A customer newsletter from Schaeffler Group Industrial’s Production Machinery Business Unit Issue 2011/2012

CURRENT NEWS Performance scaled up

The best performing rotary axes in the world
Schaeffler highlights

EMO Hannover 2011

Page 3

34!
th C
Boo
7/
Hall
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com
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Riding pleasure
Higlights for machine tools in high swings
Highly efficient FAG torque
sensor bottom bracket
The advantages of the RKI motor se-
bearings for e-bikes ries in machine tools, and for power-
Page 3 ful, high-speed rotary table axes in
particular, are convincing at a single
glance:
Torque: increased by + 30 %
Speeds: increased by + 400 %
P mechanical: increased by a factor of 5
Total Cost of Ownership:
reduced by up to 60 %
Installation space:
identical outside diameter
Costs: same performance, same price
Efficiency in motion
added competence
for textile machinery
Page 8
The impetus came from the automotive
industry. The RKI wheel hub motors and
The downsizing option is convincing and
can be achieved without major changes
in design: The use of RKI motors with the
same power enables costs to be cut in
conjunction with converters. When using
the combination of RKI direct drive + new
Schaeffler ZKLDF..B axial angular contact
RKI motor
ball bearing, manufacturers of machine
tools and associated subsystems now
have the option to build the most power- thermal stress for the motor. Roughly a
ful rotary table axes in the world. magnitude of about 150 Hz can be as-
sumed for conventional motors and be-
RKI – A revolution in direct drive tween 300 and 700 Hz for high-speed
technology: systems. This value is calculated by mul-
Over the past 20 years, direct drives tiplying the speeds per second (n) by the
have developed from special motors into number of pole pairs (2p) in the motor
volume production products. Their tech- ( f = n * 2p ).
nology has been optimized step by step.
Today’s commonly available motors have Fivefold mechanical power:
reached a technical level that is almost With the optimization of the power gen-
impossible to improve in big leaps. The erating systems, the mechanical power
achieved force (torque) intensity is now of the RKI has been increased fivefold
sufficient for the majority of applica- compared with a standard RI motor.
tions. The only constraint worth mention-
ing is limited speeds resulting from eddy
current losses in the motor.
Torque (Nm)

Hall 2 / Booth C142

drives used in electric cars or hybrid
solutions achieve a mechanical power of
up to 400 kW. Thanks to the over 400 %
increase in speeds and approx. 30 %
higher torque compared to conventional
torque motors, there are now additional
applications opening up for the RKI se-
ries in the field of machine tools.
RKI with Zx winding
Whenever a magnet moves along a coil
or current flows through a coil, the mag- RI with WL winding
netic field will generate a current that RKI with WL winding
counteracts the cause of its generation.
In concrete terms this means that the
iron parts of the motor heat up. This can
Speeds (rpm)
be compared with eddy current brakes in
streetcars. Kinetic energy is converted Comparison torque over speeds: RI versus RKI
into heat. This represents additional with WL and Zx winding resp.

Continued on Page 2
 Issue 2011/2012 – Page 2 Issue 2011/2012 – Page 3

Editorial Assistance on demand ensures riding pleasure

Highly efficient FAG torque sensor bottom bracket bearings for e-bikes
Performance scaled up –
For the first time, the total torque is de- developed FAG Generation C deep groove
“added competence” for machine tools termined from the sum of the pedal force ball bearings, which have around 30 %
from the left and right pedals. less friction compared with previous
EMO 2011 in Hannover is likely to be a special yardstick of We are delighted to be able to present to you in this issue and at EMO 2011 models. Numerous components in the
what has really been achieved in the field of machine tools dur- a wide range of new products on offer, including Correct detection of the rider’s require- area of the shaft are also coated
ing the past years. After all, EMO 2009 was hallmarked by the - the most powerful rotary axis in the world ment for motor assistance depends on with Corrotect® corrosion protec-
economic crisis and many companies, including us, decided - high-performance bearing solutions for large-size machines the riding situation and corresponding tion developed by Schaeffler.
not to put in an appearance there. In hindsight we can say that ● - new bearings for main spindles – thermally robust and suited control of the power outputs. These are
this turbulent time highlighted our great internal makeup which was conducive to for extremely high speeds decisive factors for a positive riding
producing some very respectable product innovations and portfolio expansions ● - the new torque motor RKI, a revolution in direct drives experience on e-bikes. Besides the direc-
in spite of everything. ● - linear guidance solutions for heavyweights tion of rotation and speed, measurement
to name only a few. We hope you’ll be able to pick up lots of of the exact torque produced by the
So our message “Performance scaled up” refers on one hand to the new bearing useful impressions for your day-to-day work! rider during pedaling is a prerequisite
dimensions that have been added to our range of products. We have both extend- Sincerely yours, for precisely determining the additional
ed the external format and increased our internal performance depth. On the other drive power required from the electric
hand, “Performance scaled up – added competence for machine tools” refers to motor. This is controlled principally by
the large number of innovative additional benefits, the understanding of the overall the torque sensor system in the bottom
system and the application engineering proximity to you – and all of these are all Helmut Bode bracket. The rider no longer needs to
crucial for our joint success. President, Production Machinery Welcome to Hall 7 / Booth C34! provide additional “pedal power”.

The new FAG torque sensor bottom

Performance scaled up
Continued from Page 1
This was mainly achieved with the fol-
lowing two design measures:
- Up to 30 % higher torque:
While standard motors of series RI still
feature surface magnets on the rotor,
these can no longer be found in the new
RKI design. The RKI rotor consists of a
magnet system, in other words: a lami-
nated steel package in which many mag-
nets are embedded. This package con-
centrates the magnetic flux (B). Using
this rotor, up to 30 % higher torque can
be generated in the motor (stator + ro-
tor) compared with conventional surface
magnets.
- Up to 400 % higher speeds:
In order to keep the countervoltage as
low as possible, a special winding is
used in RKI motors. A combination of
this Z winding and a laminated rotor en-
The Schaeffler Group will once again
be offering training sessions in
­Schweinfurt related to the maintenance
and servicing of main spindle bearings.
These all-day sessions are made up of
theoretical and hands-on units. Dur-
ing the theoretical part, participants
are taught basic knowledge of bearing
types, performance characteristics, ma-
chining tolerances, lubrication and the
monitoring of super precision rolling
bearings. The hands-on unit includes
mounting exercises, the handling of
ables losses to be significantly reduced
so that up to 400 % higher speeds can
be achieved. Air gap speeds of 50 m/s
are possible now.
Gigantic performance and cost efficien-
cies: 60 % reduction in power losses,
TCO dramatically reduced.
Considering the heat dissipation of
torque output, one will notice another
significant improvement. A direct com-
parison is possible based on the motor
constant Km (unit in Nm/√W) which
stipulates that ‘Half the Km constant
results in fourfold losses’.
The direct comparison between the RI
and RKI series shows that the power
loss is up to 60 % lower for the same
torque output. Less heat is generated.
Consequently the cooling requirements
are lower, which has a positive effect
on total costs of ownership (TCO).
measuring equipment and the assess-
ment of rolling bearing damage. All
participants will receive detailed training
documents. On-site training sessions for
main spindle bearings can also be sched-
uled any time with machine tool and
spindle manufacturers, repair centers
and rolling bearing distributors.
Your contact partner: Karin Morgenroth
Tel.: +49(9543)68-403
E-mail: Schulungszentrum.Hirschaid@
schaeffler.com
Speeds doubled with the new rotary
table bearings ZKLDF..B:
The bearing units YRTS and ZKLDF, de-
signed for screw-mounting, have proved
their worth in the combined turning-
milling operations in machining centers.
However, there was a demand from the
market for even higher speeds without
compromising rigidity.
The new axial angular contact ball bear-
ings of series ZKLDF..B enable up to
100 % higher speeds to be achieved
compared with the previous standard
– at the same price and despite grease
lubrication!
This speed capacity is the absolute
top of the range performance in the mar-
ket. When combined with the RKI motor,
this enables not only optimal cutting
speeds for smaller workpiece diameters
but also completely new – and simpler
– bearing design options: the main
spindle function for screw mounting.
The next spindle bearing
training session will take place
in Schweinfurt on:
Sep. 8, 2011
Dec. 15, 2011
Feb. 9, 2012
Jun. 14, 2012
Sep. 20, 2012
Innovation boost: Technology leader-
ship and trend setting.
For the machine tool industry, this
hand-in-hand development of direct
drive technology and bearings means
an enormous innovation boost and
stability of costs at the same time.
Moreover, it is a
perfect ex-
ample of the
“added com-
petence” of
global play-
ers united un-
der one umbrella: The Schaeffler Group,
together with IDAM (INA Drives & Me-
chatronics) and its brands INA and FAG,
have over 100 years of accumulated
concentrated rolling bearing and motor
expertise on board. The result: Perform-
ance scaled up!
Tipquickly!
ter
Regis e training h
s c
Th e
ns ar
sessio ght after
sou
Training course for attendance
and maintenance of maichine tools
main spindle bearings
bracket bearing is used, for example in
the new high-performance drive from
Bosch. The drive characteristics 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 % (speed) is available depend-
ing on the mode and assistance level.
Like all bottom bracket units from FAG,
the new torque sensor bottom bracket
is characterized by its excellent smooth
running characteristics. This has been
Newly developed FAG torque and speed
facilitated by an optimized bearing ar- sensor bottom bracket bearing for e-bikes
rangement and the use of the newly
EMO highlights for direct drive technology
IDAM’s RKI motors make significant contribution to world’s best performing rotary axis
At the same time, power losses are redu- motor housings represent the specific
ced by up to 60 %. This means less heat feature of a segment motor. Every motor
generation, improved energy efficiency housing/individual segment has its own
and a significant cut in operating costs cable connection and is connected to
due to less cooling requirements. the other segments externally in termi-
nal boxes. Initial mounting and servicing
But the downsizing options are also con- is especially easy.
vincing: With unchanged output, smaller
motors can be used and the costs for the Heavy-duty hoisting equipment or spe-
converter reduced. cial tools are not required thanks to
High-performance rotary direct drive series RKI Torque motors in segment design the segment design of the primary and
e mu
!
In combination with the new ZKLDF..B secondary parts: If service is required,
INA Drives & Mechatronics GmbH & Co. rotary table bearings with doubled limi- Segment motor – Easier to install and every segment can be checked and re-
oHG (IDAM) – the Schaeffler Group’s ting speeds, the fastest rotary axis in the lower costs. placed, if necessary. The principle motor
specialist for direct drive technology world can be built. For the machine tool Torque motors in segment design from functionality is maintained through the
– achieves over 30 % torque compared this represents a unique selling proposi- INA Drives & Mechatronics GmbH & Co. other segments. This means that a de-
with conventional torque motors with tion in the market. The RKI series offers oHG (IDAM) offer a maximum in eco- gree of emergency running is possible,
its high-performance rotary direct drive special benefits when used in turning- nomic efficiency. The motors are very which ensures high equipment availabi-
series RKI. Speeds can be increased up milling centers. maintenance friendly in the large diame- lity. Moreover, the replacement of parts
to four times and the mechanical perfor- ter range. Coil winding systems that are can be carried out with conventional
mance fivefold. composed and installed in individual mounting tools.

EMO highlights: Machine tool bearings
Rotary table bearing ZKLDF..-B – The speed doubler
ZKLDF..-B
Schaeffler Group Industrial has further
optimized the internal design of its
­double row axial angular contact ball
bearing ZKLDF..-B, cutting the frictional
torque by half. As a result, the bearing’s
limiting speeds have doubled, without
compromising its high accuracy and ri-
gidity.
Used in combination with the new speed-
increased RKI torque motors from IDAM
in particular, the ZKLDF opens up new
opportunities in turning and milling op-
erations that were impossible to achieve
with standard components in the past.
Further optimizations have gone into the
bearing design in the wake of the con-
version to Generation B. To facilitate re-
lubrication, the new Generation B bear-
ings feature an axial lubrication duct on
the screw mounting surface in addition
to their lubrication groove on the bear-
ing circumference. In this way, the lubri-
cant can be supplied reliably, indepen-
dent of the selected fit.
EMO highlights for main spindle bearing supports
New design options for motor spindles
When it comes to motor spindles,
Schaeffler Group Industrial is combining
suitability for maximum speeds with high
load carrying capacity and insensitivity
to changing operating conditions. This
is done thru the new high performance
spindle bearing series RS and thermally
robust cylindrical roller bearings of series
TR. Bearing supports for direct drive motor
YRTC
YRTC – A combination of high rigidity, pre-
cision and low frictional power for more
productive and efficient machine tools.
In the bore diameter range between 580
and 1,030 mm, Schaeffler Group has
combined its well-known YRT and RTC se-
ries to form the new YRTC series which
provides even better performance. It is
the basis for extremely dynamic rotary
axes for high-speed positioning and form
milling using multi-axis simultaneous ma-
chining. Even operation with steady-state
speeds, e.g. for temporary turning, is pos-
sible within the limitations of use. At the
same time, the frictional power has been
significantly reduced compared with con-
ventional axial-radial cylindrical roller
bearings.
Due to the significant decrease in friction,
there is a considerably higher proportion
of the drive torque from the drive avail-
able for axis acceleration and machining.
Both aspects are conducive to increasing
the productivity. Moreover, the heat in-
duced within the machine structure is re-
duced. As a consequence, the tempera-
ture-related changes in machine geometry
spindles can be considerably simplified
compared with conventional solutions.
RS – New high-performance series
“Robust and high Speeds”:
FAG’s RS spindle bearings (Robust and
high Speeds) are super precision angular
contact ball bearings with large balls.
They feature a nominal contact angle of
are reduced and the machining accuracy
rises. With cooled axes, the cooling pow-
er can be reduced analogous to the re-
duced frictional power, which means
there is an additional benefit in the form
of lower operating costs.
ZKXDF on track for volume production –
High speeds and compact size for com-
bined milling/turning applications with
over 1 m table diameter.
This product opens up the option of de-
signing economical and highly efficient
compact bearing supports for high-speed
rotary tables. Currently size ZKXDF580 is
being implemented with 580 mm bore
diameter. The innovation is based on a
double row axial angular contact ball
bearing in an O-arrangement with bearing
rings that are neither split nor interrupted
by a plug in the raceway. Benefits of this
design include:
- Improved transferability of bearing run-
ning accuracy to the machine assembly
due to single-piece bearing rings.
- Higher rigidity due to reduced number
of joints resulting from the use of single-
piece bearing rings.
- More cost-effective adjacent structure:
Since the bearing rings are axially offset,
it is sufficient to have plane screw mount-
ing surfaces. Depending on the rigidity
requirements, ZKXDF bearings do not
have to be supported across the entire
bearing height by the shaft due to their
single-piece bearing rings.
20 degrees and an inter-
nal design with opti-
mized friction charac-
teristics. These char-
acteristics make RS
spindle bearings ro-
bust against changes
in radial clearance and
combine the speed suitability of a small-
ball high-speed series with the sturdiness
and load carrying capacity of bearings with
balls with large cross-sections. Bearing
supports with these new spindle bearings
are less sensitive to operating and envi-
ronmental influences and open up new
design options for high-speed spindles
with high machining forces. The bearings
are offered with balls made from bearing
steel. In addition, they are also available
in a hybrid version and in open, sealed
and DLR design for oil-air lubrication.
Issue 2011/2012 – Page 4
Welcome to Hall 7 / Booth C34!
ZKLF..Hybrid – Reliable even in short
stroke operation:
The new hybrid axial angular contact ball
bearings ZKLF..-HC now offer a reliable
and economical solution with the ulti-
mate in robustness. This applies even
under the most adverse operating condi-
tions, in particular lengthy, short stroke
operation of ball screw drives. The higher
purchasing costs compared with stan-
dard bearings pay for themselves within
a very short time, since the bearings will
not break down due to the dreaded false
brinelling.
ZKLF..Hybrid
The use of ceramic balls results in an in-
crease in limiting speeds and a tripling of
the grease life. The DIN working groups
have decided to revoke the theoretical
reduction in dynamic load ratings due to
overwhelming results achieved in field
operation. Now there is nothing in the
way of these bearings being used as
problem solvers for the replacement of
steel bearings, or as a new standard for
enhanced reliability in short stroke op-
eration.
TR – Thermally Robust bearings for motor
spindles:
The new Thermally Robust FAG cylindrical
roller bearing TR, for the first time, com-
bines the security for the non-locating
bearing function with suitability for high
speeds and operation under temperature
fluctuations. It features a radially elastic
outer ring with standard dimensions that
can compensate for distortions resulting
from radial clearance.
The bearing’s very high speed capability
has been achieved through the adoption
of the high speed design and a PEEK cage
with optimized friction characteristics
guided on one side on the outer ring. The
optimized lubricant distribution and a low
temperature level during operation pro-
vide additional security for the non-locat-
ing bearing function.
EMO highlights in linear technology
INA Linear Technology: Components and systems for heavy-duty linear guides
The Schaeffler Group offers a wide
range of linear guidance systems and
related accessories for the economical,
high-quality machining and handling
of heavy-duty workpieces.
Flat cage guidance systems:
INA flat cage guidance systems of series
M/V represent a combination of high
load carrying capacity with supreme pre-
cision. Their load carrying capacity re-
sults from a high number of load-bearing
rolling elements in the load zone as well
as from the possibility of further increas-
ing the number of needle rollers due to
longer cages.
The trend of heavy-duty machines to-
wards increased dynamics can be satis-
fied by means of an integral restricted
cage guidance system. This system
prevents cage creeping even under
very high dynamics, which results in
increased lifetime. Typical application
examples of such guidance systems are
press transfer systems that take over
the precise and high-speed handling of
heavy components in between the vari-
ous press stages. Here the parts weigh
up to 200 kg. The transfer arm has a
feed length of 8,500 mm and the travel
speed is 8 m/s.
Linear roller bearings:
Linear roller bearings of series RUS and
PR, based on cylindrical rollers, offer
load ratings of up to 840,000 N and
thus provide a high degree of flexibility
and freedom of design. Sealed at the
end faces, these linear roller bearings
run especially smoothly and quietly. The
patented end piece geometry and lubri-
cation voids have been redesigned and
optimized for load entry and lubrication
distribution. This has resulted in im-
proved running behavior with optimum
preload even under the highest loads.
As for the RUS linear roller bearing se-
ries, the rolling elements are kept at a
distance by spacers. In comparison, the
PR series comprises full complement
bearings that do not use plastics. This
makes the PR linear roller bearing par-
ticularly suitable for high temperatures
and high-speed applications. A classic
field of application for recirculating
roller bearings is the main guidance of
presses where extremely high forces are
encountered. Used with correspond-
ing adapters, linear roller bearings can
be integrated directly into the adjacent
structure so that the highest possible
performance capacity can be achieved in
a minimum of space.
A selection of possible axis configurations
Monorail guidance systems:
High load carrying capacity, robustness,
high rigidity and precision as well as
excellent sealing – these are the most
important features of the latest, fifth
RUE..E generation. Unlike other manu-
facturers who use barrel-shaped rollers
in their monorail guidance systems,
RUE..E is based on cylindrical rollers
with end profiling. The large contact
area of the cylindrical roller results in
extremely high load carrying capacity
and rigidity, while the contact pressure
is reduced.
The pure line contact enables slippage-
free rolling. RUE 100 E-L was added
to the size range. A carriage of this
size features a dynamic load rating of
1,490,000 N. Such guidance units are
used for example in ring dressing facili-
ties for large rolling bearings destined
for wind turbine applications. During the
machining of rings with a weight of up
to 4 t and a diameter of 4,500 mm, the
RUE 100 E-L must support forces of up
to 2 meganewtons in tension.
Recirculating roller bearing RUE
Vibration damping:
The Schaeffler Group has extended its
range of damping accessories, making it
available for its large, high load-capacity
series. For example, damping carriages
of series RUDS 100 are now available for
RUE 100 E in lengths of 150, 300 and
450 mm. These damping carriages are
positioned on the guideway between
the carriages. They feature a defined gap
between the guideway surface and the
bottom of the carriage that is filled with
unpressurized oil. The resulting squeeze
film dampens vibration and improves
the machining result.
Hydrostatic monorail guidance system:
Moreover, INA Linear Technology offers
the fully hydrostatic HLE linear guidance
system. This ready-to-fit, sealed system
with integrated pressure regulation
combines the functions of “guidance”
and “damping” in the design space of
a monorail guidance system. Thus it
replaces the monorail guidance system
and enables optimum damping behavior
with correspondingly positive effects on
machine performance.
Monorail guidance system
INA linear technology for multi-axis
positioning systems handling and
gantry robot systems from INA save
time and money:
The INA Linear Technology business
unit now also offers multi-axis handling
and gantry robot systems as ready-to-
use complete solutions. Tailored to
the requirements of the application in
question, the new multi-axis positioning
systems are functionally reliable units
consisting of perfectly matched com-
ponents from a modular system. Upon
customer request, this offer can include
all services such as project planning,
overall and detailed design, preassembly
and final assembly of components, pro-
Issue 2011/2012 – Page 5
tection and operating systems, control
and programming, transport and final as-
sembly of machines, commissioning and
servicing as well as maintenance (includ-
ing remote maintenance). The user saves
time and money.
Handling and automation solutions of
different types and performance classes
of up to 30 m stroke (travel distance),
with traverse speeds up to 10 m/s and
moving masses up to 500 kg can be im-
plemented. INA Linear Technology offers
the following products and services:
- A wide range of guidance systems and
monorail guidance systems for different
applications (track roller and shaft guid-
ance systems, linear recirculating ball
bearing and guideway assemblies),
- Different drive systems such as toothed
belt drives, ball screw drives or trapezoi-
dal lead screws and 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 control-
lers matched to tasks,
- A wide range of accessories for adapt-
ing linear actuators and multi-axis
systems perfectly to operating condi-
tions, such as fasteners and connectors,
clutches or clutch housings.
In addition to individual consultation
through the Schaeffler field service engi-
neers, customers can simply enter their
data for requirements analysis, consul-
tation, design and project planning in an
online form available at
www.ina.com/positioning_systems.

Bearing solutions for large-size machinery
Supports for rotary tables in vertical turret lathes
The Schaeffler Group offers comprehen-
sive application, production and service
expertise for large-size machining
centers, combined with a wide range of
corresponding products. One-bearing
solutions represent a good compromise
in relation to performance, design effort
and price for the majority of these appli-
cations. However, two- or three-bearing
solutions are also frequently used as
they enable design solutions that are se-
lectively matched to the specific require-
ments of the machine tool in question.
Now a detailed catalog (TPI 205) has
been published in German, English and
Chinese that can be ordered via www.
schaeffler.com and is also directly avail-
able for download.
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The economical one-bearing solution:
From a mechanical point of view, the use
of one single bearing represents the sim-
plest bearing arrangement. It supports
forces and moments from all directions
and permits convenient relubrication.
Bearing units of series YRTS and ZKLDF
for screw-mounting are used here, for
example. They are available in bore
One-bearing solution with crossed roller bearing
for the rotary table of vertical turret lathes: This
economical solution for the majority of standard
applications represents a good compromise be-
tween performance, design effort and price.
­ iameters of up to 460 mm and 725 mm
d tapered roller bearing): Axial runout is
respectively. For larger diameters,
­Schaeffler offers crossed roller bearings
that were developed specifically for these
applications. They are available with
diameters ranging from 457.2 mm to
2,100 mm.
Optimum performance through multi-
bearing solutions:
n If several bearings are used as rotary
hinery
mascchine
­table support, then this offers the pos-
e lu
ngens
ag
1-L g so
earin rlösu lutiognen
o-be gerlso ösu n s
lution sibility for application-specific combina-
Tw 3-Laaring
-be
tions. In principle, each of the bearings
can be selected based on its load car-
rying capacity, rigidity and speed suit-
ability. The main bearing, which takes
the form of an axial bearing, is the heart
in multi-bearing solutions. Its character-
istics determine the machine’s perfor-
mance to a considerable degree. The fol-
lowing two design variants have proved
especially effective:
The two-bearing solution:
consists of an axial bearing (axial deep
groove ball bearing or axial cylindrical
roller bearing) and an angular contact
bearing (angular contact ball bearing or
Safety through vigilance: FAG SmartCheck
FAG SmartCheck – Maximum performance in
a small package; compact and easy to operate.
Designed for maximum speed requirements with
optimum price/performance ratio in rotary tables
of vertical turning machines: Two-bearing solution
with ball bearings.
determined by the axial bearing, and the
radial runout by the angular contact bear-
ing. As a rule, the axial bearing sets the
speed limits due to its larger diameter. It
is preloaded by the angular contact bear-
ing in order to ensure defined kinematic
conditions in the rolling contact in every
conceivable load case.
The three-bearing solution:
consists of two axial bearings combined
with a radial bearing: The larger axial
bearing supports the main loads of the
table plate and the tool, while the smaller
axial bearing is used for axially preload-
ing the bearing support and as the coun-
teracting bearing to support tilting mo-
ments. Radial guidance is via the super
precision radial cylindrical roller bearing.
As a general rule it can be said that
design variants with ball bearings can
achieve higher speeds, while those with
cylindrical roller bearings offer higher
rigidity and load carrying capacity. Axial
deep groove ball bearings achieve speed
parameters of up to 460,000 mm . min-1
compared to 270,000 mm . min-1 for
The FAG SmartCheck is a new, innova-
tive “single-channel online system” for
the monitoring of machines and plants.
It comes with a set of more than 20 pre-
defined parameter templates for monitor-
ing, for example, imbalance, alignment
errors, rolling bearings and gearings. In
view of its outstanding price/performance
ratio, this highly efficient tool makes
online monitoring extremely economical.
The FAG SmartCheck makes a valuable
contribution to operational reliability and
reduced Life Cycle Cost (LCC) and Total
Issue 2011/2012 – Page 6
Welcome to Hall 7 / Booth C34!
Offering maximum rigidity and load carrying
capacities: Three-bearing solution with roller
bearings.
cylindrical roller bearings. The highest
load ratings can be achieved with axial
cylindrical roller bearings featuring diam-
eters of up to 3,830 mm. The accuracies
achievable with large bearing diameters
are also impressive.
Schaeffler Group Industrial’s range of
products is rounded off by a compre-
hensive range of services that represent
high added value for the customer. This
begins with our on site engineering
service and continues right on through
solidly-based bearing design using
­Schaeffler’s calculation software Bear-
inx®. This tool enables calculating the
conditions under all load cases, from
the complete system down to every
single rolling contact. The service units
from the Industrial Aftermarket support
customers in mounting and initial opera-
tion. Last, but not least our competent
technical advisory service regarding
operation, lubrication and maintenance
issues makes a contribution to reduced
operating costs and maximize bearing
life. If required, the Industrial Aftermar-
ket unit also offers bearing recondition-
ing and helps to minimize downtime.
Cost of Ownership (TCO). In addition to
the standard parameters – vibration and
temperature –, the system also records
other operating parameters such as pres-
sure or loads. This provides a broad basis
of information which permits experts to
make a very accurate assessment of a ma-
chine’s condition.
Both the number of sensors and the level
of system integration can be adapted to
the specific application.
Issue 2011/2012 – Page 7
You can count on it!
Schaeffler Group demonstrates concentrated calculation expertise with extended tools: Easy Solution
Rolling bearing design is one of the elements taking account of the contact
focal points in design support. The angle displacement, the non-linear de-
Schaeffler Group has been successfully flection behavior of the rolling element
using bearing selection and calculation contacts as well as the elastic guideway
programs for this purpose for over 30 and the carriage. Calculation is based on
years now. Examples include the bear- the most up-to-date algorithms for the
ing calculation software Bearinx® and simulation of linear rolling bearings. All
the electronic product catalog medias®. data inputs for calculation, such as the
Right on time for EMO 2011, there’s a axis configuration, forces and load cases
new feature on offer: Linear EasySolu- Start screen for the Linear Easy Solution calculation tool can be saved for further processing and
tion – Powerful calculation software optimization purposes.
for linear guidance systems and rolling 24/7. Based on the Bearinx® bearing sary data input. The most commonly
bearings. calculation software developed by used linear axis combinations in a drive, Thus INA Linear Technology offers quick
Schaeffler, Linear Easy Solution enables guideway and carriage arrangement are and immediately available customer
The Schaeffler Group’s INA Linear Tech- the user to calculate the basic rating preconfigured. In addition, users have support and personal consulting ser-
nology business unit offers its custom- life of a driven linear axis supported by the option of freely selecting an axis vices; all which emphasize the focus on
ers a new online calculation module rolling bearings. A user-friendly and self- combination with up to four guideways customer support by Schaeffler’s world-
for monorail guidance systems – free explanatory interface with transparent and 16 carriages. Linear Easy Solution wide engineering service.
of charge and available on the Internet menu navigation manages all the neces- models the actual load on the guidance
The Basics of Failure Analysis, Part 1
As part of our new section “The Basics of Failure Analysis”, in this issue we would
GERMAN INDUSTRIAL STANDARD October 2010
like to introduce you to the classification of “failure modes”.
In general, bearing damage can be classified according to two different points of view:
Starting from the existing operating conditions, such as contamination or overload, on
one hand and from the failure mechanisms on the other. The latter approach has been 3.1
Life:
standardized in ISO15243. Our explanations of failure analysis in this and the coming For an individual rolling bearing, the number of revolutions which one of the bearing rings
issues of “added competence” will be oriented on the standardized classification. (or washers) makes in relation to the other ring (or washer) before the first evidence of fatigue
develops in the material of one of the rings (or washers) or rolling elements.
In our first chapter, we will be dealing with the issue of “rolling contact fatigue” as the The influence of wear, corrosion and electro-erosion on the bearing life is not dealt with in the
number one of the standardized failure mechanisms. It is founded on the calculation International Standard:
of the basic dynamic load rating. The corresponding DIN ISO 281 standard defines the
term life as follows:
Structure of failure mechanisms
Fatigue Fatigue
Subsurface fatigue
Surface fatigue
Fatigue is apparent through symptoms of material spalling on the bearing
raceways and the rolling elements, also known as flaking (see picture). Abrasive wear
Wear
The root cause of fatigue is “contaminants” that are un- Adhesive wear
avoidable in steels and mainly take the form of alloy com-
ponents. These represent discontinuities in the grid struc- Corrosion
Corrosion through humidity
Fretting corrosion
ture of the steel and lead to local displacements in the Friction corrosion
structure and rehardening as a consequence. Starting False brinelling
from these rehardening zones (butterfly), microscopically Creeping currents
Electro-erosion
small cracks develop. During continuing operation these
Passage of electric current
grow towards the surface into fatigue fracture in the roll-
ing direction. When the fracture reaches the surface, the material will spall in local- Overload
ized areas. The cause of this damage is due to local pressure in the material. This Plastic deformation Particle indentations
Indentations
damage can be the “natural end” of a bearing’s life, but it can also be an indication
Indentations resulting
of partial overload due to tilting or stress. Forced fracture from improper handling
Action: The existing loads and operating times should be validated and, if necessary, Fracture Permanent fracture
the causes for elevated pressure should be identified and eliminated.
Heat crack

Efficiency in motion: added competence for textile machinery
The Schaeffler Group at ITMA in Barcelona
An
anwendungsorientierte
application-oriented Alternative
to grease
zu fettgeschmierten
Rolling bearings for textile Lubtect®
machinery
An extensive range of precise, ready to
install and maintenance ready rolling
bearing solutions are available for the
textile industry. From simple compo-
nent to complete high-tech solutions,
­Schaeffler provides reliable and eco-
nomical bearing supports for nearly all
types of machines in the textile industry.
These include:
- Thread guidance rollers with integrated
wear and corrosion-protection layer and
optimized friction characteristics,
- A wide variety of low friction and du-
rable tape tension pulleys with reduced
residual imbalance,
- Easy-to-fit radial insert ball bearings and
housing units for machines in spinning
preparation and texturing machines,
- Spindle neck bearings, rotor bearings,
tape tension pulleys and guide rollers in
spinning machines,
- Damped friction spindles and precise
compacting rollers with integrated pivot
joint in texturing machines,
- Shock resistant yoke and stud-type
track rollers in the gearboxes of weaving
machines,
- Lubtect – lubrication in difficult environ-
ments,
- Full complement needle roller bearings
with optimized operating clearance in
the swivel type operation of knitting and
weaving machines,
- Narrow needle roller and ball bearings
with high load-carrying capacity in dobby
looms,
- Cages with Triondur coating in needle
felt machines,
- Linear guidance systems in embroidery
machines, cutting machines, handling
equipment, textile printing machines and
many other textile machines.
Whether innovative, application-opti-
mized system solutions or proven and
continually refined standard products,
they all bring about a considerable in-
crease in machine power, whilst reduc-
ing costs at the same time – in spinning
preparation, thread production, creating
Lubtect®
alternative
lubrication of bearings
Lagern
Bearing Supports for Textile
Machinery
surfaces, finishes or in the manufacture
of ready-to-wear clothing. The two com-
petence publications, BTM and TMB, for
textile machinery are available for direct
download at: www.schaeffler.com
INA thread guidance rollers –
Lightweights for improved machine
profitability:
The new INA thread guidance roller is
extremely lightweight and thus increases
the dynamics of every texturing machine.
Due to its significantly trimmed outer
ring wall thickness, this roller accelerates
much faster. The moment of inertia of this
machine element has been reduced by
30 % compared with conventional solu-
tions. Featuring a chromium coating, the
outer ring surface is resistant to corrosion
and wear. Its surface roughness is such
that the filament drives the outer ring
whilst being protected against damage.
Improved machine profitability
FAG tapered roller bearings X-life for
higher efficiency in weaving machines:
Lower friction and higher performance.
FAG tapered roller bearings X-life feature
up to 75 % lower frictional torque com-
pared with standard products. Their dy-
namic load rating has been increased by
20 %, which results in up to 70 % longer
basic life rating. This was achieved
by optimizing their geometry, surfaces
and materials as well as their dimension-
al and running accuracies. As a conse-
quence, the operating temperature in the
bearing was reduced, which means that,
for example, the stress on the lubricant
is now considerably lower. This results in
INA thread guidance roller
extended maintenance intervals and the
tapered roller bearing operates at notice-
ably lower noise levels.
In addition, the new premium tapered
roller bearings offer significantly higher
energy efficiency. This also opens up
downsizing options, that brings in the
wake not only reduced installation space
requirements but also further benefits
such as lower weight and energy costs.
Moreover, FAG tapered roller bearings
X-life make a contribution to lower oper-
ating costs in terms of Total Cost of Own-
ership (TCO) and they reduce expenses
in conjunction with maintenance and
repairs. In the textile machinery industry,
FAG tapered roller bearings X-life are ide-
ally suited, for use in weaving machine
gearboxes, for instance.
Needle roller bearings: More efficiency
in spinning preparation thanks to down-
sizing and less friction.
Earlier this year, Schaeffler Group
­Industrial launched two new INA needle
roller bearing designs that can be used
in typical needle roller applications
such as combers, knitting machines and
double rib looms:
The performance-enhanced X-life solid
needle roller bearing -D (for downsizing):
Here a newly developed, profiled steel
cage, produced by optimized forming
methods, enables an increase in load rat-
ings by up to 25 % with unchanged bear-
X-life solid needle roller bearing with the TWin Cage
Issue 2011/2012 – Page 8
Hall 2 / Booth C142
ing dimensions. This means that bearings
installed in the same mounting space
can be subjected to significantly higher
loads. Alternatively, they open up new
design options for downsizing.
The friction-reduced machined X-life
needle roller bearing with TWin cage:
The new machined needle roller bear-
ing with the TWin Cage made of plastic
provides higher efficiency as a result
of lower friction. Two individual short
needle rollers are inserted next to each
other in one cage pocket – instead of
the otherwise usual single long needle
X-life solid needle roller bearing -D (for downsizing)
roller. This completely new combination
of cage and rolling elements reduces the
friction by up to 25 % in comparison with
conventional needle roller bearings. The
resulting lower heat generation in the
bearing leads to longer grease operating
life and therefore longer lubrication inter-
vals, and also to higher accuracy of the
application. Extensive test series have
shown that needle roller bearings with
TWin Cage have a considerably increased
operating life.
Waldrich Coburg, partner of Schaeffler
Gear milling technology on WALDRICH COBURG machines
Machine tool manufacturer WALDRICH
COBURG, a company with a long-stand-
ing tradition, and the Schaeffler Group
have maintained a close and very suc-
cessful partnership for many decades
now. Various WALDRICH machines incor-
porate, for instance, Schaeffler spindle
bearings, large-size super precision
bearings, linear guidance solutions and
many more.
Established back in 1920, machine tool
manufacturer WALDRICH COBURG has
been continually expanding and refining
its product portfolio ever since. Today
the company manufactures products
such as gantry milling machines and
vertical turning turret lathes as well as
grinding and boring machines. Now the
world leader in the machining of large
parts is entering uncharted technological
territory by adding gear milling technol-
ogy to its range of machining equipment.
One example is a highly automated and
flexible production system for the com-
plete machining of internally toothed
ring gears, used mainly in the planetary
gearboxes for wind turbines. This system
is optimally tailored to these workpiec-
es. Consisting of two MultiTurn machin-
ing centers, it achieves an extremely
high level of productivity. The machines
are connected with a pallet transport
system. Each machine is equipped with
a rotary table for turning and milling
operations. Both machining centers offer
turning, boring, milling and gear milling
functions. Due to the reduced number of
clamping processes and minimal auxil-
iary process times, the workpieces can
be manufactured more quickly, precisely
and cost-effectively. Maximum quality
and productivity are in focus.
For the machining of straight and angu-
lar internal gears with gear form milling
tools, WALDRICH COBURG has devel-
oped a special gear milling head. This
has a maximum output of 75 kW and a
torque of 7,000 Nm. It automatically piv-
ots to the correct position for the helix
angle of the gear.
Large gear rings, as used in iron ore
mills for example, have diameters of
15 meters and more. At the moment,
WALDRICH COBURG is processing orders
for two machines for the complete ma-
chining of such parts. The two PowerTec
Gantries feature integrated rotary tables.
The first machine has a clearance width
Issue 2011/2012 – Page 9
of 7.5 m and a rotary table diameter of
6.5 m. It is capable of machining ring
gears up to 12 m in diameter. Gear
rings larger than 6.5 m are fixed using a
clamping star that carries the clamping
devices. The second gantry has even
larger dimensions. Featuring a clearance
width of 13 m, its rotary table has a di-
ameter of 8 m. It can machine ring gears
of up to 17.5 m. The machine’s clamping
plate measures 10 x 20 m. In addition
to standard milling heads, the machines
feature a gear milling head developed
specifically for this purpose.
The advantages of gantry machines for
gear ring production are obvious:
- Complete machining (turning, boring, Headquarters of WALDRICH COBURG
milling and gear milling),
- No lower diameter limits for workpieces,
- Machining of all kinds of workpieces
possible,
- Use of modern standard CNC machin-
ery, also for extremely large gear rings,
- Productivity and degree of automation
to WALDRICH COBURG standards.
In all machines, the gear milling head
is picked up automatically. The Z-axis
remains in the same position during
the entire milling process. However, the
vertical movement is done with the cross
rail of the machine. The cross rail is hy-
drostatically guided along both machine
columns, giving the whole system con-
stant rigidity.
Gear milling head
The performance of the rotary table is
particularly critical for the production
of high-precision gears. Especially for
its large machines, WALDRICH COBURG
used its expertise in the field of me- Spindle bearings
in practice
chanical systems and control engineer-
ing for large machine tools to optimize
the driving unit, consisting of gear ring The Schaeffler compendium for students Welcome to Hall 7 / Booth C34!
and drives. This is the only way to safely and design engineers
control the tremendous mass moments Here you will find what you are looking for!
of inertia in the control system. Application knowhow from the technology leader
- Comprehensive compendium for spindle
The design of the rotary table drive with bearing practice compiled for students and
its extremely high mechanical rigidity design engineers,
was undertaken in cooperation with the - Guideline for the selection and design of spindle
Schaeffler Group using the “Bearinx®” bearing supports for the design engineer,
calculation software. The bearing con- - Concentrated spindle bearing knowledge from
cepts and products of the INA, FAG and over 100 years of rolling bearing history,
IDAM brands have also been supplied by - Far more than just a catalog,
the Schaeffler Group. - Specific bearing stressing in machine tools:
- Design guidelines for the spindle environ- Spindle Bearings
ment,
Theory, Design and Application
- Profound information on bearing arrange-
ment, lubrication, mounting,
- Prevention and analysis of bearing damage
in main spindles,
- and much more.

The most popular rolling elements in the world
adidas and Schaeffler Group at Technical Meeting in Herzogenaurach
This year’s highlight in bearing sup-
ports and direct drive technology for
machine tools was an all-round event
in the true sense of the word: It is a
well-known fact that the adidas Group
has a good feel for balls, producing
top-of-the-range “rolling elements”.
This was illustrated in a fun way during
the evening program on the occasion of
the Schaeffler Group’s Eighth Techni-
cal Meeting, held at the central adidas
Event Center. However, the technical
aspects also got their fair share of the
limelight, namely when guest speaker
Dipl.-Ing. Nürnberg from the adidas
Group explained in his presentation the
development of the World Champion-
ship ball Jabulani.
But in addition to top grade footballs,
there are other kinds of balls that come
from Herzogenaurach too. The city is
also renowned for being home to an-
other global player who is “on the ball”,
and also produces first-grade rolling ele-
ments, albeit in a different playing field.
In this context, the latest relaunch of the
leading rolling bearing forum offered a
wide range of technical presentations
from the segments of main spindles
and feed spindles, rotary tables, linear
axes and direct drive technology that all
dealt with products having a “bearing
on efficiency”. In view of the impressive
accuracy of the adidas football, Helmut
Bode, President of Production Machin-
ery, launched a “counterattack” and de-
scribed the extraordinary characteristics
of Schaeffler rolling bearing balls. Hav-
ing dribbled out the ingenious Jabulani
here, it was time for the latest market
and company figures.
With his lecture “Motor Series RKI –
High Speeds and High Torque”, Dipl.-
Ing. Marko Pfeiffer, Head of Distribution
at IDAM, presented an initial insider
outlook to this year’s EMO highlight, the
“world’s best performing rotary axis”.
Downsizing options enabling the same
output in a smaller design space and
offering enormous cost reduction po-
tentials due to motor size adjustments
and the elimination of converters etc.
This surprised the participants and was
met with great interest. This was raised
once again when Dipl.-Ing. Robert Jung
from Application Engineering Machine
Tool Bearings introduced in his presen-
tation “Performance Increase in Bearing
Supports for Precision Axes” the new
ZKLDF..B rotary table bearing genera-
tion – a real speed doubler. Dipl.-Ing.
Michael Heid, Head of Application En-
gineering Linear Technology, provided
insights into proven and brand-new sup-
port services from the Schaeffler Group
regarding the dimensioning and design
of linear bearing supports.
The dynamic calculation of the machine
structure, as well as the type, place and
effects of adaptive damping formed spe-
„Rolling element“ training with a feel for the ball
cial highlights of his presentation “Simu-
lation of a Machine Tool”. “Damping”,
albeit the “damping of main spindles”
was also the focus of a lecture given by
Dr.-Ing. Martin Voll, Head of Application
Engineering Spindle Bearings. The opti-
mization of the dynamic spindle behav-
ior as well as the approach in damping
design raised many interested queries,
and so did Dipl.-Ing. Christoph von Kress
from Application Engineering Spindle
Bearings with his key note address en-
titled “What bearing for what spindle?”
He offered a practice-oriented overview
of the main fields of application for spe-
cific bearings and bearing supports and
brought into play the benefits of the new
RS spindle bearings (Robust and high
Speeds) under the motto “RS Opens up
New Possibilities”.
“Added Value through Adaptation of
King Pin Bearing Supports”, a contribu-
tion by Dr.-Ing. Jörg-Oliver Hestermann,
rounded off the meeting. It provided de-
tailed information about the implemen-
tation of vertical rotary axes in machine
tools, exemplified with existing bearing
solutions, in particular in large-size
rotary tables. On the eve of the meet-
ing, nearly all conference participants
had used the opportunity to take a look
behind the scenes at the Schaeffler
plant in Herzogenaurach. “Handball”
was explicitly allowed in these practical
workshops:
1. Production tour
(Focus: precision forming);
2. Failure analysis (Rotary and linear
bearings in machine tools);
3. Validation (From request for quote
to delivery: Testing and calculation
exemplified using rotary table bearings);
Production of adidas world cup ball Jabulani
Issue 2011/2012 – Page 10
4. The new Schaeffler Surface Technol-
ogy Center (added competence for coat-
ings as a design element).
The contributions lead to a large number
of informal personal contacts, an inspir-
ing exchange in the forum and useful
suggestions for the day-to-day business
and beyond. The meeting was staged
twice and both events were fully booked
early on. The number of participants
in these Technical Meetings is limited
Technical Meeting 2011
deliberately in order to maintain the op-
portunity for mutual personal exchange
of experience as well as the forum char-
acter of this exclusive event. The next
meetings are scheduled to take place
at the end of 2012. Until then it can be
expected that the world’s most popular
rolling elements from Herzogenaurach
will be key players in the game many
times over.
Tried and tested in renewable energy applications
Bearing solutions for solar, wind and water power plants
Schaeffler Group Industrial is system-
atically stepping up its activities in the
field of regenerative energies. For more
than 30 years now, the Schaeffler Group
has been successfully positioned in the
wind power sector and is an important
development partner of all wind turbine
and wind turbine gearbox manufacturers
worldwide. In addition, the newly es-
tablished Power Generation sector man-
agement handles all activities related
to solar, wave and tidal power plants. It
is also concerned with applications in
classic water power (dams etc.) and con-
ventional thermal power plants as well
as with the transmission of energy.
Thousands of hydraulic rod ends from Schaeffler
Group Industrial have gone into the Andasol solar
power plant. Here they support several hundreds
of hydraulically adjustable parabolic troughs, posi-
tioning them with millimeter precision and helping
them to continuously follow the sun.
Solar energy: Bearings for precise sun
tracking ensure higher efficiency.
Schaeffler plain bearings installed in the
Andasol solar power plant in Spain, for
example, enable the precise swivel mo-
tion of the parabolic troughs and thus
make a contribution to the plant’s high
efficiency. A total of 1,248 hydraulic rod
ends are used here. They support the
several hundred hydraulically adjustable
parabolic troughs, position them with
millimeter accuracy and enable them to
continuously track the sun.
Plain bearings are ideally suited for slow
and precise swivel motions. They can
support high forces and are suitable
both for single-direction and alternating
loads, e.g. resulting from changing wind
directions. Thus the 150-meter collec-
tor chains can be aligned with the sun’s
daily path from east to west with a preci-
sion of tenths of a millimeter.
Rolling bearings, for instance AXS an-
gular contact roller bearings, are used
for example in double-axis tracking
systems of solar-thermal facilities such
as solar towers and solar Stirling power
plants. Mirror adjustment is a typical
bearing application in these plants. Roll-
ing bearing supports in the double-axis
Sea waves as a source of regenerative energy: Schaeffler Group Industrial is a development partner for
the Pelamis wave energy converter. The individual segments are connected using bearing units that are
subject to constantly changing loads of up to several hundreds of tons.
drive units enable the motion of the
azimuth and elevation axes. High load
carrying capacity and rigidity as well
as high guidance accuracy are crucially
important here too. These characteris-
tics are the prerequisite for the reliable,
smooth and low-vibration support of the
solar mirrors. The bearings have to sup-
port high forces and torques caused, for
example by gusts of wind. The bearing
supports therefore play a decisive role
in the plants’ reliability and economic
viability.
Hydropower: Bearings for wave
power plants.
In addition to solar energy, new forms
of hydropower such as wave or tidal
power plants will also make a consider-
able contribution to the energy supply of
the future. The potential in wave power
alone is many times higher than today’s
worldwide energy demand. About 15
percent of this demand could actually
be covered through wave power plants,
according to estimations by the World
Energy Council.
Schaeffler Group Industrial has been
a strategic partner in one of the most
promising projects of this kind right
from day one, helping the British com-
pany Pelamis Wave Power to achieve a
major breakthrough in the development
of wave energy converters. Both being
keen to leave a long term legacy of clean
energy, two cooperation partners have
made this progress possible by pushing
the boundaries of bearing and seal tech-
nology and by thinking ‘outside the box’.
In 2004, Pelamis Wave Power built the
world’s first offshore wave energy con-
verter. Based on this experience, they
have now developed the ‘P2’ design
which is more efficient and cost effective
than its predecessor.
Comparable to a sea snake, the Pelamis
wave energy converter floats on the sur-
face of the water, firmly anchored to the
sea bed. Gigantic steel tubes are hinged
via joints and positioned transverse to
the crests of the waves. Via hydraulic
cylinders and pressure accumulators,
the upward and downward motion of the
waves drives hydraulic motors that are
coupled with generators. The individual
segments are linked with bearing units
consisting of a combination of different
Schaeffler bearings. Working forces on
each of these joints can be up to several
hundred tons, and these must be sup-
ported by the bearings.
Plain or spherical roller bearings are used in
dams in particular to enable the radial gates to
be opened and closed. The picture shows the
Benmore Dam in New Zealand.
Conventional hydropower: From turbines
to water screws.
Schaeffler Group Industrial has also been
excellently positioned in conventional wa-
ter power generation for many years now.
For example, plain bearings and spherical
roller bearings are used in dams, in par-
ticular for opening and closing the radial
gates. Bearings in such applications are
subject to extreme loads since the water
pressure and the weight of the lock act on
them from a single direction. Neverthe-
less it must be possible to open the gates
reliably and with low friction, even after
Issue 2011/2012 – Page 11
With the Andasol power plants, the technology
of solar-thermal power production celebrates
its premiere in Europe. Andasol 1 is the largest
parabolic trough power station worldwide. The
climate-friendly 50-megawatt facility covers the
power demand of some 200,000 people and
saves about 150,000 tons of carbon dioxide.
(Courtesy of: Solar Millennium)
long times of disuse. Since the bearing
positions are difficult to access, plain
bearings are used that operate absolutely
maintenance-free and rolling bearings
are required to offer maintenance inter-
vals of as long as possible.
Bearing expertise is required also for the
turbines used in water power generation,
for example Kaplan or Francis turbines.
This applies to the turbine rotor supports
where, for example rolling bearings are
used in smaller power packs. In addi-
tion, special plain bearings are used to
support the turbine guide vanes that
regulate the optimum water flow to the
runner’s vanes. But simpler applications
in hydropower, such as water wheels and
water screws, also require suitable bear-
ing solutions. The bearings used here
are manufactured from high nitrogen,
corrosion-resistant steel (Cronidur 30),
developed by the Schaeffler Group for
such extreme demands. So they can
operate directly in the medium without
sealing, the water itself serving as the
‘lubricant’.
Archimedes’ screw for water power generation on
the Saale River: Rings and rolling bearings of the
semi-locating bearing consist of Cronidur 30, a
high-nitrogen, corrosion-resistant bearing steel.

WIN!!!
Win a trendy
Blue Ray Player!
Competition:
Please complete our
EMO slogan.
Please enter the correct answer
on the adjacent coupon. Complete
the form and return it to:
Schaeffler Technologies GmbH & Co. KG
Production Machines division
IEBSWE-SM
Georg-Schaefer-Strasse 30
D-97421 Schweinfurt
Fax: +49 (0) 97 21/91 14 35
Closing date: May 31, 2012
There is no legal recourse.
Employees of Schaeffler KG and trading
partners are not permitted to take part.
Preview of Issue 2012
1. EMO highlights in field operation
2. Innovations for printing machines
3. AMB in Stuttgart
+++ NEWSTICKER +++ NEWSTICKER +++ NEWSTICKER +++ NEWSTICKER +++ NEWSTICKER +++ NEWSTICKER
You will find Schaeffler Group
Industrial at ITMA in Barcelona
(Sep. 22-29, 2011 – Hall 2, C142),
at IMTS in Chicago (Sep. 10-15, 2012)
and once again at AMB in Stuttgart,
Germany (Sep. 18-22, 2012)
+++ NEWSTICKER +++ NEWSTICKER +++ NEWSTICKER +++ NEWSTICKER +++ NEWSTICKER +++ NEWSTICKER
Your local distributor:
Issue 2011/2012 – Page 12
Yes, I would like to win a Blue Ray Player!
LAST BUT NOT LEAST
Solution:
P Data Matrix code ensures high-
“added competence” for machine tools er safety with spindle bearings
Last name, first name: ____________________________________________________
Company: _______________________________________________________________
Street/No.: _____________________________________________________________ Counterfeits are fake products that look
very similar to original goods, so much
City/postal code: ________________________________________________________ so that it is hard to tell them apart by
looks alone. They are manufactured
Tel.: ___________________________________________________________________ with the goal of (unjustifiably) realizing
the market price of the original. In ad-
Fax: ____________________________________________________________________ dition to this fraudulent approach, the
intent is often also to damage the im-
E-Mail: _________________________________________________________________
age of a particular manufacturer.
We would appreciate it if you would answer the following questions:
Did we get your address right? Please let us know of any changes we need to make. To protect high-grade Schaeffler
(Please print letters) products and their users against such
machinations, FAG spindle bearings
will in future be marked with an ad-
ditional Data Matrix code. This will
Who else in your company should receive “added competence”? allow the immediate identification of
every single super precision bearing.
Applied both to the bearing and to the
What improvements would you like to see in the Production Machinery division? packaging, this 2-D bar code will show
in the fraction of a second whether the
scanned bearing really is the original
FAG bearing as described in great
detail. Alternatively it will immediately
The winner of our quiz in Issue 1/2010 indicate that a second version of this
product “exists”, in other words that
Dietmar Loh from the Engineering this is a case of counterfeiting. Marking
department at Klingelnberg GmbH in products with the Data Matrix code is
Hückeswagen is the lucky winner of part of Schaeffler’s Group-wide STOP
an iPad2. The trendy high-tech device project (Security Technologies for Origi-
was presented to him by field service nal Products in the Schaeffler Group).
representative Jürgen Donath from For Schaeffler business partners, this
Schaeffler’s engineering office in measure means considerably higher
Wuppertal in May. safety and security.
Imprint
Published by:
Schaeffler Technologies GmbH & Co. KG
Production Machinery division
Editor in chief:
Claudia Kaufhold
Adress:
Schaeffler Technologies GmbH & Co. KG
IEBSWE-SM
Georg-Schaefer-Strasse 30
D-97421 Schweinfurt
Tel.: +49 (0)9721/91 19 11
HOTLINE
Fax: +49 (0)9721/91 63 16
A Member of the Schaeffler Group
INA Schaeffler Group USA Inc. · Tel: 803-548-8500 · Fax: 803-548-8599 Editorial team:
Helmut Bode
FAG Schaeffler Group USA Inc. · Tel: 800-243-2532 · Fax: 203-830-8276 Rainer Eidloth
Clemens Hesse
The Barden Corporation USA Tel: +1 203-744-2211 · Fax: +1 203-744-3756
Claudia Kaufhold
U.K. Tel: +44(0) 1752 725506 · Fax: +44(0) 1752 725506
Norfried Köhler
Martin Schreiber
E-Mail: pmsales@schaeffler.com Produced by:
www.schaeffler.com Buena la Vista AG, Würzburg