Tapered Roller Bearings in X-life quality Customer Information. Business Unit TRB Schweinfurt, 2013
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1 Tapered Roller Bearings in X-life quality Customer Information Business Unit TRB Schweinfurt, 2013
2 X-life roll-out BU TRB Agenda Tapered Roller Bearings in X-life quality X-life what is it? X-life what is the benefit? X-life what are the technical advantages? X-life how does the assembly work? 1 Dec. 2013
3 X-life what is it? Definition of X-life Schaeffler standard S X-life = extended life proven to be better X-life = highly reliable products with an extended rating life & longer operating time Increased dynamic load rating C dyn* Optimized surfaces and functionally optimized internal product design *) for certain products increased fatigue limit load C u / increased static load rating C 0 2 Dec. 2013
4 X-life what is it? Customer benefit Why X-life? What is the benefit for our customers? In addition to extended rating life and usage time, X-life offers energy efficiency in both technical and economic aspects, on the one hand regarding the design of the bearing and on the other hand regarding the entire product life cycle for each application. Therefore, X-life is the basis for a holistic Total Cost of Ownership-approach (TCO). Increased energy efficiency Higher reliability Down-sizing possibilities or higher load density Reduced grease and oil consumption Longer operating time Lower overall costs (TCO) X-life TRB significant key figures: 20% higher basic dynamic load rating Up to 70% extended rating life Up to 50% reduced friction (for TRB with large contact angle: up to 75%) Up to 20% lower operating temperature compared to Standard bearing 3 Dec. 2013
5 X-life what is it? Customer applications Where are X-life TRBs found? X-life TRBs are used in various industrial applications. Mobile hydraulics (e.g. axial-piston- & orbital-engines) Construction and agricultural machinery (e.g. wheel bearings) Processing - vertical mills Steel - rolling stands Oil & gas sheaves Wind transmission Road roller Drill head bearing X-life TRB product features, such as: higher radial load capacity combined w/ higher axial load capacity wider range of usable speeds, precise and more rigid shaft guidance and reduced maintenance offer significant improvements compared to standard. 4 Dec. 2013
6 X-life roll-out BU TRB Agenda Tapered Roller Bearings in X-life quality X-life what is it? X-life what is the benefit? X-life what are the technical advantages? X-life how does the assembly work? 5 Dec. 2013
7 additional aspects X-life core aspects X-life what is the benefit? One-Pager product characteristics X-life = extended life proven to be better Product Features Technical Advantages Customer Benefits Improved rolling contact surface finishes Optimized ring rib & raceway geometry Enhanced roller geometry 20% higher basic dynamic load rating C dyn Up to 70% extended life time Up to 50% reduced friction (for TRB with large contact angle: up to 75%) Longer operating time Higher reliability Downsizing possibilities or higher load density Superior material Enhanced heat treatment options Standardized cage design Lower operating temperatures Higher precision Lower overall costs (TCO) Reduced grease and oil consumption Increased energy efficiency Comparison C dyn Applications Types available 100 up to 109 Mobile hydraulics: axial-piston- & orbital-engines Tractors: wheel bearings and transmissions Vertical mills: grinding rollers Hot & cold rolling steel mills: rolling stands working rolls Oil & gas sheaves Off & on shore wind turbines: transmission Construction machinery: road roller Construction machinery: drill head bearing Change-over of existing core program types (up to 420 mm OD) New types up to 635 mm OD Start-types in 320, 322 and 302 series Benchmark Competitor (premium product) FAG X-life 6 Dec. 2013
8 Customer Benefit X-life what is the benefit? Product characteristics abstract Product information Adjustments regarding material, geometry and surface quality 70% extended rating life 20% higher dynamic load rate 50% lower friction (large contact angle TRB: up to 75%) Innovation Steps Material & Heat treatment Optimized Geometry Optimized Surfaces Higher Precision Mixed Friction Contamination Friction Downsizing Noise Temperature Lifetime Running in is not necessary 7 Dec. 2013
9 X-life roll-out BU TRB Agenda Tapered Roller Bearings in X-life quality X-life what is it? X-life what is the benefit? X-life what are the technical advantages? X-life how does the assembly work? 8 Dec. 2013
10 X-life what are the technical advantages? Superior material & enhanced heat treatment Selected material in combination with optimized heat treatment X-life Superior through hardened material for inner and outer rings Increase of wear resistance Significant increase in expected rating life Smaller bearing supports can be used in relevant applications Standard Performance impact of material and heat treatment between standard and X-life TRBs. 9 Dec. 2013
11 X-life what are the technical advantages? Optimized rolling contact surfaces Abbott curve rolling contact surfaces Honed rolling contact surfaces New surface finishing specification (S ) DIN EN ISO (Abbott curve) Significantly improved surface parameters for raceway, lip and roller results in 50% reduced friction and up to 20% lower operating temperature. R pk = reduced peak height R vk = reduced valley depth R k = core roughness depth 10 Dec. 2013
12 X-life what are the technical advantages? Optimized contact surface at the lip-roller contact Optimized internal design The geometry of the inner ring lip as well as the roller face were optimized in order to reduce the development of friction and heat significantly. Optimized geometry of roller and inner ring lip contact reduced friction by approx. 20%. Lip height is reduced Lip roller contact point has been moved closer towards to the raceway 11 Dec. 2013
13 X-life what are the technical advantages? Optimized surface, higher dimensional & running accuracy High impact at low revolution speed Lower surface roughness of rings and rollers Formation of an elastohydrodynamic lubricant film even at very low speeds Increase in rating life High load carrying capacity of the bearing immediately after initial operation Reduced development of friction and heat Along with the increased dimensional and running accuracy, the improved surface topography significantly reduces the development of friction and heat. 12 Dec. 2013
14 X-life what are the technical advantages? Improved inner design Overview of improved inner design Matched logarithmic profile of the raceways and the outside surface Prevention of stress peaks in extreme situations (e.g. during high loads and skewing) Increase in rating life 13 Dec. 2013
15 X-life what are the technical advantages? Standardization of sheet metal cage design Optimized sheet metal cage design: JP.B About 70% of standard FAG TRB use the sheet metal cage in JP.B design. In alignment with the X-life roll-out the remaining JP sheet metal cages will be replaced by JP.B design. Technical advantages are optimized contact conditions between roller and cage. This improves the usage time of the bearing. 14 Dec. 2013
16 X-life what are the technical advantages? X-life product features in comparison to standard bearings Summary Harmonization of technically most relevant product features Standardization on a higher performance level All product features are well known and the technical advantage proven: material heat treatment rolling contact surfaces lip roller contact cage design 15 Dec. 2013
17 X-life roll-out BU TRB Agenda Tapered Roller Bearings in X-life quality X-life what is it? X-life what is the benefit? X-life what are the technical advantages? X-life how does the assembly work? 16 Dec. 2013
18 X-life how does the assembly work? Mounting of X-life products How does the assembly work? Adjustment of the preload by the following criteria: displacement, friction torque and force. displacement For a reliable mounting Schaeffler recommends the adjustment by displacement. Various factors (e.g. speed, lubrication, temperature) affect the result of friction torque measurement. The friction torque by having the same preload is considerably less for tapered roller bearings with X-life quality than for standard bearings. Range Standard Friction torque friction torque force Range X-life axial load 17 Dec. 2013
19 X-life roll-out BU TRB Thank You B u s i n e s s U n i t Ta p e r e d R o l l e r Bearings 18 Oct. 2013
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