In addition, a

logarithmic profile was developed for the raceways and the outside surface of the

rollers, which compensates stress peaks under high loads and any skewing that

may occur. An elasto-hydrodynamic lubricant film is formed even at very low speeds

due to the optimized surfaces. This enables the bearings to be subject to high loads

from the very beginning of operation. Furthermore, significantly reduced dimensional

and geometrical tolerances ensure optimum load distribution. Stress peaks are

therefore avoided, which reduces material loading.

The frictional torque of the new X-life tapered roller bearings has been reduced by

up to 75 % compared with conventional products. This is due to high dimensional

and running accuracy in conjunction with an improved surface topography. The

additionally revised contact geometry of inner ring rib and roller end face also has

lower friction characteristics. The new X-life tapered roller bearings are therefore not

only considerably more economical. The operating temperature in the bearing is

also lower, which in turn, places significantly less strain on the lubricant. This

enables maintenance intervals to be extended and the tapered roller bearings

operate with significantly less noise.


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Schaeffler Group Industrial is now offering the world’s widest range of high-

performance tapered roller bearings with its FAG tapered roller bearing series in X-

life quality.

Rei

bung

[Nm

]

Belastung [kN]

Standard-Design

X-life

The frictional torque of the new X-life tapered roller bearings has been reduced by

up to 75 % compared with conventional products.

Amongst others, FAG tapered roller bearings in X-life quality are used in hydraulic

units, for example in tractors and construction machinery. The improved

characteristics of these bearings mean the performance of the gearbox is improved

while the design envelope remains the same.

Contact: Martin Adelhardt Schaeffler Technologies GmbH & Co. KG Director of Communication Schaeffler Group Industrial Georg-Schäfer-Strasse 30 97421Schweinfurt, Germany Tel.: +49 9721 91-3400 Mobil: +49 172 8820421 [email protected] Please send a specimen copy.

Press Release

Page 1


Calculating energy efficiency: BEARINX®-online Easy Friction for

calculating the friction of rolling bearings

HANOVER/SCHWEINFURT, April 5, 2011. The Schaeffler Group’s improved

calculation and simulation program BEARINX®, which now includes a new function

for calculating friction, will be available to customers and users online and free of

charge as of mid-2011. The new BEARINX®-online Easy Friction module enables

users to calculate the energy efficiency of different bearing arrangements in

applications. This means the highest-possible potential for savings in the system can

be identified, even early on in the design phase. This is a prerequisite for using

bearings with reduced friction characteristics in an optimal manner, or for increasing

the energy efficiency of applications even further by means of downsizing. This

procedure takes the internal load distribution with the contact pressures on the

raceways and ribs with the actual rolling element profiles into consideration. The

new module is based on a friction calculation theory that is based on physical

algorithms that have been confirmed by a series of comprehensive values from tests.

Furthermore, bearing life is also calculated according to ISO/TS 16281.

Self-explanatory menu navigation – simple data input

Users can pre-register now at this address: http://BEARINX-online-easy-

friction.schaeffler.com. Users then receive notification via email as soon as the

program becomes available. It will be possible to carry out online calculations as of

mid-2011 after initial registration. The self-explanatory menu navigation enables

users to enter data quickly and easily for modeling, selecting bearings, and

operating conditions. The bearing arrangement for the elastic shaft system can

either be modeled with a locating/ non-locating bearing support or as an adjusted

bearing arrangement. The geometric data of INA and FAG rolling bearings is easily

loaded from an integrated database. The user enters the operating data such as the

loads on the shaft system, the shaft speed, the internal clearance class and axial

preload of the rolling bearings. Details about lubrication and cleanliness complete

the data entered into the system. Furthermore, any saved files can be exchanged

with Schaeffler’s Engineering Service in order to produce an optimum bearing

design. Powerful servers at Schaeffler then perform the actual calculation. The most

important results are displayed immediately in a results window. In addition, the

input data and the calculation results are documented in a PDF file.

http://bearinx-online-easy-friction.schaeffler.com/

http://bearinx-online-easy-friction.schaeffler.com/

Calculating friction with BEARINX®

Until now, there were essentially only two means of calculating the friction of rolling

bearings – the catalog method and highly-specialized multi-body simulation

programs (MBS programs). The catalog method uses an empirical approach that

enables calculations to be performed quickly using low model accuracy. The MBS

programs on the other hand have a very high model accuracy that also requires

longer calculation times. The Schaeffler Group’s new method based on physical

attributes offers both short calculation times and high model accuracy. It considers a

large variety of influencing factors such as actually occurring stress distribution and

internal bearing geometry. In addition to load distribution and rating life, the system

also enables users to calculate the frictional torques of rolling bearings and thus the

power loss of entire shaft systems or transmissions. This means it is possible to

select a bearing concept with optimized friction characteristics early on during the

product development phase.

The new friction calculation considers both rolling friction and sliding friction in solid

body, mixed and fluid friction. Elastohydrodynamic theory (EHD) is at the core of the

friction calculation. It deals with the formation of a lubricant film in the contact points

of bodies under high loads when rolling at high speeds. The theory includes the

formation of a hydrodynamic lubricant film and elastic deformation of the contact

bodies. Every single contact in the bearing is analyzed, since stress, sliding speed,

viscosity, and temperature are not constant over the contact surface of a contact. All

frictional forces on the discreet points of the contact surface are then available in the

calculation results.


Calculating the load distribution of a needle roller bearing with BEARINX®: Even the

contact pressure on every single rolling element is considered in the calculation.

Menu: Self-explanatory menu navigation and simple data input

Stribeck curve

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Elasto-hydrodynamic (EHD) contact

Contact: Martin Adelhardt Schaeffler Technologies GmbH & Co. KG Director of Communication Schaeffler Group Industrial Georg-Schäfer-Straße 30 97421Schweinfurt, Germany Tel.: +49 9721 91-3400 Mobil: +49 172 8820421 [email protected] Please send a specimen copy.

mailto:[email protected]

Press Release

Page 1


Online monitoring of greases in rolling bearings

HANOVER/SCHWEINFURT, April 5, 2011. In conjunction with Freudenberg

Dichtungs- und Schwingungstechnik GmbH & Co. KG and lubrication experts Klüber

Lubrication München KG, Schaeffler Group Industrial has developed a grease

sensor incorporating an electronic evaluation system that enables the condition of

grease in bearings to be analyzed during operation. This enables the schedule for

replacing the grease to be precisely planned and any changes in the condition of the

grease to be detected, long before any damage to the rolling bearing occurs. This

means in future, grease will be replaced while taking actual requirements into

consideration and not according to defined time periods. This reduces outlay and

costs and is also beneficial to the environment and resources. Downtimes that are

attributed to operational disturbances are reduced as well as costs for lubricants,

maintenance and replacement parts. At the same time, the degree of utilization and

efficiency of machinery increases.

Grease operating life is the decisive factor in maintenance

The grease operating life is the decisive value during preventive maintenance if it is

shorter than the bearing life. In this case, bearings are usually relubricated halfway

through the so-called grease operating life. The great disadvantage of this

procedure is that absolutely nothing is known about the condition of the grease. Up

to now, users could only receive information about the grease in bearings by taking

samples and undertaking costly and time-consuming analyses of these samples in a

laboratory.

Process development with Fraunhofer Institut ENAS

The grease sensor now enables the condition of the lubricant to be analyzed

immediately during bearing operation. The optical near-infrared reflection method is

used here. The process, developed in conjunction with the Fraunhofer Institut for

Electronic Nano Systems (ENAS) in Chemnitz, Germany, is based on the infrared

process used in laboratories to measure grease quality and was adapted for online

measurements in rolling bearings. The know-how involved is not only in the setup of

the sensor, rather in particular in the evaluation of the measured signals. The grease

undergoes rotationally symmetrical irradiation with certain wavelengths from the

sensor. The sensor head is embedded in the lubricant during this procedure. The

reflected light is measured perpendicular to the grease. This enables shadow effects

and surface inhomogeneities to be completely excluded. The reflected light is

evaluated in terms of the quality of the grease. Power is supplied and signals

transmitted from the sensor to the evaluation cable by means of a cable. A wireless

solution can also be provided if required.

Four grease parameters can be detected using the sensor: Water content,

cloudiness, wear (thermal or mechanical wear) and temperature. An analog signal (4

– 20 mA) is generated from these parameters in the electronic evaluation system,

which displays the condition of the grease quickly and simply. A digital signal can be

generated that indicates poor/good grease quality by setting a trigger threshold (limit

value).

This measurement method can be used for around 95 percent of greases available

on the market. Schaeffler, Freudenberg, and Klüber have validated the method for a

wide variety of greases. The online evaluation of the condition of the grease enables

users to draw conclusions about any changes that may suddenly occur and, due to

the digital signal, quickly react to them. Options for optimizing the design and

selection of the rolling bearing also quickly become apparent by using the method.


Basic setup and function of the grease sensor

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The grease sensor and electronic evaluation system enable changes in the

condition of the grease to be detected long before damage occurs to the rolling

bearing.

Principle setup of the optical sensor head.

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The output analog signal quickly informs the user about the condition of the grease.

Contact: Martin Adelhardt Schaeffler Technologies GmbH & Co. KG Head of Communication Schaeffler Gruppe Industral Georg-Schäfer-Straße 30 97421Schweinfurt, Germany Tel.: +49 9721 91-3400 Mobil: +49 172 8820421 [email protected] Please send a specimen copy.


Press release

Page 1

Schaeffler Group Industrial Aftermarket at the HMI 2011

Innovative Solutions for Reducing Life Cycle Cost

HANOVER/SCHWEINFURT, April 5, 2011. At this year’s Hanover Fair from 4 - 8

April, the Industrial Aftermarket division will present itself at the Schaeffler Group

Industrial booth (Hall 22, Booth A12) as a provider of innovative solutions for

industry. The portfolio of showcased products will comprise both novel maintenance

products – such as the FAG SmartCheck – and industry specific solutions that

combine proven bearing and service products to achieve an optimized machine and

plant availability. To enable companies to develop a consistent Total Cost of

Ownership strategy, a comprehensive analysis of all costs related to the life cycle of

rotating machine elements forms a central element of all solutions.

FAG SmartCheck: The Innovation on the Monitoring Market

FAG SmartCheck is a new and innovative measuring system for real time monitoring

of machines and plants. Due to its very attractive price/performance ratio, online

monitoring of small, redundant or non-redundant units becomes cost-efficient for the

first time. Examples include electric motors, pumps, compressors, ventilators, fans

and gearboxes. FAG SmartCheck uses novel technologies and trend-setting

functions, making a valuable contribution to optimizing processes and thus reducing

Life Cycle Cost (LCC) and Total Cost of Ownership (TCO). In spite of its wide range

of functions and features, the FAG SmartCheck is very easy to operate, requiring no

expert knowledge. The scope of delivery includes a number of parameter templates

which make the system ready for use immediately. Fundamental operating functions

can be carried out by pressing keys, and alarms are visualized by LEDs in the

housing.

FAG SmartCheck – a different kind of sensor

At first glance, FAG SmartCheck resembles a classic vibration sensor. But FAG

SmartCheck can do much more than conventional measuring devices. In spite of its

small size of about 44 mm x 58 mm x 45 mm, the intelligent system records not only

the standard parameters – vibration and temperature – but also other operating

parameters such as pressure or flow rate. This provides a broad basis of information

which permits experts to make a very accurate assessment of a machine’s condition

that contribute to optimizing processes and reducing LCC. LCC include, apart from

acquisition costs, the operating and maintenance costs throughout a machine’s

entire service life. Customers increasingly demand that manufacturers guarantee the

LCC to them. This is only possible if manufacturers know the LCC or can assess

them as accurately as possible. This becomes feasible by the new FAG

SmartCheck. It already offers numerous options that future machine monitoring

schemes cannot be imagined without.

Fields of application and commissioning

Typical fields of application of the FAG SmartCheck include electric motors, pumps,

compressors, ventilators, fans and gearboxes. The compact, cost-efficient system

can be installed very easily at the machine to be monitored and is immediately

operational. It comes with a set of parameters that permit a reliable general

monitoring of machines. In addition, more than 20 predefined parameter templates

for monitoring, for example, imbalance, alignment errors, rolling bearings, fans and

gearings are available. Users who wish to use the parameter templates may access

the integrated bearing database. The templates can be adapted easily to specific

monitoring tasks with the help of assistants. At customers’ requests, the Schaeffler

Group defines additional user specific parameter templates and makes them

available to the user.

Data storage, visualization and analysis

The system’s alarm thresholds are adjusted automatically thanks to a patented self-

learning mode. After commissioning, the FAG SmartCheck works autonomously.

The relevant machine parameters are recorded and saved continuously in the

system. In this way a substantial database of history data is created over time.

Users can access the FAG SmartCheck’s web server via a standard Internet

browser to configurate the system and visualize the latest data in real time. The

recorded data can be retrieved directly and easily via the FAG SmartCheck’s

Ethernet interface and analyzed using the analysis software that is included in the

scope of delivery.

Flexible and expandable

The new FAG SmartCheck offers many different expansion options. Both the

number of sensors and the level of system integration can be adapted, depending

on customers’ specific requirements. If, for example, a user wishes to include

additional parameters into the analysis, the recorded data can also – instead of

being retrieved locally at the machine itself – be transmitted to a control unit or

control station via TCP/IP or user specific RS 485 protocols. Moreover, users can

retrieve and analyze data from other locations via remote link.

Unique service

The Schaeffler Group offers a unique range of services for FAG SmartCheck users

– from initial training courses to expert support during the introduction stage and in

diagnosis related questions to customized service contracts including remote

monitoring. The various services were developed – like the product itself – on the

basis of an exact knowledge of customers’ requirements. So they offer far more than

the usual type of after sales service and always aim to optimize plants and

processes while helping to minimize the LCC and TCO of machines and plants.

Solutions for the Paper Industry

Rolling bearings in the dry section have to fulfill special characteristics. Self-aligning

FAG cylindrical roller bearings offer significant advantages in comparison with the

normal non-locating bearing arrangements with spherical roller bearings. They

enable e.g. large changes in the axial length of the dryer roll compensated without

constraint and angular misalignment, an optimum lubrication and they are easy to

mount. Self-aligning cylindrical roller bearings, when combined with a plummer block

housing that is rigidly screw mounted to the machine frame, have favourable

vibration behaviour and thus provide the conditions for higher speed. The ideal

solution for monitoring the optimum vibration behaviour of a paper machine is the

online monitoring system FAG VibroCheck. It detects signs of imbalance,

misalignment, rolling bearing damage and gearing problems at an early stage,

enabling operators to avoid unscheduled shutdowns of machines and plants.

Solutions for the Raw Material Extraction and Processing Industry

A combined exhibit – consisting of an FAG spherical roller bearing, the online

monitoring system FAG ProCheck and the automatic lubricator FAG Motion Guard

CHAMPION – will showcase an example of an integrated plant concept in the raw

material extraction and processing industry. To achieve a long rolling bearing

service life, all factors – from the selection of a suitable bearing to permanent

monitoring of the bearing’s condition to the selection and best possible supply with

the optimum lubricant – are of great importance.

A further highlight of the Industrial Aftermarket: The Continuous Caster Bearing

Program (CoCaB Program), a rolling bearing program perfectly tailored to the

requirements of continuous casting plants. It comprises full-complement FAG

cylindrical roller bearings as well as open and sealed FAG branded spherical roller

bearings for strand guide rolls, and INA needle roller bearings for the rolls in the

upper segments of continuous casting machines. Split FAG spherical roller bearings

and split INA cylindrical roller bearings are available for installation in driven rolls.

Special FAG bearing housings with circulating cooling water complete the bearing

program.


FAG SmartCheck

FAG cylindrical roller bearings for strand guide rolls.

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Spherical roller bearings for vibrating screens, E1, X-life,

Martin Adelhardt

Schaeffler Technologies GmbH & Co. KG Head of Communication Schaeffler Group Industrial Georg-Schaefer-Strasse 30 97421Schweinfurt Tel.: +49 9721 91-3400 Mobil: +49 172 8820421 [email protected] Voucher copy requested.

Contact: Sabine Drescher FAG Industrial Services GmbH Marketing Industrial Aftermarket Kaiserstrasse 100 52134 Herzogenrath Tel. +49 (0)2407 9149-78 Fax +49 (0)2407 9149-59 E-Mail: [email protected]



Press Release

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System know-how and solutions for all bearing positions

HANOVER/SCHWEINFURT, April 5, 2011. Schaeffler Group Industrial's Wind

Power Business Unit with the INA and FAG product brands has more than 30 years

of experience in the development and manufacture of rolling bearings for wind

turbines and is considered an important development partner for all wind turbine and

wind turbine gearbox manufacturers worldwide. The range comprises considerably

more than innovative rolling bearing solutions. It covers the entire process chain

from design and prototype phase up to volume production readiness. Customers are

supported with calculation and simulation tools for turbine design and specialists for

rolling bearing mounting or tribology. Product and engineering know-how as well as

consultation services and a close development partnership with the customer reduce

development times and increase the level of quality, reliability and cost-

effectiveness.

Consultation, production and service available locally around the world

In addition to corporate development and application engineering departments, the

Schaeffler Group has highly qualified, specialized external sales engineers who

provide comprehensive advice to customers on site. The manufacturing locations for

wind power bearings are also in close proximity to customers around the world: The

Group’s modern large size bearing plants are in Germany and Romania, but also in

China, India and USA.

The Schaeffler Group is the only manufacturer worldwide with solutions for all

bearing positions in the rotor shaft, gearbox and generator, as well as for wind

tracking and blade adjustment. There is currently at least one Schaeffler part fitted in

around half of the wind turbines installed around the world. Manufacturers rely on

this know-how when it comes to designing, developing and optimizing wind turbines

or components. Detailed attention is paid to all customer requirements as early as

the project planning phase. In this way, Schaeffler Group Industrial contributes to

keeping the operating costs of wind turbines low.

High-performance bearing concepts for rotor shafts

The rolling bearings for rotor shaft bearing supports are subjected to highly-dynamic

loads and operating conditions. Schaeffler Group Industrial develops solutions for

rotor bearing supports for all modern wind turbine variants from 220 kW up to the

current multi-megawatt class. The different concepts range from the “classic” 3-point

shaft bearing support and hub bearing support up to the 2-point shaft bearing

support or single bearing concept. Bearing housings calculated according to state-

of-the-art methods ensure optimal support of forces and moments. Current

innovations are e.g. a combination of tapered roller and cylindrical roller bearings

with angular adjustment facility which allows particularly narrow axial guidance of the

rotor shaft, and radial spherical roller bearings in X-life quality, which are now also

offered in typical bearing sizes with a sheet steel cage instead of the conventional

solid brass cage.

The right bearing support for every gearbox

The bearing technology in wind turbine gearboxes is faced with the challenges

posed by highly-dynamic forces with extreme peak and minimum loads, sudden

alternating loads and also varying operating temperatures. The Schaeffler Group

offers bearings with high static safety and reliable dynamic design. Current

examples are the tube roller bearing with tube rollers that allow the bearing to rotate

without slippage under all load conditions, and the high-capacity bearing that

enables high load ratings and low friction due to a newly developed cage geometry.

Wind tracking and blade adjustment

Wind turbines must be aligned to the wind conditions. The tower and the rotor

blades are adjusted so that they make optimal use of the wind conditions and are

not subject to excessive loads that could cause damage. Tower and blade

adjustment are therefore significant prerequisites for cost-effective operation of wind

turbines. Schaeffler Group Industrial develops and manufactures slewing rings with

an outside diameter of up to 4,000 millimeters for applications for wind tracking of

the nacelle and adjustment of the rotor blades in wind turbines with up to 5.0 MW

output.

Condition monitoring

In addition, Schaeffler Industrial Aftermarket offers a large range of solutions for the

condition monitoring of wind turbines. This means that the planning of maintenance

intervals during operation can be improved, unplanned downtimes can be prevented

and therefore costs can be significantly reduced. FAG DTECT X1 s and FAG WiPro

s are two compact online systems for carrying out reliable and continuous vibration

diagnosis on machines. A combination of oil and vibration monitoring is possible with

the newly presented oil sensor, the FAG wear debris monitor. This enables damage,

e.g. in gearboxes, to be detected at a very early stage and the origin within the unit

to be determined precisely. Wind turbine operators therefore obtain more

comprehensive protection for gearboxes allowing unplanned stoppages to be

prevented and maintenance costs to be minimized.


Spherical roller and cylindrical roller bearings with an angular adjustment facility

from Schaeffler Group Industrial enable particularly narrow axial guidance of the

rotor shaft. This means that shaft displacements and the effects of vibrations can be

significantly reduced.

The three tube rollers allow the tube roller bearing to rotate without slippage under

all load conditions.

Page 3

Higher load rating, reduced friction and simplified mounting: The streamlined sheet

steel cage provides space for at least one additional rolling element in the bearing.

In cooperation with manufacturers, the Schaeffler Group develops innovative blade

bearings for precise, dynamic and continuous adjustment of each individual blade

depending on the rotor position, the wind conditions and the operating condition.

Mounting a double row tapered roller bearing.

Page 4

Contact/s: Martin Adelhardt Schaeffler Technologies GmbH & Co. KG Director of Communication Schaeffler Group Industrial Georg-Schaefer-Strasse 30 97421 Schweinfurt, Germany Phone: +49 9721 91-3400 Cell phone:+49 172 8820421 [email protected] Please send a specimen copy.

Press Release

Page 1

Schaeffler Group Industrial at Hanover Fair 2011 (Hall 22, Booth A12)

Challenging engineering for the rotor bearing supports of multi-

megawatt wind turbines

HANOVER/SCHWEINFURT, April 5, 2011. With rotor bearing supports designed to

requirements, Schaeffler Group Industrial offers a bearing support concept that

makes the use of multi-megawatt wind turbines more reliable and efficient both

onshore and offshore. Engineering is carried out with the Schaeffler Group’s

advanced rolling bearing calculation program that combines the advantages of the

finite element method (FEM) with the existing features of BEARINX. This makes it

possible to not only evaluate selected load conditions, but to assess all relevant,

critical load conditions very precisely. The use of moment bearing supports in so-

called single bearing concepts enables a high level of system integration and results

in particularly compact and less complex wind turbine designs. The preloaded

bearing also prevents the transfer of negative axial loads to the drive train.

A trend towards compact single bearing concepts

The trend towards large multi-megawatt turbines that are used particularly in

offshore wind farms is also changing bearing support concepts for wind turbines.

Single bearing concepts in particular are gaining importance. With this concept, the

rotor is only supported by a single double-row tapered roller bearing – a so-called

moment bearing – in a back-to-back arrangement that supports all forces and

moments. This single bearing concept can take different forms, for example, with a

shaft and gearbox as well as a high-speed generator, as a hybrid solution with

shortened gearbox and medium-speed generator or as a direct drive without a

gearbox.

Single bearing concepts always result in very compact designs. Irrespective of the

extent to which the idea of system integration is implemented in the concept – the

options range right up to concepts in which the nacelle is fully integrated in the

bearing-gearbox-generator unit – it is possible to eliminate components and thus

reduce weight. This means that the head weight is reduced, smaller foundations can

be used and the logistics are simplified.

This bearing support also has the advantage that preloaded tapered roller bearings

can be used that prevent axial clearance and small axial displacements. This narrow

guidance of the rotor shaft means less movements act on the system and the

negative effects on the gearbox and generator are reduced.

Evaluation of all load conditions

Schaeffler Group Industrial has already implemented many single bearing solutions,

for example, for 5-MW offshore turbines. The engineering for these bearing variants

is especially challenging because standard tools cannot be used for the design and

calculation of the rating life. The Schaeffler Group has, therefore, expanded its

rolling bearing calculation program BEARINX to include elastic influences that are

calculated using the finite element method (FEM). The calculation program can now

analyze bearings including the influences of housings not just for selected load

cases. Instead, around 250 classified load cases are evaluated taking all elasticities

into account so that an optimal design can be produced that takes almost all critical

load conditions into consideration. The results of the FEM calculations for the

housing are transferred to a rigidity matrix and entered in the BEARINX calculation.

This rigidity matrix represents not only the elasticities at individual bearing positions,

but also the influences of the elasticities from one bearing position to another. The

BEARINX system is therefore able to carry out complete rating life calculations

based on the load distribution and taking elasticities into account. This means the

Schaeffler Group has a unique calculation program for designing rotor bearing

supports for multi-megawatt turbines.

The Schaeffler Group supplies moment bearing supports that are individually

designed for the respective turbine type. They are available with classic steel pin

cages or alternatively with plastic segment cages. The material used in plastic cages

is PEEK, a high-strength plastic that has low wear characteristics, low weight and

can support high forces. The plastic segment cage reduces friction and increases

the efficiency of the turbine. The new cage type not only improves the guidance of

the rolling elements, but also enables optimization of the lubricant supply. Moment

bearings can also have integrated anti-corrosion protection that is achieved by

applying a zinc flame-sprayed surface and multi-layer painting. Special hardening

processes enable customized material characteristics for integrated functions, for

example, seals or connections to the adjacent construction.


Single bearing concepts with preloaded moment bearing supports prevent the

transfer of negative axial loads to the drive train and allow a high level of system

integration.

Assembly of a moment bearing: Double-row tapered roller bearing in an O

arrangement.

Hardening a moment bearing: Material characteristics, processing and coating

increase reliability, rating life and safety, e.g. due to anti-corrosion protection.

Page 3

There is a noticeable and significant trend towards single bearing concepts with

moment bearing supports for multi-megawatt turbines.

Contact/s: Martin Adelhardt Schaeffler Technologies GmbH & Co. KG Director of Communication Schaeffler Group Industrial Georg-Schaefer-Strasse 30 97421Schweinfurt Tel.: +49 9721 91-3400 Cell phone: +49 172 8820421 [email protected] Please send a specimen copy.


Press Release

Page 1


Tracking the sun with precision

HANOVER/SCHWEINFURT, April 5, 2011. Tracking systems for solar power plants

must fulfill two very different requirements. On the one hand, robust and compact

drives that can withstand all weather conditions are required that are resistant to

rough environmental conditions such as those created by extreme differences in

temperature, aridness, dust and high winds. On the other, reliability and precision

play a decisive role in facilitating the maximum efficiency and high cost-effectiveness

of the plant. Alongside its varied product range of rolling and plain bearings,

Schaeffler Group Industrial and its brands INA and FAG now supplies the new axial

angular contact roller bearing AXS for drive solutions in solar power plants. The new

bearing type is especially suitable for tracking systems of solar power plants from

both a technical and economic perspective. The option of integrating AXS angular

contact roller bearings in existing and new designs leads to optimum solutions that

always meet requirements.

Lightweight, compact, high load carrying capacity

Series AXS angular contact roller bearings 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. These methods require special manufacturing expertise, which the

Schaeffler Group has been using for several years on a very wide range of products.

Consistent use of forming technology 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. The roller and cage assemblies are comprised of cylindrical rollers that are

snapped into high-rigidity plastic cages with very close spacing. Lightweight steel

cages formed of strip material are used for bearing dimensions of > 250mm. This

means high load ratings are achieved and, at the same time, the high bearing

preload ensures high system rigidity.

Tracking systems: Precision, safety and cost-effectiveness

In the case of tracking systems for solar power plants, high load carrying capacity

and rigidity as well as a small cross-section play a particularly decisive role. These

characteristics ensure high flexibility in the design and facilitate compact, reliable,

and cost-effective gearboxes. The high load carrying capacity of the AXS bearing

means the high loads generated by the mirrors and high winds are securely

supported. On the other hand, the clearance-free setting of the bearings and the

high rigidity of the entire system create a particularly smooth bearing support without

vibrations. This enables the power plant to track the sun more evenly and also

results in higher positioning accuracy. The bearing support’s precision and

robustness contribute decisively to achieving maximum efficiency and high cost-

effectiveness in a plant.

AXS bearings are very easy to mount securely. The geometry of the bearing rings is

identical, which means they cannot be mixed up during fitting. Simple, turned

bearing seats are sufficient for supporting the bearing rings manufactured using

forming methods. In addition, special lubricants (both grease and oil can be used)

mean the bearing supports have particularly low maintenance requirements.

Other applications

Series AXS bearings are also used successfully in medical technology. They make a

convincing case in the ceiling stands of operating rooms as they smoothly position

the medical equipment without stick-slip. The large center clearance of the bearings

means supply lines, which cannot be installed on the floor in operating rooms, can

easily be fed through them. AXS bearings also open up new opportunities for

compact and cost-effective designs in the hand axes of painting robots. The low

mass of the bearings and large diameter facilitate lightweight designs with high load

carrying capacity while offering a large space for the paint hoses to pass through.


Axial angular contact roller bearing AXS for precise, reliable and cost-effective drive

solutions in the tracking systems of solar power plants.

Tracking systems for photovoltaic plants.

Contact/s: Martin Adelhardt Schaeffler Technologies GmbH & Co. KG Director of Communication Schaeffler Group Industrial Georg-Schaefer-Strasse 30 97421Schweinfurt Tel.: +49 9721 91-3400 Cell phone: +49 172 8820421 [email protected] Please send a specimen copy.


Press Release

Page 1


Plain bearings – no maintenance and high load carrying capacity,

even under extreme conditions

HANOVER/SCHWEINFURT, April 5, 2011. Renewable energy applications are ideal

for plain bearings in several ways. Plain bearings demonstrate their advantages in

solar and hydro power in particular, since these applications often involve conditions

requiring slow swiveling movements with high loads. In addition, plain bearings are

highly suitable for operation in media such as water and are also suitable for dry

running. Schaeffler Group Industrial has systematically expanded its range of plain

bearing solutions. In addition to the ELGOGLIDE plain bearings that have proven

themselves for several years, the product range also includes metal-polymer

composite plain bearings as well as the newly-developed ELGOTEX plain bearings.

ELGOTEX – suitable for dry running and resistant to corrosive media

Our new ELGOTEX plain bearings are particularly suitable for dry running

applications subject to high loads and vibrations. The combination of materials

means that ELGOTEX bearings are resistant to corrosive media and facilitates a

constant low friction value with low wear and absolute freedom from maintenance.

These bearings have a high radial load carrying capacity, can be used for axial

movements and they are insensitive to shocks and edge stresses. They are not

sealed, but can be supplied with internal seals for protection against abrasive

contamination if required.

The material comprises two layers that are wound onto each other. The internal

sliding layer, which is embedded in a resin matrix with fillers and solid lubricants, is

made of synthetic and PFTE fibers. The external layer comprises continuous glass

fibers (glass filament) in epoxy resin. A specific winding angle of the glass fibers

stabilizes the layer thereby significantly increasing the strength of the bush.

ELGOTEX plain bearings are available with bore diameters ranging from 20 and

1200 millimeters as standard, outer diameters ranging from 24 and 1400 millimeters

as well as widths from 15 to 2000 millimeters. Special dimensions deviating from

these standard dimensions are available on request.

Metal-polymer composite – cost-effective within the smallest space

In addition to ELGOTEX plain bearings, Schaeffler Group Industrial has brought a

new metal-polymer composite plain bearing onto the market under its INA brand. Its

special features are created by combining metal and plastic. This material

compound enables low-wear sliding characteristics as well as a high load carrying

capacity and thermal conductivity. Its high resistance to moisture means this product

can also be used in water or other media. The metal-polymer composite bearings

are a cost-effective alternative for applications with minimum available space and a

comparatively high sliding speed. The plain bearings are available as bushes and

flanged bushes, as well as thrust washers and strips. The excellent material

formability also enables customer-specific components to be designed for various

rotary, linear and swivel motions.

ELGOGLIDE – proven quality with the highest requirements

Maintenance-free ELGOGLIDE spherical plain bearings and rod ends have been the

standard in “classic” hydropower applications for several years. The advantages of

these bearings are the total freedom from maintenance and very high load carrying

capacity, especially in the case of very high loads on one side and swiveling motion.

ELGOGLIDE stands for a sliding layer that essentially comprises a technical woven

material comprising support fibers and Teflon fibers and a synthetic resin matrix.

The textile woven fabric is soaked in synthetic resin and attached by adhesive to the

precision-manufactured steel body of the outer ring or bush. After a thermal

hardening process, a fully-meshed thermoset is generated in which the woven

material is embedded. Despite being only 0.5 millimeters thick, the finished product

has exceptional performance characteristics and absolute freedom from

maintenance.


No maintenance and resistant to corrosion: ELGOTEX wound bushes

ELGOTEX: The material combination generates a constant low friction value with

low wear for the entire operating life.

INA metal-polymer composite bearings: Plain bushes for rotary and linear

movements and thrust washers for supporting axial loads.

Page 3

Maintenance-free spherical plain bearing with ELGOGLIDE coating: The sliding

layer provides total freedom from maintenance, high load carrying capacity and

maximum reliability, even after long periods without movement.

Contact/s: Martin Adelhardt Schaeffler Technologies GmbH & Co. KG Communications Schaeffler Group Industrial Georg-Schaefer-Strasse 30 97421Schweinfurt Tel.: +49 9721 91-3400 Cell phone: +49 172 8820421 [email protected] Please send a specimen copy.


Press Release

Page 1


Schaeffler’s solutions expertise enables major engineering

breakthrough in wave power technology

HANOVER/SCHWEINFURT, April 5, 2011. The Scottish company, Pelamis Wave

Power Ltd. has achieved a decisive breakthrough in the development of a new

generation of wave energy converters thanks to close collaboration with the

Schaeffler Group. By pushing the boundaries of bearing and seal technology and by

thinking ‘outside the box’, a new renewable energy solution has been made possible

by the cooperation of two companies both keen to leave a long term legacy of clean

energy.

The bearings and seals in the new P2 model make a decisive contribution to the

success of this wave energy converter. The main steel tube structures are

connected by main bearing units which use a combination of different bearings from

INA and FAG. Each of the main joints has four pivoting hydraulic rams. Mike Woods,

senior engineer and bearings group leader at Pelamis, explains: “Our biggest

challenge has always been how we manage the loads and motions from such an

active and constantly variable environment, whilst at the same time extracting as

much power as possible. The working forces generated across each joint can be

several hundred tons, which can present huge problems for the bearings as they

have to take up the reactive forces coming back through the joints.”

The first P1 wave energy converter was a simpler design which had separated

hinged joints. Although this allowed useful working space between the axes, it had

to carry high transferred loads and was unable to manage the combined motions

necessary for the P2 configuration. Also, the bearings themselves were relatively

high friction making the system less energy efficient.

Woods continues “Our engineering team had been trying to work out a way of

overcoming this problem and eventually came up with the idea of bringing the axes,

or joints, together. However, this meant a completely new bearing solution which

was able to manage combined angles in a single package, so Pelamis engineers

turned to the Schaeffler Group for help and support. Key to the success of this new

joint concept was a new low friction material designed and developed in-house by

Schaeffler engineers. This modified PTFE fabric liner is a member of the Elgoglide®

family with low friction characteristics that has effectively eliminated the problem of

“stick-slip”. This has allowed the operating envelope of the machine to be extended

beyond the capabilities allowed by standard bearing materials.

“Now that we have been able to put all the bearings in one place, we have taken a

major technological step forward. As well as being a much more efficient bearing

mechanism, the new design is a self-contained, modular bearing unit. It is a bit like

being able to take an engine out of a car in one go; it allows us to improve our

inspection procedures and reduce our exposure to technological risk. Schaeffler has

been with us every step of the way and has provided us with an extremely capable,

enthusiastic and knowledgeable team of specialists to work with us on our ever-

evolving application. We are constantly reviewing and developing the design of the

machine, and on a number of occasions we have had to reject the current design

and start again. What has surprised us is the commitment and willingness of the

Schaeffler specialists to cooperate in what has been a remarkably productive

dialogue for both companies” emphasizes Mike Woods.

The development of the P2 wave energy converter is a big step forward for Pelamis.

“We are very excited about the P2,” says Pelamis’ Business Development Director,

Max Carcas. “The first unit, ordered by Eon, is now nearing completion and will be

fully tested in the spring of next year, but we have already received major interest

and potential further orders from leading utility companies – a first for a wave power

project anywhere in the world. We are constantly striving to drive down costs whilst

at the same time increasing energy capture, and by working with a supplier such as

Schaeffler, we are confident that we will be able to achieve our goals.”

Pelamis Wave Power has been working on the development of economically viable

and environmentally-friendly solutions for generating electric power from wave

energy for more than ten years. With strength of innovation, continuous research

and development work as well as a willingness to question existing technical

knowledge, Pelamis has made the seemingly impossible, possible – namely

continuous energy production in the active and constantly variable environment of

the high seas. The company built the world’s first offshore wave energy converter in

2004. The P2 model was developed using this experience, and exceeds its

predecessor with regard to performance and cost-efficiency.


Using ocean waves as a source of renewable energy: Schaeffler Group Industrial is

development partner for the Pelamis wage energy converter. Each main structure is

connected by means of bearing units that are subject to permanently changing loads

of up to several hundred tons. (Source: Pelamis Wave Power)

Contact/s: Martin Adelhardt Schaeffler Technologies GmbH & Co. KG Communications Schaeffler Group Industrial Georg-Schaefer-Strasse 30 97421Schweinfurt Tel.: +49 9721 91-3400 Cell phone: +49 172 8820421 [email protected] Please send a specimen copy.


Press Release

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Train Support System with Generator Sensor Bearing

HANOVER/SCHWEINFURT, April 5, 2011. The Schaeffler Group has developed a

Train Support System based on a generator sensor bearing. This new on-board unit

enables information about the condition of the bearing, axlebox and rails to be

recorded and transmitted to a higher-level control system via a wireless system such

as a cell phone network. The analyzed data can be used not only as a basis for

maintenance but also for positioning and location monitoring and even for optimizing

logistics. The potential of the development project, which was awarded the

“Intelligence for Transportation and Logistics” innovation award in 2010, is currently

being verified with customers and will subsequently be put into volume production.

From rolling bearing to on-board unit

The TSS is based on an FAG axlebox bearing that can be used with an integrated

generator sensor unit as an independent energy source, for example, in freight cars.

Comparable with a dynamo, the generator sensor bearing induces the electrical

power required through the rotary motion of the permanent magnets arranged on the

wheel axle. This produces an independent and self-sufficient source of energy that

means the system provides additional functions such as recognizing switch positions

and operating sensors by means of an energy store. The Schaeffler Group has now

further developed the GSB for the Train Support System by including an intelligent

electronic system making it a so-called “on-board unit” that is now linked to a higher-

level information management system. This means the signals are not only recorded

and pre-processed in the bearing but also transmitted to a wireless interface.

It has not been possible to develop such “on-board units” in the past, especially in

the railway freight sector. Information and data can only be provided by means of a

self-sufficient and independent energy supply system. This has only become

available due to the development of the generator sensor bearing by Schaeffler.

This major innovation for transport and logistics has been created by linking self-

sufficient power generation in the generator sensor bearing and the sensor data with

the relevant on-board units and the higher-level information and control system.

Thus, the Train Support System represents an important step towards creating a

railway guidance system. For example, there are plans for it to be integrated in the

European Train Control System (ETCS) designed for European rail traffic. In

addition to collecting data and therefore localizing individual freight cars, this system

checks the entire logistics chain.


The Train Support System is based on an FAG axlebox bearing from the Schaeffler

Group that can be used with an integrated generator sensor unit as an independent

energy source, for example, in freight cars. Schaeffler engineers developed the

electronics and software for the system and integrated them in the bearing, thus

forming an on-board unit.

Signals are recorded in the generator sensor bearing, pre-processed and

transmitted to a central computer via a wireless system. The evaluated data are the

basis for the use of railway supervision systems as well as online time-table

generation, routing, process and risk analysis or position determination.

Page 2

Contact: Martin Adelhardt Schaeffler Technologies GmbH & Co. KG Director of Communication Schaeffler Gruppe Industrial Georg-Schäfer-Straße 30 97421Schweinfurt, Germany Tel.: +49 9721 91-3400 Mobil: +49 172 8820421 [email protected] Please send a specimen copy.


Press release

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FAG Torque Sensor Bottom Bracket for Increased Comfort and Efficiency

Assistance on demand:

Precise control makes e-bikes more attractive

HANOVER/SCHWEINFURT, April 5, 2011. Schaeffler Group Industrial is extending

its range of bottom bracket units for e-bikes with a newly-developed torque and

speed sensor bottom bracket under its FAG brand. The total torque from the sum of

the pedal force from the left and right pedals is determined for the first time. The new

FAG torque sensor bottom bracket is used, among other applications, in the new

high-performance drive from Bosch.

Correct detection of the rider’s requirement for motor assistance depending on the

riding situation and corresponding control of the power output are decisive factors

for a positive riding feel on e-bikes. Besides the direction of rotation and speed,

measurement of the exact torque produced by the rider during pedaling is a

prerequisite for precisely determining the additional power requirement. The

additional drive power provided by the electric motor is controlled principally by the

torque sensor system in the bottom bracket. The rider no longer needs to provide

additional “pedal power”.

Increased comfort, improved range

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. The drive characteristics of the

new Bosch drive can be programmed and matched to the type of bicycle in up to

four levels – eco, tour, sport and speed. A degree of assistance up to 250 percent

(speed) is available depending on the mode and assistance level.

Two different non-contact measuring methods are used in the compact bottom

bracket unit. The speed and direction of rotation are measured by a Hall effect

sensor, while torque measurement is carried out by means of a magneto-elastic

method. The measurement range is between 0 and 90 Nm with an accuracy of up to

one percent. Up to 300 Nm is optionally available in professional applications, for

example, for performance measurement on racing bicycles. Additional applications

are ergometers in the fitness or rehabilitation sectors.

Smooth running due to FAG Generation C ball bearings

Like all bottom bracket units from FAG, the new torque sensor bottom bracket is

characterized by its excellent smooth running characteristics. This has been

facilitated by an optimized bearing arrangement and the use of the newly-developed

FAG Generation C deep groove ball bearings, which have around 30 percent less

friction compared with previous models. Numerous components in the area of the

shaft are also coated with Corrotect® corrosion protection developed by Schaeffler.

Pictures: Schaeffler Group

Page 2

The newly-developed FAG torque and speed sensor bottom bracket makes e-bikes

even more comfortable to ride and more efficient. The bearing determines the total

torque from the sum of the pedal force from the left and right pedals.

Contact: Martin Adelhardt Schaeffler Technologies GmbH & Co. KG Communication Schaeffler Group Industrial Georg-Schäfer-Straße 30 97421Schweinfurt Tel.: +49 9721 91-3400 Cell phone:+49 172 8820421 [email protected] Please send a specimen copy.


Press release

Page 1

CompaMed 2010: Smooth Movement or Secure Location – According to Requirements

Axial Angular Contact Roller Bearings with Integrated

Electromechanical Brake

HANOVER/SCHWEINFURT, April 5, 2011. Schaeffler Group Industrial has

developed a new, particularly compact and lightweight bearing support featuring an

electromechanical brake. The new ZAXB bearing unit is particularly suitable for the

reliable fixing and smooth positioning of ceiling mounts in operating rooms. The

incorporated AXS angular contact roller bearing can support high axial loads and

tilting moments. This ensures that the numerous medical devices as well as

computers and screens can be reliably brought to their optimal ergonomic positions.

The electromechanical brake enables their secure location. Compared to

conventional systems with separately attached brake, the unit is much lighter and

more compact. At the same time, it is a closed system, which means that there is

less exposure to aggressive disinfectants which could damage the materials used.

Ceiling mounts in operating rooms must reliably support a growing number of ever

heavier devices, whilst at the same time allowing their quiet and vibration-free

positioning. Classic mechanical components play a “supporting” role in this context.

The bearings must exhibit high static load safety and tilting rigidity in the smallest-

possible installation space. At the same time, their inside diameter should be

relatively large to allow the supply lines and cables to pass through easily.

The new unit with integrated brake comprises an outer ring with fixing thread, an

inner ring with coil and pressure springs, an adjusting nut with fixing thread, an

anchor plate with axial movement facility and a lining plate that is connected to the

outer ring as well as two double direction axial angular contact roller bearings in an

O arrangement. As a result of the O arrangement and the contact angle of 60

degrees, the bearing unit has high load-carrying capacity and exhibits significant

radial stiffness. The bearing rings and adjusting nut are precision-turned parts made

from high-strength steel, while the axial roller and cage assemblies and axial bearing

washers are manufactured using non-machining methods.

The integrated brake prevents the bearing unit from rotating when the current is

turned off since the anchor plate is pressed against the brake lining by springs. Thus

the ceiling mount is safely fixed. When current is supplied, an electromagnet pulls

the anchor plate against the springs and releases the brake lining so that the unit

can rotate and be brought smoothly into another position.

In addition to ceiling mounts, the bearing unit with integrated brake is also suitable

for use in examination tables, mammography devices, x-ray cameras, surgical

microscopes and stair lifts.


The new ZAXB bearing unit: particularly compact and lightweight bearing support

featuring an electromechanical brake.

The new bearing unit ensures that the numerous medical devices as well as

computers and screens can be reliably brought to their optimal ergonomic positions.

The electromechanical brake enables their secure location.

Page 2

With its AXS series, Schaeffler Group Industrial has developed a bearing series with

a particularly small cross-section that is capable of supporting very high loads.

Contact person: Martin Adelhardt Schaeffler Technologies GmbH & Co. KG Head of Communications Schaeffler Group Industrial Georg-Schäfer-Straße 30 D-97421Schweinfurt Tel.: +49 9721 91-3400 Mobile: +49 172 8820421 [email protected] Please send a specimen copy.


Press Release

Page 1


Handling and Gantry Robot Systems from INA Linear Technology

Save Time and Costs

HANOVER/SCHWEINFURT, April 5, 2011. The linear technology business unit of

Schaeffler Group Industrial now also offers complete, multi-axis handling or gantry

robot systems. The individually configured machines which are based on the

comprehensive modular system of linear technology components and actuators are

handed over ready-to-use and offer considerable advantages in terms of time and

costs. The background to the launch of these systems are the increasing

requirements of design engineers and users from the handling technology and

automation engineering sectors not just to use components, but preferably ready-to-

fit, complete solutions. With the new multi-axis positioning systems, the customer is

provided with a functionally reliable complete solution manufactured from

components that are perfectly matched to each other, and saves time and costs

during project planning, design, procurement, assembly and initial operation and can

fall back on the worldwide service network of the Schaeffler Group.

Handling and automation solutions of different types and performance classes up to

30 m stroke (travel distance), with traverse speeds up to 10 m/s and moving masses

up to 500 kg can be manufactured from this modular system for multi-axis systems.

This includes at the customer’s request all services such as project planning, overall

and detailed design, preassembly and final assembly of components, protection and

operating systems, control and programming, transport and final assembly of

machines, initial operation and service as well as maintenance (including remote

maintenance). In addition to consultations by Schaeffler’s external sales engineers,

data for the requirements analysis, consultation, design and project planning can be

simply entered in an online form by visiting www.ina.com/positioning_systems.

INA linear technology therefore started meeting the growing requirements for system

solutions by manufacturing linear tables and handling actuators during the last few

years that are now offered in almost any combination and include all control and

drive units as well as the complete machine periphery up to initial operation at the

customer’s premises as an overall solution. The new portfolio is based on the range

of products and services for linear technology components which is backed up by

the rolling bearing expertise of the Schaeffler Group. Almost all tasks can be

http://www.ina.com/positioning_systems

achieved in practice by correctly selecting and combining this range of products and

services, e.g. in assembly and handling technology, automation engineering,

packaging machinery, electronics manufacturing, etc. Individual requirements for

dynamics, loads, moving masses, positioning and repeat accuracy as well as

environmental influences can be fully met. INA Linear Technology offers:

A wide range of guidance systems and monorail guidance systems for

different applications (track roller and shaft guidance systems, linear

recirculating ball bearing and guideway assemblies),

Different drive systems such as toothed belt drives, ball screw drives or

trapezoidal lead screws or linear motors,

Linear actuators with special functions such as telescopic linear actuators or

clamping actuators,

Different actuator options equipped in line with performance requirements

and motors, gearboxes, sensors and controllers matched to tasks

A wide range of accessories for adapting linear actuators and multi-axis

systems perfectly to operating conditions, such as fasteners and

connectors, clutches or clutch housings.

The correct solution for every application

INA linear tables or INA linear actuators are used depending on the requirements for

dynamics, traverse distances/ operating ranges or stroke lengths and speeds as well

as accuracy. Linear tables are used in machine tools, measuring equipment and

testing machines, electronics manufacturing facilities, in medical technology and in

other high-precision applications. On the other hand, high precision multi-axis

handling and feeding systems e.g. for automation in production, packaging, material

flow and intralogistics are manufactured from linear actuators. The different

combination options are clearly illustrated in publication PMP, which can be obtained

free of charge from INA Linear Technology. Individual consultation and design

services are provided locally to the customer by the Schaeffler Group’s technical

external sales which is available on a worldwide basis.


INA Linear Technology now also offers complete, multi-axis handling or gantry robot

systems based on the comprehensive modular system of linear technology

components and actuators in addition to components and multi-axis combinations.

Complete systems can be manufactured individually in performance classes up to

30 m stroke (travel distance), with traverse speeds up to 10 m/s and moving masses

up to 500 kg.

Page 3

Data for the requirements analysis, consultation, design and project planning can be

simply entered in an online form by visiting www.ina.com/positioning_systems.

A selection of possible axis configurations

Martin Adelhardt

Schaeffler Technologies GmbH & Co. KG Director of Communication Schaeffler Group Industrial Georg-Schaefer-Strasse 30 97421 Schweinfurt, Germany Phone: +49 9721 91-3400 Cell phone: +49 172 8820421 [email protected] Please send a specimen copy.

Contact: Jürgen Klein Schaeffler Technologies GmbH & Co. KG Linear Technology Business Unit Head of Marketing, Linear Technology Berliner Strasse 134 66424 Homburg (Saar), Germany Phone: +49(6841)701-2106 Fax: +49(6841)701-45 2106 [email protected]

http://www.ina.com/positioning_systems



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