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SKF Explorer and SKF Energy Efficient bearings provide sustainable solutions

12. Jun. 2010

Drawing on more than 100 years of engineering knowledge and unmatched

expertise in the field of tribology, SKF is continuously working to

create products that are so much more efficient that over their

operating lives, they save more energy than it took to manufacture

them. At the same time, SKF engineers want to give manufacturers a

proven way to reduce energy use, decrease maintenance costs, improve

machine reliability and contribute to global sustainability.

Success has come in the form of two bearing performance classes, each

designed to provide money- and resource-saving advantages in specific

applications. SKF Explorer bearings provide benefits for heavy load

applications, while SKF Energy Efficient (E2) bearings decrease power

consumption in light-to-normal load applications.


SKF EXPLORER BEARINGS: FOR HEAVIER LOADS
SKF Explorer bearings (fig. 1) have been developed to run cooler,

smoother and longer than standard rolling bearings in heavy load

applications. These bearings reduce environmental impact by enabling

downsizing and by reducing both lubricant and energy consumption. Just

as important, this performance class of bearings can reduce the need

for maintenance and contribute to increased productivity.

Key to the performance of SKF Explorer bearings is the optimized

internal geometry. Using proprietary software, SKF engineers analyzed

the interrelationship of the rolling elements, raceways and cage. They

devised methods to reduce friction, heat generation and wear in the

bearing, while enabling SKF Explorer bearings to withstand heavier

radial and/or axial loads.

The rolling elements of SKF Explorer bearings are manufactured to

extremely close tolerances to reduce vibration levels and equalize load

distribution. Cages are enhanced to improve guiding of the rolling

elements and optimize the effect of the lubricant while lowering heat,

friction, noise and vibration levels. The surface topography of the SKF

Explorer bearing rolling elements and raceways is optimized to enhance

the formation of a hydrodynamic lubricant film, maximizing the effects

of the lubricant, while reducing heat generation and wear. Exceptional

strength and durability have been achieved through the use of extremely

clean, highly homogeneous steel, while a unique heat treatment process

results in better dimensional stability in applications where operating

temperatures are high. Today, SKF manufactures a large number of SKF

Explorer bearings covering different bearing types.


Environmental savings and increased uptime
A practical example of the savings that can be achieved comes from

Stora Enso, a paperboard producer in Sweden. With sealed SKF Explorer

bearings, Stora Enso has increased uptime, eliminated its lubrication

system and reduced water reclamation costs.

Previously, the company was experiencing continuous bearing failures in

a suction box vacuum system used to extract water from pulp. After just

four to seven months of operation, the bearings were failing, as water

leaked into the bearing arrangement, washing grease out, which also led

to fretting corrosion and finally to premature bearing failure. Grease

in the water had to be extracted and disposed of, adding to water

treatment costs.

Stora Enso installed SKF Explorer sealed spherical roller bearings in

two suction boxes. These sealed bearings, which keep lubricant in and

water out of the bearing cavity, prevent the ingress of water and

contaminants into the bearing.

The SKF Explorer sealed spherical roller bearings in both suction boxes

ran trouble-free for more than 13 months. In addition to extended

bearing service life, the company was able to eliminate the lubrication

system and reduce grease consumption by approximately 3 kg/y per

bearing. Eliminating the need to extract and dispose of grease from

process water realized additional cost savings and environmental

benefits.


SKF ENERGY EFFICIENT BEARINGS: FOR LIGHT TO NORMAL LOADS AND RELATIVELY

HIGH SPEEDS
SKF Energy Efficient (E2) bearings belong to a performance class of

bearings that have been specially designed to reduce the frictional

moment in the bearing by at least 30 % when compared to SKF standard

bearings (figs. 3, 5, 7 and 9).

Like the SKF Explorer bearing, the SKF Energy Efficient bearing is the

result of rethinking and redesigning virtually every facet of bearing

design. New theories in tribology, metallurgy, lubrication, sealing and

manufacturing were combined to create new bearing geometries,

specialized cages and refined manufacturing techniques.

A significant breakthrough with the SKF E2 bearing is the development

of new grease formulas to lubricate the bearings and extend the grease

life or lubrication intervals.

The SKF E2 deep groove ball bearing (fig. 2) is particularly well

suited for electric motors (fig. 3), pumps, gearboxes, conveyors, fans

and other applications characterized by light-to-normal loads and

relatively high speeds.

Results have shown that, when applied to a shielded deep groove ball

bearing, the new low-friction grease developed for the SKF E2 bearing

will last at least two times longer than conventional greases used in

similar standard bearings (fig. 4).


Medium size NJ design cylindrical roller bearings, which are typically

used on the intermediate shafts of gearboxes, are also available in the

E2 performance class.

These bearings typically run under combined loads, with axial loads of

up to 30 % of the radial loads. NJ design cylindrical roller bearings

in the gearbox of a wind turbine have been tested. The power losses in

SKF Energy Efficient cylindrical roller bearings were up to 80 % lower

compared to standard SKF cylindrical roller bearings. (fig. 5). The

outstanding frictional moment reduction under combined loads was

achieved by optimizing the roller end face profile and the roller-

flange contact area.


SKF Energy Efficient tapered roller bearings offer a number of

advantages. These bearings, like other SKF E2 bearings, are

characterized by a power loss reduction of at least 30 %. These

improvements were achieved by optimizing the number of rollers,

replacing the steel cage with a new-design polymer cage and by

optimizing the topography of the rollers, raceways and flange (fig. 6).

The result: a lighter-weight, cooler running bearing that consumes less

lubricant and less power (fig. 7).


SKF Energy Efficient spherical roller bearings (fig. 8), like all other

SKF E2 performance class bearings, reduce the frictional moment in the

bearing by at least 30 % (fig. 9). Developed for light-to-medium loads,

these bearings, lubricated with SKF LESA 2 grease, run cooler than SKF

Explorer bearings to reduce lubricant consumption and extend

relubrication intervals.

Return on investment
The SKF E2 bearing has proven its worth many times over in applications

worldwide. At the Sangam Group, a textile company in India, SKF E2 deep

groove ball bearings were installed in an electric motor powering a

textile machine. The motor runs at 1,470 r/min, operating 22 hours per

day, 363 days per year. By switching to the SKF E2 deep groove ball

bearings, Sangam Group estimates a yearly energy saving of more than

2,600 kWh per motor, and additional savings provided by the bearings’

longer service life. The company calculated a return on investment of

just 37 days. As a result, Sangam Group installed SKF E2 deep groove

ball bearings in the other motors and pumps in the factory.

At one of the GlaxoSmithKline Consumer Healthcare factories, with the

installation of SKF E2 deep groove ball bearings in electrical motors

for pumps, the return on investment included money savings as well as

contributions to a better environment. The plant reports annual energy

savings per motor of more than 4,500 kWh per year, equalling an annual

savings of 390 euros. A two-tonne reduction in CO2 was realized, and

the company estimates that it gained 20 euros for every euro invested.


Sustainability and savings
In conclusion, SKF Energy Efficient (E2) bearings have the potential to

make a significant contribution to global sustainability. In fact, if

SKF Energy Efficient deep groove ball bearings were used on every

industrial motor in the EU and US (and assuming a minimum of 30 % lower

frictional moment), potential energy savings would equal 2.46 billion

kWh/year. And this estimate does not take into account the millions of

motors and other applicable machines in use elsewhere throughout the

world

by Daniel C Statler SKF Group Communications Bearings & units, Downingtown, Pennsylvania, USA


obt bearing
shandong obetter bearing co., ltd
www.obtbearing.com


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