FEBRUARY Bearings. Case Studies Technical Article Product Focus. w w w. p o w e r t r a n s m i s s i o n. c o m

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1 PTE powertransmissionengineering FEBRUARY 2007 Bearings Case Studies Technical Article Product Focus w w w. p o w e r t r a n s m i s s i o n. c o m

2 Inside Front Cover AD

3 PTEC powertransmissionengineering o FEBRUARY n 2t e 0 n 0 t 7s FEATURES Bearings Case Study: World's Largest Wind Turbine Generates New Large-Shaft Bearing Technology 13 Case Study: Cool Bearings for High-Speed Trains 19 Technical Article: Investigation of Tapered Roller Damage Detection Using Oil Debris Analysis 22 Bearing Product Focus Recent product releases for a variety of applications 33 A bearing assembly is being mounted on the shaft of a 5MW wind turbine. february 2007 powertransmissionengineering 1

4 PTE powertransmissionengineering FEBRUARY C o n t e n t s DEPARTMENTS Product News The latest power transmission products Events Coverage of Pacific Design & Manufacturing Show, Hannover Messe, plus our Technical Calendar Industry News The latest news from the power transmission industry Classifieds Our product and service marketplace Advertiser Index Contact information for companies in this issue ON L I N E powertransmission.com Power Transmission Engineering Sign up for a free subscription to our new magazine FORUMS (new January 2007) Voice your opinion, ask an expert, and talk with the worldwide power transmission industry BUYERS GUIDE Search for power transmission products and services and communicate with the industry's leading suppliers BUYERS GUIDE Search for gear industry products and services and communicate with the industry s leading suppliers SUBSCRIPTIONS Sign up for subscriptions to Gear Technology and the geartechnol ogy.com newsletter E-GT Subscribers get access to back issues of Gear Technology NEW POLLS What's the best way to find skilled labor? Cast your vote, and see what your peers think. Randall Publishing makes every effort to ensure that the processes described in POWER TRANSMISSION ENGINEERING conform to sound engineering practice. Neither the authors nor the publisher can be held responsible for injuries sustained while following the procedures described. Postmaster: Send address changes to POWER TRANSMISSION ENGINEERING, 1425 Lunt Avenue, P.O. Box 1426, Elk Grove Village, IL, Contents copyrighted by RANDALL PUBLISHING, INC., No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission in writing from the publisher. Contents of ads are subject to Publisher s approval. 2 powertransmissionengineering february

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6 PTE powertransmissionengineering VOL. 1, NO. 1 Randall Publishing, Inc Lunt Avenue P.O. Box 1426 Elk Grove Village, IL Phone: Fax: Half Pg Ad EDITORIAL Publisher & Editor-in-Chief Managing Editor Senior Editor Assistant Editor Editorial Consultant Technical Editors ART Art Director ADVERTISING Advertising Sales Manager CIRCULATION Circulation Manager INTERNET Web Developer Michael Goldstein publisher@powertransmisssion.com William R. Stott wrs@powertransmisssion.com Jack McGuinn jmcguinn@powertransmisssion.com Robin Wright robin@powertransmisssion.com Paul R. Goldstein Robert Errichello, Don McVittie, Robert E. Smith, Dan Thurman Kathleen O'Hara kathyohara@powertransmisssion.com Ryan King ryanking@powertransmisssion.com Carol Tratar subscribe@powertransmisssion.com Dan MacKenzie webmaster@powertransmisssion.com RANDALL PUBLISHING STAFF President Michael Goldstein Vice President Accounting Richard Goldstein Luann Harrold PTE powertransmissionengineering SPRING 2007 Bearings Power Transmission Basics 4 powertransmissionengineering spring

7 product news Danaher s New Electronic Indexer DELIVERS INCREASE IN THROUGHPUT Danaher Motion introduces the rotary indexer product set. This fully programmable, direct- drive solution provides electronic indexing in a package that delivers increased throughput comparable to mechanical indexers and is maintenance-free over the entire life of the system. The Danaher Motion rotary indexer product set provides unmatched operational performance and flexibility, allowing OEMs to build a better machine, faster, and end-users to precisely assemble even the smallest of parts faster with far less scrap and better yield, while actually lowering the cost of ownership over the life of the machine, says Dennis Gallagher, vice president of systems for Danaher Motion. This solution enables users to achieve software-selectable motion sequences that run circles around mechanical indexer capabilities. Precision technology allows for superior repeatability to +/-1.2 arc-sec, with no backlash and system accuracy to +/- 26 arc-sec. In comparison, mechanical indexers typically provide best-case repeatability to +/- 33 arc-sec and accuracy to+/-66 arc-sec, he says. According to the company s press release, Danaher Motion s rotary indexer product set is programmed to go in any direction, at any speed, and at any angle. This feature is important to system integrators that deal with multiple product designs, including custom machines, as they are able to use a single indexer solution to satisfy any number of requirements. Additionally, should the demands of the manufacturing process change, this flexibility would allow end users to update the motion sequence to satisfy their application needs. This indexer product set can rotate both clockwise and counter-clockwise to achieve the shortest cycle time and increased throughput. Index times are programmable and no honing is ever required, as absolute position feedback maintains position, even under power cycling. Users should benefit from a noticeable 20dB reduction in system noise when compared with mechanical indexers. For more information: Danaher Motion 1500 Mittel Blvd. Wood Dale, IL Phone: (866) ContactUS@DanaherMotion.com Internet: Haydon Switch and Instrument RELEASES NEW CATALOG OF LEADSCREW ASSEMBLIES Haydon Switch & Instrument Inc. has a new, detailed technical catalog for its leadscrew assemblies product line. The new leadscrew assemblies include an offering of acme leadscrews, advanced coatings and anti-backlash nuts. According to the company s press release, these patent-pending designs not only eliminate backlash between the screw and nut, they also maximize system stiffness and minimize lost motion. Haydon offers five different nut styles, ranging from freewheeling, nonanti-backlash nuts to a user-adjustable anti-backlash nut. Leadscrews are available in diameters ranging from 1/8 to 5/8, and leads as fine as up to fast leads as high as All Haydon leadscrews are rolled from precision-ground 303 stainless steel. Leadscrews are also available with Haydon s unique Black Ice coating, a specially developed PTFE coating process, which eliminates flaking that commonly occurs with other PTFE coatings in today s marketplace. Haydon s anti-backlash nuts are made from a self-lubricating, polyacetal thermoplastic. Haydon s high-strength, freewheeling nut is made from a glass-fiber reinforced polyester that offers high load carrying capability and very high mechanical strength. In addition to the standard nuts, custom designed nuts and flanges are available. For more information: Haydon Switch & Instrument Inc Meridien Rd. Waterbury, CT Phone: (203) mcolucci@hsi-inc.com Internet: february 2007 powertransmissionengineering 5

8 product news Rexroth s New Drive System CONTAINS DRIVE, MOTION CONTROL AND LOGIC CONTROL MOUNTED ON THE MOTOR The IndraDrive Mi from Rexroth is a new motion control design concept. The motor casing serves as the heat sink for the servo/control system, which is attached to the long axis of the motor, adding only a small amount to the cross sectional profile. According to the company s press release, this results in up to 30% less area required, compared to other integrated systems where the electronics are fitted behind the motor, and more than 50% less total space compared to a traditional servo system with separate motor and drive packages. Overall, this reduces the required space and air conditioning requirements of the control cabinet. In addition, a single cable carries both power and SERCOS communications. When several IndraDrive Mi systems are connected in series, the wiring costs are reduced even further. Instead of two cables running from the control cabinet for each axis, only one cable now is required. Each additional axis is daisychained to the preceding axis with prefabricated connectors. All connections, as well as the IndraDrive Mi itself, are rated to protection class IP65. The new IndraDrive Mi combines top power density with total functionality and is fully compatible with the IndraDrive range. As with all IndraDrives, these servo drives have over 100 technology functions, including the integrated Motion Logic system conforming to IEC The integrated concept of IndraDrive Mi eliminates the need to replace wearing parts such as fans, electrolytic capacitors and relays. Specialized electronics are designed to handle extreme temperature ranges, while providing more rated power than competitive solutions. For more information: Bosch Rexroth AG Phone: (630) edeist@market-sense.com Internet: Stock Drive Products INTRODUCES NEW SERIES OF TIMING BELT CLAMPS Stock Drive Products introduced a new series of 16 timing belt clamps for long-span reciprocating synchronous drives. These compact, lightweight clamps made from polycarbonate resin offer a solution for space and inertia concerns. According to the company s press release, these clamps accommodate single- and double-sided MXL (A 6M16M...), XL (A 6M 3M...), GT2-2 mm (A 6M51M...),3 mm (A 6M53M...), 5 mm (A 6M55M...) and HTD-3 mm (A 6M563M...), 5 mm (A 6M55M...) timing belts and are supplied with stainless steel assembly hardware. For more information: Stock Drive Products 2101 Jericho Pkwy. New Hyde Park, NY Phone: (516) hrarum@aol.com Internet: 6 powertransmissionengineering february

9 product news PowerJacks OFFER MORE PRECISE MOVEMENT WITH SPRING COIL LIMITER To push the cover into position precisely, Power Jacks designed a special coil spring load limiter for the end of the jack s lifting screw. The load limiter consists of a helical coil wire spring, with squared ends held in place between two mounting plates. One plate is a restraining plate and the other a moving plate that is bolted to the cover structure. The spring is preloaded between the two plates so that the spring will not compress under normal working load when the cover is not in contact with its dead stops. When the screw jack drives the cover against a dead stop, the spring compresses over a normal working distance of 10mm. Within this 10mm The newest innovation from PowerJacks addresses an industrial machine s need to move a cover or lid onto a dead stop or sealing face. The movement must be precise, with contact on all dead stops or over the complete sealing face. A mechanical linear actuator or screw jack is frequently used for this type of application. Conventionally, these are best suited to lowering applications, as a simple elongated slot in an actuator s ram or clevis end allows the cover to be lowered into position and mate under its own weight by driving the actuator until the lifting pins are midway in the clevis slot. However, this method cannot be used to push a cover into position. Spooner Industries asked Power Jacks to solve this problem for one of their dryer hoods. For this particular application, a screw jack was the optimum solution. Half Page Island Ad february 2007 powertransmissionengineering 7

10 product news window, a limit switch is positioned to signal the machine s control system to stop the screw jack as a positive stop position is reached. As the rate of compression of the spring is critical to the operation, each spring is custom designed for each application s specific requirements. Half Page Island Ad In addition, for the device to work correctly, the spring assembly must remain stationary in its fixture. The screw jack was therefore fitted with a keyed lifting screw to prevent rotation. Two extra features were included on the screw jack to address safety concerns: 1. A rotation monitor to detect a jamming condition, consisting of a proximity sensor creating a train of pulses from a target ring that rotates with the gear wheel in the screw jack. The machine s control system can then compare pulse rates to determine a moving or stopped condition. 2. A secondary holding device for the lifting screw was provided by fitting a safety nut in series with the worm gear. This safety nut is not normally in contact with the lifting screw threads and is only engaged in the unlikely event that the trapezoidal screw thread on the gear wheel fails. To complete the unit for system installation, the screw jack s lifting screw was fitted with a bellows boot cover, and a special flange-mount Neeter Drive bevel gearbox was used to connect the drive system to the screw jack at right angles. Since installation, the unit has worked successfully for Spooner Industries, which has now used several variations and models of the design up to 100kN screw jack capacity rating. For more information: Power Jacks Ltd. South Harbour Rd. AB 439BZ Scotland Phone: sales@powerjacks.com Internet: R + W America s New Couplings DESIGNED FOR POWER TRANSMISSION AND PUMP DRIVE APPLICATIONS R +W America s new ECOLIGHT- TX1 series of molded thermoplastic insert couplings offer a reduced mass and moment of inertia, accompanied by a 8 powertransmissionengineering february

11 product news high level of chemical compatibility and tolerance for heat. The TX couplings are suitable for pump drives and other power transmission applications. According to the company s press release, the plastic-to-metal interface between the coupling hub and the shafting allows for quieter operation than with metallic couplings. The hub material is a glass-fiberreinforced polyamide developed for rigidity and corrosion resistance. Accelerated life testing involved 40 million load reversals at the coupling s rated torque. No change to the integrity of the coupling keyway was discovered, as the steel key itself was the more brittle and compliant of the two materials. R+W America says the thermal stability of the material is also critical, as an H7 shaft fit tolerance for the hub must be maintained, regardless of the environments in which the couplings will be used. R+W TX couplings have an elastomer element that is press-fit between the two precision-molded coupling halves, resulting in zero backlash and guaranteed concentricity. The elastomer insert is available in several shore hardness values, allowing the designer to choose the level of damping effect. The TX1 series coupling is designed for a pure keyway connection and is molded or bored to customer shaft specifications. Shaft mounting is achieved via a keyway and a set screw. Sizes are available for torque capacities ranging from 2Nm (17.7 lbs/ in) to 660Nm (5841 lbs/in), and bore diameters from 8 to 45mm and.375 to 1.75 inch with standard or metric keyways. Allegro s Two New Motor Drivers DESIGNED FOR ONE OR TWO DC MOTORS Half Page Island Ad Allegro Microsystems recently released three new products to the marketplace. The A3995 drive is designed for applications that have two DC motors. The 6 x 5 x 0.9 mm QFN package is designed for applications where PC board space is at a premium. For more information: R + W America 1120 Tower Lane Bensenville, IL Phone: (888) amendocha@rw-america.com Internet: february 2007 powertransmissionengineering 9

12 product news The A3989 drive is designed for applications that have one DC motor and one stepper motor. The company also introduced the A8286 and A8292 dual LNB supply control voltage regulators that utilize the company s BCD process. The low-noise block converter regulators (LNBRs) are monolithic linear/switching voltage regulators, specifically designed to provide power and interface signals to an LNB downconverter via a coaxial cable. The integrated boost switch has been optimized to minimize both switching and static losses. Voltage drop across the regulator has also been minimized. For more information: Allegro Microsystems 115 Northeast Cutoff Worcester MA Phone: (508) Internet: Half Page Island Ad PCB s Pressure Sensors CERTIFIED FOR HARSH ENVIRONMENTS PCB Piezotronics introduced a series of dynamic, ICP pressure sensors that have been certified under ATEX and CSA for use in hazardous environments. Series 102 and 121 pressure sensors are suitable for monitoring the performance of compressors, pumps, and gas turbines because they measure dynamic pressure events such as surges, pulsations, and spikes. These sensors also detect wellhead acoustics to determine properties of 10 powertransmissionengineering february

13 product news mud and water. Sensors may be used with ICP signal conditioning and permit the use of a variety of two-wire cable systems. The low-impedance signal may be transmitted over long cable distances, and the sensors may be used in dirty environments with no signal degradation. For more information: PCB Piezotronics Phone: (716) pressure@pcb.com Internet: Steinmeyer MINIATURIZES BALL BEARINGS Steinmeyer Inc. announced an addition to its standard line of miniature precision screws the world s smallest commercially available stainless steel ball screw. According to the company s press release, the new ultra-miniature ball screws are available in stainless steel with diameters as small as 3 mm and a choice of two pitches 1 mm or 0.5 mm. Steinmeyer now offers a range of miniature screws in stainless steel, from 16 mm diameter (with up to 30 mm pitch), down to 3 mm diameter. The products are manufactured especially for demanding applications in clean room, high-vacuum or corrosive environments. The screws are equipped with one of four types of ball nuts, with or without preload. By using Steinmeyer s internal ball deflector returns instead of external tubes, the nuts offer smooth, low-noise operation. Several standard lengths are included in the production program, complete with finished ends. Screws are manufactured from a 400 series stainless steel, hardened and then precision-ground to meet ISO tolerances from T0 to T5. All parts of the ball screw unit are manufactured from corrosion- resistant stainless steel including the shaft, nut, ball deflectors and balls For application flexibility, the miniature screws are offered with a choice of four nut types: Series 1112 a cylindrical single nut with convenient attaching thread, available with play or preloaded using over-sized balls. Series 1214 a compact, cylindrical single nut with fitting key, available with play or preloaded using over-sized balls. Series 1412 a single nut with flange, available with play or preloaded using oversize balls. Series 1510 a spring preloaded double nut, that effectively compensates for torque variations due to inaccuracies in the ground thread. The result is extremely smooth motion with near-constant idling torque a critical requirement in many scanning applications. Applications for stainless steel miniature ball screws include semiconductor production machines, medical devices, including surgical robots and aerospace mechanisms. For more information: Steinmeyer Inc. 217 Middlesex Turnpike Burlington MA Phone: (781) Internet: Third Pg Ad february 2007 powertransmissionengineering 11

14 bearings QBC s Ball-Less Ceramic Bearings FEATURE LIGHTER WEIGHT The new BCCRIXM Series of 28 ball-less ceramic bearings from Quality Bearings and Components features lighter weight and better shock absorption characteristics when compared with conventional types. The bearings are constructed of Zirconia ZrO2 ceramic material, which resists deformation, can be operated at high temperatures, and has improved resistances to chemicals. Their anti-friction characteristics make the bearings suitable for use in powder, dust and muddy water environments at speeds up to 1,000 rpm. Zirconia is also nonmagnetic, serces as an effective electrical insulator, and has low thermal conductivity and high fracture toughness. These ceramic bearings are designed to fit shaft size diameters ranging from 4 30 mm. Outer ring bearing outside diameters range from mm. AST Bearing LAUNCHES TAPERED ROLLER BEARING LINE AST Bearings added a new product line of high-carbon, chromium-steel tapered roller bearings. According to the company s press release, the tapered roller bearings are completely interchangeable with those of major bearing manufacturers. These bearings consist of four basic components: the cone (inner ring), the cup (outer ring), tapered rollers and a cage (roller retainer). The cone, cup and rollers carry the load, while the cage spaces and retains the rollers on the cone. The cone, rollers and cage are referred to as the cone assembly. Individual cup and cone components are available as well as the complete assembly. AST Bearings plans to supply both through-hardened and case-hardened tapered roller bearings. Throughhardened bearings have a consistent hardness throughout the component, and case-hardened bearings have a surface hardening combined with a tough, flexible core. Casehardened bearings will be supplied upon special request only. According to AST s press release, the tapered roller bearings offer dimensional stability under heavy loads, long life performance in harsh and contaminated environments and a durable steel cage. Tapered roller bearings are used for heavy-duty, moderate speed applications. Typical applications include agriculture, construction and mining equipment, various axle systems,conveyance vehicles, gearboxes, engine motors and reducers. systems,conveyance vehicles, systems,conveyance vehicles, For more information: Quality Bearing Components 2101 Jericho Pkwy. New Hyde Park, NY Phone: (888) qbcsupport@qbcbearings.com Internet: 12 powertransmissionengineering february

15 bearings gearboxes, engine motors and reducers. gearboxes, engine motors and ra variety of inch and metric sizes are available. The standard stock sizes are: ID mm ( ) and OD mm ( ). educers. For more information: AST Bearings 115 Main Rd. Montville, NJ Phone: (800) Internet: tapered-roller-bearings.php Quarter Page Ad SKF s Ball Bearing Units OPERATE AT DYNAMIC LOAD CAPACITY SKF s ConCentra ball bearing units for high-speed air handling applications integrate concentric locking technology to form a near-360º interference fit with the shaft. This serves to reduce noise, vibration, and potential fretting corrosion; reduce risks of uneven load distribution, imbalance, and shaft damage; and enable units to run at their bearing s full dynamic load capacity. Unlike conventional set screw bearing units used in fans and blowers (which contact the shaft in only two or three places), ConCentra ball bearing units feature a patented multi-step sleeve arrangement. As the special mounting screws are tightened during installation, the bearing unit s inner ring is driven up a series of inclined planes, compressing a sleeve around the shaft. The resulting secure and concentric fit delivers the optimized performance benefits. For removal, the mounting screws are loosened and dismounting screws tightened to reverse the process. This eliminates a need to Quarter Page Ad february 2007 powertransmissionengineering 13

16 bearings Quarter Page Ad cut bearings from shafting during removal. According to the company s press release, the bearing unit s concentric mounting technology creates a high locking force without requiring extremely close shaft tolerances. Shaft tolerances of ISO h9/it5 can be used. Shafts also can be specified as commercialgrade or hollow to provide cost-effective alternatives to typically expensive ground, specially machined, or polished shafts normally mandated with set-screw air-handling units. The ConCentra ball bearing units incorporate SKF deepgroove ball bearings, either pre-lubricated for the life of the bearing (with special air-handling quality grease) or equipped with lubrication fittings. A two-part sealing arrangement consists of a low-friction contact seal and phosphated metallic flinger to prevent intrusion of solid and liquid contaminants, enhance grease retention, and minimize maintenance demands. Ball bearing units are available in pillow block and two- and four-bolt flange versions. Bore sizes (1 to 2-15/16 ) fit most standard fans and blowers. For more information: SKF USA Inc Gehman Rd. Kulpsville, PA Phone: (800) 440-4SKF skfusainfo@skf.com Internet: Quarter Page Ad igus Bearings 14 powertransmissionengineering february ON DISPLAY AT PACIFIC DESIGN AND MANUFACTURING SHOW igus Inc. plans to showcase iglide bearings and DryLin linear guide systems and other motion control technologies at the Pacific Design and Manufacturing Show. Some of the new products on display will include: Igus first linear actuator, DryLin ZLW, designed for compact, quick positioning of lightweight parts. DryLinW compact linear guide system, now available with a stainless steel shaft for maintenance-free operation and optimal machine performance. DryLin linear slide tables available in a variety of options to

17 bearings suit numerous requirements from compact, to fast-pitch to lowcost. Compact igubal pivoting bearings to compensate for alignment errors. Iglide plastic plain bearings, which are a replacement for bronze or re-circulating ball bearings. These bearings need no oil; they are self-lubricating and maintenance-free. Iglide plastic is also used in igubal, DryLin R and the gliding elements of all DryLin guide systems and tables. Therefore, igus entire line of machinery components is lubrication free. Quarter Page Ad For more information: Igus Inc. P.O. Box East Providence, RI Phone: (800) fphillipo@igus.com Internet: INA/FAG s New Cylindrical Roller Bearing INCREASES LOAD-CARRYING CAPACITY The X- Life cylindrical roller bearings from INA/FAG were designed to increase loadcarrying- capacity and extend bearing life. A c c o r d i n g to the company s press release, the changes in surface quality have yielded an average improvement of 18% in dynamic load rating and an average increase in nominal rating life of 70%. Additional features include reduced peak roughness values on raceway surfaces providing optimized stress concentrations. INA/FAG offers two new cage designs pressed-steel cage and profile-milled brass cage, in addition to the three traditional types of materials (polyamide, pressed steel and conventional machined press). Quarter Page Ad february 2007 powertransmissionengineering 15

18 bearings Quarter Page Ad The one-piece brass cage offers optimized roller contact on the cross piece, optimized roller retainment and minimized weight with necessary component strength. Applications involving strong vibration or high acceleration (such as gear/bearing arrangements) are most compatible with the one-piece, rib-guided solid brass cage. Bearings with a pressed-steel cage are usually suitable for applications requiring high temperature, good lubrication and high geometric stability of the cage. The X-Life pressed-steel cage is characterized by precisely defined guidance surfaces on the crosspieces, with which the rollers are in contact and therefore have precise parallelism to the crosspieces. In the old design, the guidance surface for the roller on the crosspiece was affected by the stamped surface and its poorer surface quality. The contact running surfaces of the new cage are both flat and uniform. For more information: FAG Bearings Corp. 200 Park Ave. P.O. Box 1933 Danbury, CT Phone: (800) Internet: LM76 ANNOUNCES FDA- AND USDA-COMPLIANCE Quarter Page Ad 16 powertransmissionengineering february LM76 s new FDA- and USDA-compliant bearings were designed for applications involving processed food, packaged food, medical instruments, medical devices and pharmaceutical

19 bearings products. The bearings are manufactured in inch sizes of 1/4 1 1/2 and a profile rail-and-slide system that can be integrated into new and existing applications. Bearing options include self-lubricating Teflon composite bearings in a 304 stainless steel shell, and bearings with a ceramic-coated shell and FDA- and USDA-compliant liner. The bearings are available in closed and open configurations, and are drop-in replacements for inch-sized linear ball bearings. Shafting options include solid and hollow L 304 stainless steel and ceramic-coated aluminum shafts in lengths of 12. Quarter Page Ad For more information: LM-76 Linear Bearings 140 Industrial Dr. East Longmeadow, MA Phone: (800) sales@lm76.com Internet: MRC Bearing s CUSTOMIZED STEEL BEARINGS PERFORM BEST IN HARSH, CORROSIVE ENVIRONMENTS Quarter Page Ad MRC s custom HNCR steel bearings are constructed from high-nitrogen corrosion- resistant steel, and they offer improved corrosion resistance and fatigue life compared with conventional stainless steel bearings. The company says these bearings perform best in harsh, corrosive environments. Applications include food processing equipment, paper mill machinery and industrial pumps, among others. The presence of nitrogen coupled with high chromium in february 2007 powertransmissionengineering 17

20 bearings HNCR steel in these bearings contributed to improved corrosion resistance, compared with 440C stainless. According to the company s press release, hardened and tempered HNCR provides hardness (58HRC) comparable to steel and HNCR steel yields fatigue life better than to extend service life. For more information: MRC Bearing Service 1510 Gehman Rd. Kulpsville, PA Phone: (716) Internet: Boca Bearing s Ceramic Bearings MANUFACTURED FOR HARSH ENVIRONMENTS Boca Bearing s expanded range of full ceramic and ceramichybrid ball bearings is constructed of a highly manufactured ceramic similar to the heat-absorbing, super-resilient tiles on the Space Shuttle. According to the company s press release, ceramic is best suited for any application seeking to achieve higher rpm s and to reduce overall weight for harsh environments with high temperatures and corrosive substances. Ceramic silicon nitride balls, for example, exhibit much greater hardness than steel balls, resulting in at least 10 times greater ball life due to ceramic s ability to maintain the surface finish longer. The ball has dramatically smoother surface properties than the best steel ball, resulting in less friction between the balls and bearing race surfaces. Thermal properties are improved over steel balls, resulting in less heat build-up at high speeds. Ceramic has 35% less thermal expansion, 50% less thermal conductivity, and ceramic balls are lighter weight and non-corrosive. Boca also says the inner and outer races of anti-friction bearings become frosted, fluted or can get a corrugated pattern imprinted on them. These are not mechanical scars but are in fact due to electromagnetic forces and can lead to bearing failure. They are usually found in modern systems that routinely feature pulse-modulated adjustable speed motors and inverters with high switching frequencies and short rise times. Ceramic hybrid bearings can replace the more traditional, chrome steel counterparts to eliminate scarring and run cooler due to less microweld adhesion. Boca Bearing Co. manufactures ceramic balls, ceramic-hybrid bearings and full-ceramic bearings for cry pumps, medical devices, semiconductors, machine tools, turbine flow meters, robotics and optics. For more information: Boca Bearing Co. 755NW 17th Ave. #107 Delray Beach, FL (561) Internet: Saint-Gobain s Newest Bearing Material OFFERS UNIVERSAL CHEMICAL INERTNESS Rulon LR is a bearing material from Saint-Gobain that is compatible with most hardened-steel substrates. Mild steel is acceptable; harder running surfaces are better. According to the company s press release, Rulon has a virtually universal chemical inertness. Of the chemicals encountered in commercial practice, only molten sodium and fluorine, at elevated temperatures and pressures, show any signs of attack. For continuous non-lubricated service, RULON LR sleeve bearings are capable of operating up to 10,000 PV. Higher values are possible for intermittent service. For more information: Saint-Gobain Performance Plastics, Rulon and Meldin Bearings 386 Metacom Ave. Bristol, RI Phone: (401) Internet: 18 powertransmissionengineering february

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22 Investigation of Tapered Roller Bearing Damage Detection Using Oil Debris Analysis Abstract A diagnostic tool was developed for detecting fatigue damage to tapered roller bearings. Tapered roller bearings are used in helicopter transmissions and have potential for use in high bypass advanced gas turbine aircraft engines. This diagnostic tool was developed and evaluated experimentally by collecting oil debris data from failure progression tests performed by The Timken Company in their Tapered Roller Bearing Health Monitoring Test Rig. Failure progression tests were performed under simulated engine load conditions. Tests were performed on one healthy bearing and three predamaged bearings. During each test, data from an on-line, in-line, inductance type oil debris sensor was monitored and recorded for the occurrence of debris generated during failure of the bearing. The bearing was removed periodically for inspection throughout the failure progression tests. Results indicate the accumulated oil debris mass is a good predictor of damage on tapered roller bearings. The use of a fuzzy logic model to enable an easily interpreted diagnostic metric was proposed and demonstrated. Introduction Oil analysis is one diagnostic tool used to indicate transmission and turbine engine health (ref. 1). Bearing fatigue failures in helicopter transmissions and aircraft turbine engines generate significant debris in their lubrication systems. Oil debris monitoring for detecting damaged bearings in engines and transmissions consists of periodic off-line analysis of oil samples, magnetic chip detectors that capture the ferrous particles from the oil line and inductance type on-line oil debris sensors that monitor disturbance to a magnetic field as debris particles pass through the sensor. Reviewing data from oil debris sensors often requires expert analysis. False alarms of oil debris technologies can be caused by non-failure debris. This debris can bridge the gap of plug type chip detectors. Inductance type oil debris sensors cannot differentiate between debris generated by a failing component and debris due to operational conditions (ref. 2). Monitoring debris in lubrication systems with an inductance type oil debris sensor has been successfully used to indicate damage to critical components in aircraft engines (ref. 3). Several companies manufacture inductance type oil debris sensors that measure debris size and count particles (ref. 4). The oil debris sensor selected for this research was used in a previous analysis, and results demonstrated the debris mass measured by the sensor showed a significant increase when gear and bearing pitting damage began to occur (refs. 5 to 8). Earlier work performed at Timken also showed that particles measured by the inductance oil debris monitoring system (ODM) could provide early indication of impending failures during tapered roller bearing failure progression rig testing (refs. 9 and 10). Additional failure progression testing is required to define warning levels using oil debris analysis. The objective of the work reported herein is to first identify the best feature for detecting tapered roller bearing damage from a commercially available in-line, real-time, inductance type oil debris sensor. Once a feature for detecting bearing damage is defined through analysis of the oil debris data collected during failure progressions tests, a method for setting threshold limits for varying magnitudes of damage to the bearings will be identified. 20 powertransmissionengineering february

23 Fig. 1 Tapered roller bearing test rig. Facility Description Failure progression tests were conducted in the Tapered Roller Bearing Health Monitoring Test Rig at Timken. The test rig is illustrated in figure 1. The test rig consists of two tapered bearings supported on the shaft. The test bearing was at the load cylinder end and the slave bearing at the motor end. The test and support bearings are loaded in the axial direction with a hydraulic load cylinder. A 200 hp electric motor is used to drive the test system to the required rpm. There is a direct drive connection from the motor to the bearing shaft, with a small coupling shaft connecting the two that compensates for minor misalignment. Mobil Jet II oil (per MIL- L specifications) was used as the lubricant. Bearing geometry information is listed in Table 1. During failure progression tests, each bearing is loaded to an axial load of 40,000 lbf. The cylinder is applying the 40,000 lbf which is seen by each bearing. The axial dynamic load thrust rating for each bearing is 28,559 lbf. The shaft speed is 3200 rpm. Tests are performed until a significant amount of debris is measured by the ODM. The test rig is instrumented to measure cup temperatures, input oil temperatures, oil flow rates, speed and torque. Vibration data was also collected from accelerometers located on the test bearing housing in the radial, axial horizontal and vertical positions. Oil debris data were collected from a 1-1/4 in. ODM installed downstream of the bearing housing. A 120 µm screen mesh was installed downstream of the ODM. A 10 µm filter was also installed on the input oil line before the oil entered the bearings. The ODM measures the change in a magnetic field caused by passage of a metal particle where the amplitude of the sensor output signal is proportional to the particle mass. The sensor counts the number of particles, their approximate size based on user defined particle size ranges, and calculates an accumulated mass (ref. 11). For these experiments, 16 size ranges, referred to as bins, were defined. Based on the bin configuration, the average particle size for each bin is used to calculate the cumulative mass for the experiment. The particle is assumed to be a sphere with a diameter equal to the average particle size. Table 2 lists the 16 particle size ranges and the average particle size used to calculate accumulated mass during bearing tests. Previous research verified accumulated mass is a good predictor of pitting damage and identified threshold limits that discriminate between stages of pitting on spur gears (ref. 6). This method will be applied to the data collected during the failure progression tests. An alternative technique recommended by the ODM manufacturer for setting oil debris mass alarm limits based on bearing damage will also be applied to the failure progression data (ref. 12). This technique uses the bearing geometry to set an alarm threshold based on the total accumulated mass of the debris, Malarm, as calculated in equation (1) below. This mass alarm limit is based on outer race damage, in which the outer race spall angle is large enough to allow two balls in the damaged portion at the same time. The calculation for this technique february 2007 powertransmissionengineering 21

24 Figure 2 Mass measured by the ODM during test 1. is shown below: where Nb = number of rolling elements = 29 Pd = bearing pitch diameter (in.) = Bd = rolling element mean diameter (in.) = 1.21 K = constant for roller bearings (mg/deg in2) = 9.31 The K factor was obtained experimentally by the sensor manufacturer based on data collected from over 40 bearing failures (ref. 12). A K factor of 9.31 for roller bearings was used for this application. A mass alarm value of 2058 mg was calculated for the roller bearing. The manufacturer also provides a method to calculate mass warning, 0.1 times the mass alarm, mg, to indicate initial spall development. Results and Discussion The analysis discussed in this section is based on data collected during testing of four tapered roller bearings, one healthy bearing and three predamaged bearings. The principal focus of this research is the detection of damage progression on tapered roller bearings. The types of damage observed on the bearings included spalling, peeling and damage from foreign material. The photos of the amount of damage observed during each failure progression test and the analysis of the oil debris will be discussed in the following sections. Bearing Test 1. After the bearing races were damaged by running in a contaminated oil containing steel powder particles for 2000 revolutions, they were then ultrasonically cleaned and installed in the test rig. The bearings were removed for inspection two times during the failure progression test. At test completion the bearings had been subjected to 81 million cycles. Figure 2 is a plot of the accumulated mass measured by the ODM during test 1. The boxes labeled 1 and 2 identify when the bearings were removed for inspection. Table 3 is a summary of the particle counts and accumulated mass measured in each bin prior to each inspection interval and at test completion. Photos of the damaged components were taken at each inspection interval and at test completion. Photos of the damage are shown in figures 3 through 6. After the first inspection interval, spalling was observed on several of the rollers and peeling was observed on the cup and cone. The spalls on the rollers increased in size during the second inspection, but the peeling on the cup and cone did not appear to increase significantly. At test completion, the spalls on the rollers increased significantly, the peeling on the cup and cone did not change, spalling began to occur on the cone and cage damage was also observed. It should be noted that the cage material of all bearings tested was silver, and nonferrous particles were not analyzed during these tests. Bearing Test 2. After the bearing was predamaged by applying hardness dents to the cone, the bearings were loaded and installed in the test rig. The bearings were removed for inspection four times during the failure progression test. At test completion the bearings had been subjected to 92 million cycles. Figure 7 is a plot of the accumulated mass measured by the ODM during test 2. The boxes labeled 1 through 4 identify when the bearings were removed for inspection. Table 4 is a summary of the 22 powertransmissionengineering february

25 Fig. 3.Test 1 roller damage. Figure 6. Test 1 cage damage. Figure 4. Test 1 cup damage. Figure 7. Mass measured by the ODM during test 2 Figure 5. Test 1 cone damage. february 2007 powertransmissionengineering 23

26 Figure 8 Test 2 roller damage. Figure. Test 2 cone damage. Figure 10 Test 2 cone damage. particle counts and accumulated mass measured in each bin prior to each inspection interval and at test completion. Photos of the damaged components were taken at each inspection interval and at test completion. Photos of the damage are shown in figures 8 to 12. After the first inspection interval, wear lines were observed on the rollers, and the dents slightly increased in size. During inspection 2, small pits were observed on the cup, no significant damage was observed on the rollers. At inspection interval 3, a largespall was observed on the cone and a few more wear lines on the rollers. At inspection interval 4, the cone spall increased in size. At test completion the cone spall doubled in size, the small pits observed on the cup at inspection 2 remained the same, and cage damage was observed. Bearing Test 3. After the bearing was predamaged by applying hardness dents to the cone, the bearings were loaded and installed in the test rig. The bearings were removed for inspection three times during the failure progression test. At test completion the bearings had been subjected to 168 million cycles. Figure 13 is a plot of the accumulated mass measured by the ODM during test 3. The boxes labeled 1 through 3 identify when the bearings were removed for inspection. Table 5 is a summary of the particle counts and accumulated mass measured in each bin prior to each inspection interval and at test completion. Photos of the damaged components were taken at each inspection interval. Photos of the damage are shown in figure 14. After the first inspection interval, no damage was observed on the bearing. In order to expedite failure, the raceway was again damaged near the original predamage hardness dents. During inspection 2, pitting damage began to occur near the location of the predamage dents and damage placed on the cone during inspection 1. At inspection interval 3, the damage observed on the cone during inspection 2 grew into a large spall. At test completion, the initial spall grew slightly Figure 11 Cup damage at test completion, observed after inspection 2, but did not progress. 24 powertransmissionengineering february

27 Fig. 15 Mass measured during baseline test. Figure 12. Test 2 cage damage at test completion. Figure 13 Mass measured by the ODM during test 3. Fig. 14 Test 3 cone damage. and another spall occurred 90 from the original spall and wear lines were observed on the rollers. Baseline Test. A healthy set of bearings was also tested to determine baseline wear debris. The healthy set of bearings was installed at the completion of test 2. The load was gradually increase during testing. Figure 15 is a plot of the accumulated mass measured by the ODM during the baseline test. Table 6 is a summary of the particle counts and accumulated mass measured at test completion. The amount of debris detected was significant during this break in period. Due to the fact that different bearing components experienced different levels of damage during each test, particle size distributions were plotted to determine if particles distributions vary when different components in the bearing are damaged. february 2007 powertransmissionengineering 25

28 Figures 16 through 19 are histograms of the three bearing tests and the baseline tests. The histograms show the frequency particles were measured within each size distribution. The histograms indicate inspection intervals and test completion particle distributions. It should be noted that when performing a particle distribution analysis on the oil debris data, the bin size ranges are critical to the results. A brief review of the figures show particle distributions are very similar at test completion and during the inspection intervals when spalling occurred on the cage and the rollers. During the inspection intervals when spalling damage was observed, the maximum particles were observed in the 275 to 325 µ bin range. During the baseline test, when no damage occurred, the maximum particles were observed in the 325 to 375 µ particle size range. Size distribution characteristics calculated from the histograms attempted to capture the difference between distributions in the baseline test and the failure progression tests. Relative skewness and kurtosis of the particle distributions were calculated to determine if these statistical parameters could be used to differentiate between the damaged and undamaged bearing. Skewness is a measure of the asymmetry of the histogram. All of the particle distributions show positive skewness, the tail on the right side of the distribution is longer. Kurtosis is a measure of the combined weight of the tails related to the rest of the distribution. As the tails become heavier, kurtosis increases. The following equations were used to calculate relative kurtosis and relative skewness from the particle distributions shown in figures 16 through 19 (ref. 13), where dj is equal to average bin size, j is equal to the number of bins and P[dj] is equal to the particles per average bin size divided by total number of particles: (2) (3) (4) (5) (6) (7) Results of the calculated relative kurtosis (RK) and relative skewness (RS) are listed in Table 7. Both calculated values were lower during test 2 inspection intervals 1 and 2 than they were for the baseline test. However, minimal wear damage was observed on the rollers during these two inspection intervals. Relative kurtosis was also lower for test 3 inspection interval 3 and test completion. Further analysis is required to determine if an increase in relative kurtosis of the particle distributions could be used as an oil debris feature for damage indication of the bearing. In order to develop an oil debris feature that best predicts damage levels to the tapered roller bearings, the bearing damage levels or state of the bearing must be defined. Three primary states of the bearing health will focus on spalling damage: O.K. (no damage); Inspect (initial spalling); Damage (severe spalling). Next, initial limits for these damage levels must be defined. The oil debris mass data from the 3 experiments with damage were plotted on figure 20. The red diamonds identify the inspection intervals during tests. Next, the plot is expanded, with the gear state transition regions expanded: O.K. (green); Inspect (yellow); Damage (red). Since spalling damage was not observed during test 2, inspection intervals 1 and 2, this mass (38.7 mg) will be used as the lower limit on the inspect region. The upper inspect band will be at mg, the maximum mass measured at the baseline test completion. One interesting observation when reviewing figure 20 is that the mass alarm value (Malarm) of 2058 mg and the mass warning value mg, calculated using the manufacturers equation (1), both fall within the damage region. <p>fuzzy logic was used to develop a feature that defines damage levels based on the accumulated mass measured by the ODM. Fuzzy logic applies fuzzy set theory to data, where fuzzy set theory is a 26 powertransmissionengineering february

29 Fig. 16. Test 1 particle distributions after inspections 1 and 2 and at test completion. Fig. 18. Test 3 Particle distributions after inspections and at test completion. Fig. 19. Baseline particle distributions at test completion. Fig. 17. Test 2 particle distributions after inspections 1-4 and at test completion. february 2007 powertransmissionengineering 27

30 Fig. 20 Oil Debris mass during each experiment. Fig. 21 Fuzzy logic membership values for oil debris feature and output of model. theory of classes with unsharp boundaries and the data belongs in a set based on its degree of membership (ref. 14). The degree of membership can be any value between 0 and 1. Membership values based on the accumulated mass measured by the oil debris sensor will be identified. The data measured from the oil debris sensor during experiments with damage and with no damage was used to identify membership functions to build a simple fuzzy logic model. Defining the fuzzy logic model requires inputs (damage detec- tion features), outputs (state of bearings), and rules. Inputs are the levels of damage, and outputs are the states of the bearings as discussed in the preceding paragraph. Membership values were based on the accumulated mass and the amount of damage observed during inspection. Membership values are defined for the three levels of damage: damage low, damage medium, and damage high. Using the Mean of the Maximum (MOM) fuzzy logic defuzzification method, the oil debris mass measured was input into a simple fuzzy logic model created using commercially available software (ref. 15). The membership function and the output of this model are shown on figure 21. Threshold limits for the accumulated mass are identified. Results from the four experiments indicate accumulated mass is a good predictor of pitting damage on tapered roller bearings and fuzzy logic is a good technique for setting threshold limits that discriminates between states of pitting wear. Conclusions The purpose of this research was to first verify, when using an inductance type, on-line, oil debris sensor, that accumulated mass correlates with tapered roller bearing fatigue damage. Then, using accumulated mass as the damage feature, a method was proposed and used to set threshold limits for damaged bearings that discriminates between different levels of pitting damage. In this process, the membership functions for each feature state were defined based on level of damage. From this data, accumulated mass measured by an oil debris sensor combined with fuzzy logic analysis techniques can be used to predict tapered roller health. Applying fuzzy logic incorporates decision-making into the diagnostic process that improves fault detection and decreases false alarms (ref. 7). This approach has several benefits over using the accumulated mass and an arbitrary threshold limit for determining if damage has occurred. One is that it eliminates the need for an expert diagnostician to analyze and interpret the data, since the output would be one of three states, O.K., Inspect, and Shutdown. Since benign debris may be introduced into the system, due to periodic inspections, setting the lower limit to above this debris level will minimize false alarms. In addition to this, a more advanced system can be designed with logic built-in to minimize these operational effects. Future tests 28 powertransmissionengineering february

31 are required to collect data from bearings with initial pitting to better define the inspect region and the severity of bearing damage. Tests of bearings of different sizes are required to determine if a relationship can be developed between damage levels and bearing dimensions to minimize the need for extensive tests to develop the membership functions for the threshold levels. References 1. Miller, J.L. and Kitaljevich, D.: In-line Oil Debris Monitor for Aircraft Engine Condition Assessment. IEEE / Howard, P.L., and Reintjes, J.: A Straw Man for the Integration of Vibration and Oil Debris Technologies. Presented at the Workshop on Helicopter Health and Usage Monitoring Systems, Melbourne, Australia, February Editor: Graham F. Forsyth. DSTO-GD-0197 published by DSTO (Defense Science and Technology Organization) Australia, February Dubowski, D. and Witwer, D.: Application of MetalSCAN Oil Debris Monitor to a Fleet of Sea King Helicopters. Presented at the American Helicopter Society 60th Annual Forum, Baltimore, MD, June 7 10, Hunt, T.M.: Handbook of Wear Debris Analysis and Particle Detection in Liquids. Elsevier Applied Science, London, Dempsey, P.J.: A Comparison of Vibration and Oil Debris Gear Damage Detection Methods Applied to Pitting Damage. NASA/TM Dempsey, P.J.: Gear Damage Detection Using Oil Debris Analysis, NASA/TM , Sept Published in the Journal of Gear Technology, January Dempsey, P.J.: Integrating Oil Debris and Vibration Measurements for Intelligent Machine Health Monitoring. PhD Thesis, The University of Toledo. Published in the Journal of the American Helicopter Society, April 2004, vol. 49, no Dempsey, P.J., Lewicki, D.G., and Decker, H.J.: Investigation of Gear and Bearing Fatigue Damage Using Debris Particle Distributions, NASA/TM , May Kreider, G.E.: Tapered Roller Bearing Health Monitoring Test for Pratt & Whitney. Application Development Summary Report Project No , January Kreider, G.E.: Tapered Roller Bearing Health Monitoring Test II for Pratt & Whitney. Application Development Summary Report Project No Supplement 1, December Howe, B.; and Muir, D.: In-Line Oil Debris Monitor (ODM) for Helicopter Gearbox Condition Assessment. ADa , BFGoodrich. 12. MetalSCAN User s Manual. Setting Alarm Limits, C000833, Revision 0, GasTOPS, Ontario, Canada. 13. Roylance, B.J.: Monitoring Gear Wear Using Debris Analysis Prospects for Establishing a Prognostic Method. Proceedings of the 5th International Congress on Tribology, vol. 4, June 15, Zadeh, Lofti, Fuzzy Logic: Advanced Concepts and Structures, New Jersey: IEEE, Fuzzy Logic Toolbox for use with MATLAB, January Paula Dempsey is an Aerospace Research Engineer employed by the NASA Glenn Research Center, Cleveland, Ohio. She joined NASA in 1991, after performing experimental and analytical research work in the area of cryogenic fluid management systems for a government contractor from 1987 to She continued her cryogenic research until 1995, then moved to Aeronautics research, serving as lead project engineer for several Aeronautics programs. Since 1998, she has been performing research in the area of health monitoring and diagnostics for aerospace drive systems and propulsion systems and has published over 20 papers in this field. She received her BS in Mechanical Engineering, an MS degree in Industrial Engineering and a Ph.D. in Engineering Science. Gary Kreider is a Senior Product Development Specialist employed by The Timken Company, Canton, Ohio. He joined The Timken Company in 1967 as an application engineer working on bearing applications for automotive and rotary wing aircraft. In 1982 he joined the Timken Company s Physical Laboratory serving as a project leader for bearing development in industrial, agriculture and aerospace programs. The latter involving hybrid tapered roller bearings for the ART program. In addition, he has managed programs for bi-directional tapered roller bearings, steel and hybrid ball bearings simulating gas turbine engine main shaft applications. He received his BS in Mechanical Engineering from Pennsylvania State University. Tom Fichter is a Senior Product Development Technician employed by The Timken Company, North Canton, Ohio. He joined Timken in 1999 and provides testing support to the product and application testing group while pursuing a BS in Mechanical Engineering Technology. february 2007 powertransmissionengineering 29

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34 case study World s Largest Wind Turbine GENERATES NEW LARGE-SHAFT BEARING TECHNOLOGY Sweden-based SKF Group s design of a bearing system for a giant wind turbine with an unusual rotor shaft led to the development of the largest-known CARB toroidal roller bearing system, as well as to advances in bearing assembly techniques and axial fixation methodology for large bearings. All wind turbines are large, but the REpower Systems 5M wind turbine is huge. Manufactured by REpower Systems AG of Hamburg, the 5M towers 120 meters above-ground and produces five megawatts of electrical power. With its three-bladed, 126- meter diameter blade span, the 5M is not only the largest, but also one of the most efficient wind turbines in the world, according to the manufacturer. Throughout its design phase, the 5M presented significant technical challenges in several different fields. One of the most crucial was the design, manufacture and installation of a bearing system for the 1.5-meter diameter rotor shaft that supports the 130-ton, three-bladed rotor. SKF assumed total responsibility for the surrounding design, including the shaft geometry in the bearings area, as well as for all needed tolerances and surface roughnesses and the functional housing design, says Hans-Jurgen Liesegang, SKF account manager for the project. A new bearing system on a hollow rotor shaft. Though required to support the heavy rotor, the cast iron rotor shaft is hollow. This is to meet weight, cost and performance requirements, all of which were crucial to the design process. To eliminate the influence of positional- and deflection-related errors, the SKF specialists, in cooperation with FIG. 1: Wind turbine designers believe that offshore installations are the most energy-productive, but they must be built to withstand the sea s harsh elements. REpower s designers, developed a system to support the shaft with two bearings. In the non-locating position is an SKF CARB toroidal roller bearing. The other bearing, in the locating position, is an axially locating, spherical roller bearing. This design affords high load-carrying capacity with the lowest possible bearing and housing weight for a two-bearing arrangement. 32 powertransmissionengineering spring

35 case study FIG. 2: The REpower 5MW turbine, at 120-meters high, is reportedly the largest wind turbine on the planet. SKF made all the service duration calculations (for the bearings assembly), says Liesegang. Calculations included first L10h calculations based on first-load estimates and the final duration calculation for the Germanischer Lloyd certification based on the given load distribution over time. (Editor s note: L10h is an industry standard based upon theoretical expectations of the maximum life expectancy of 90% of any production batch of bearings, assuming the loading and environment conditions, the same quality of ingredients of the steel, and the same manufacturing processes and quality of manufacturing execution.) Simulation and calculation tool solves problems. To ensure the bearing system s performance requirements, SKF developed, in partnership with Sweden-based Programming Environments Laboratory (PELAB), its own simulation tool BEAST or BEAring Simulation Toolbox. BEAST is a dynamic simulation program that serves as a virtual test rig in the computer. Traditional methods of long and costly experiments on a test rig are replaced by faster and more detailed computer simulations. The program was first used in the development of the SKF line of CARB bearings, and again in smaller-sized CARB bearings to evaluate how the inclined shaft in the 5M would influence bearing behavior. The 5M s bearing, with its 1.5-meter inside diameter, weighs 2,700 kg and is the largest of its type ever manufactured by SKF. How a bearing of such magnitude would affect an inclined shaft was an unknown in the early stages of the design process, but the finished product represents beyondthe-envelope bearing design. Because of the bearing size and mounting, further development requiring FEM calculations was needed to determine the interference fit on the hollow cast iron rotor shaft. Lubricating a 1500-mm diameter bearing. The bearing size also necessitated novel lubrication considerations. The behavior of grease in, for example, a 500-mm diameter bearing is well documented; but not so for a bearing with a diameter of 1,500 mm. Lubrication specialists at SKF needed continued spring 2007 powertransmissionengineering 33

36 case study FIG. 3: The 8,000 kg housing is carefully lowered onto the CARB bearing encompassing a cast iron hollow shaft. The shaft must support the 130-ton rotor. to determine whether grease distribution in a 1.5-meter bearing would cover all the relevant surfaces, or would gravity pull the grease to the bottom of the housing. Answers to those questions resulted in the housing being designed to cover oil lubrication as well as grease. But later inspections have shown dependable lubrication coverage, thus allowing for a simpler housing cover. Induction heater for bearing assembly. Another challenge for the bearing specialists was to overcome difficulties during assembly and installation of the two huge rotor shaft bearings. For one, there were no commercially available induction heaters that could uniformly heat the 2,700-kg CARB bearing and the 3,320-kg spherical roller. So when the time came for the bearings and their two 8,000-kg housings to be heated for correct assembly and installation, SKF designed and had built a 1,000-kVA (kilo volts x amps = watts) induction heater. Also, because the weight of the roller set in the CARB bearing is almost 800 kg, it had to be specially clamped during heat-up and assembly. Without induced safe-clamping, the weight of the roller set would make the rollers clamp loosely between the inner and outer ring, which could damage the raceways. (Normal, loose clamping also occurs in standard-size bearings mounted vertically, but because the weight is so much less, it is not a consideration.) Axial fixation of the bearings presented another major challenge. Fixation is usually done by shaft nuts, but the shaft in the 5M turbine has a diameter of 1.5 meters. The frictional moment on a thread of this diameter is enormous. The problem was solved by design of an outsized, safety split nut the largest ever made. Dubbed the HMS lock nut, its most notable feature is that it does not require a keyway in the shaft, thus resulting in a more robust design and reduced manufacturing costs. The system is easy to mount and open for maintenance and repair, and there are no problems with fretting corrosion when dismounting. Destined for a life at sea. The first 5M wind turbine was erected in Germany at the coastal city of Brunsbuttel; it came on-stream in 2005 as a pilot project to evaluate the total turbine design. The location was based on the conviction by the designers of the 5M that wind at sea is a much better source of power than wind on land. They believe that because wind speed at sea is typically slightly higher, and the wind frequency decidedly greater, you can harness twice as much electricity from wind at sea as from on land. Consequently, the Brunsbuttel installation serves as a beta test site in anticipation of the series installation of 5M turbines out at sea. 34 powertransmissionengineering spring

37 case study Indeed, the first proposed site is 25 kilometers from the Scottish coast, in 44 meters of water. The site is part of the Talisman DOWNWIND project supported by the European Union. Because the 5M was designed for operation in harsh environments, exceptional care was required in the design, manufacture and installation of the rotor shaft bearing system. Beyond its protection against corrosion, redundancy in many components, and continuous electronic monitoring of critical components, the 5M turbine has a rotor shaft bearing system that has been engineered for long-term reliability. For REpower, partnering with SKF was an easy strategic decision. SKF is known worldwide as the bearing company with new ideas like CARB and HMS-nuts, and WindCon (machine condition monitoring system), says REpower s Carsten Eusterbarkey, the project s development engineer. They are a global player and will help REpower to build up production and joint ventures all around the world. For more information: SKF Group SKF Business & Technology Park Nieuwegein, The Netherlands Phone: Fax: colin.roberts@skf.com Website: FIG. 4: Positioning the CARB bearing system onto the custom-designed induction heater. FIG. 5: The CARB toroidal roller bearing being clamped prior to heating. spring 2007 powertransmissionengineering 35

38 case study Timken SUPPLIES BEARING ASSEMBLY FOR SPAIN S FASTEST RUNNING TRAIN The Talgo 350 relies on Timken bearings to ensure a safe trip between Madrid and Barcelona. Detailed drawing of Talgo s axle box. In 2003, Bombardier Transportation was getting ready to introduce a new train that would break speed records for its customer Talgo while carrying 800 passengers in Spain in up to 13 coaches. Safety was the primary concern, says Marcus Pauels, Timken s manager for European sales and marketing rail. Not far behind was a serious concern for low-temperature operation. The trains were slated to run between Madrid and Barcelona, where the temperature in the summer can easily exceed 100 F. Bombardier set out to find a bearing manufacturer with extensive experience in high-speed environments. Pauels says that temperature and track conditions are the main environmental factors affecting bearing life, since the average axle load is not an issue in passenger trains. The general design of a high-speed bearing has to reflect the optimal combination of metal, heat treatment, raceway quality, cage design, cage material, quantity and size of rollers and grease performance, he says. Only if all these components have been checked and combined in the best way, can the bearing system run at that speed, which is 210 miles per hour in our case, with the lowest temperature. On top of this is the factor of the environmental conditions in Spain with its high temperatures. Of equal importance, says Pauels, is the track condition. Even if the high-speed train has fewer curves and wider angles, the bearings have to withstand rigorous radial forces at constant high speeds. The trip between Barcelona and Madrid is approximately 510 miles, with one stop in Zaragossa. 36 powertransmissionengineering february

39 case study Therefore, the trains run for two hours and 45 minutes, with only one stop in the middle. Bearing all this in mind, Bombardier and Timken were looking for a tapered roller design, instead of cylindrical roller bearings. Bombardier knew that The Timken Co. had more than a century of experience in tapered roller design and contacted them to quote on the project. Bombardier needed a solution that exceeded performance specifications of what is generally available on the market, says Mat Happach, Timken s vice president rail. They turned to us because they knew our knowledge of friction management and sensor technology could overcome the challenge. We were able to use our engineering expertise to provide our customer and the railway with a fully integrated system that will provide lasting benefits in the demanding environment of everyday operation. Timken also, supplied 480 high-tech axle-bearing assemblies to Bombardier for use in the locomotives of the next 30 trains that RENFE the Spanish state railway ordered from Talgo in Spain. The Timken components include axle bearings, aluminum housings and a sensor assembly that continuously measures the temperature throughout the entire bearing system. All the bearing assemblies are networked with the control unit in the locomotive, and data are visible to the driver. Bombardier in turn supplied 60 high-speed locomotives two for each Talgo 350 train equipped with Timken s advanced sensor technology to monitor bearing temperature. Bombardier used Timken bearings and housings for its first order from Talgo in As each train set needs two locomotives, Bombardier received the order for approximately 32 locomotives. This order required 64 trucks, including 128 axles and 256 bearings plus housings. Trains on RENFE S Madrid-Barcelona line travel at speeds up to 205 mph. In 2006, RENFE ordered an additional 30 train sets from Talgo. This translates into 60 Bombardier locomotives using 120 trucks running on 240 axles, which are equipped with 480 Timken bearing/ housing sets. Pauels says, Timken received the order in the end after 14 months of prototype testing, together with the competition s bearings because of the fact that Timken s bearings were running almost 6 cooler than the product of any other manufacturer. For more information: The Timken Co Dueber Ave. SW Canton, OH Phone: (414) marcus.pauels@timken.com Internet: Timken s axle bearing assembles were used in locomotives to facilitate travel within Spain. Tim and Jack Timken, Alfonso Prez and two Talgo representatives pose in front of train 3 on the day delivery in Spring february 2007 powertransmissionengineering 37

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41 i n d u s t r y n e w s Danaher Motion ANNOUNCES RECORD- BREAKING SHIPMENTS OF SYNQNET MOTION NETWORK Danaher Motion announced that shipments of its SynqNet motion and I/ O network have exceeded 225,000 axes. SynqNet is a motion control networking system for machinery builders in the medical imaging, packaging, machine tool, robotics, semiconductor, printed circuit board manufacturing/assembly and flat panel display industries. The system enhances machine throughput, modularity, reliability and serviceability, according to the company s press release. Global servo suppliers now offer more than 130 different SynqNet products, including standard servo and stepper amplifiers, I/O devices and custom multi-axis integrated products for a wide range of applications. The SynqNet motion network utilizes the industry standard IEE802.3 physical layer for robust electrical isolation and 100-meter cable lengths with a deterministic protocol layer engineered by Danaher Motion. According to the company s press release, SynqNet was designed to meet multi-axis motion applications and to address industry trends toward interoperable, digital machinery. SynqNet gives machine designers an open platform to meet the market demands for system modularity, HotReplace machine service without downtime, remote diagnostics, software field upgrade, multi-vendor support and fault-tolerant safety. Paccar ANNOUNCES PLANS FOR $400 MILLION POWERTRAIN MANUFACTURING PLANT Paccar Inc. unveiled plans for a new $400 million powertrain manufacturing and assembly facility in the southeast United States. Strong demand for high-quality DAF, Peterbilt and Kenworth products has resulted in record production and market share for Paccar worldwide, says Mark Pigott, chairman and CEO. The industry-leading reliability and resale value of Paccar s light-, mediumand heavy-duty commercial vehicles, including the success of Paccar s powertrain, as well as exciting initiatives such as Paccar s diesel-electric hybrids, remote vehicle diagnostics and software development have driven stellar financial performance. The 400,000-square-foot facility strengthens Paccar s global manufacturing and assembly capability and positions Paccar to capitalize on growing opportunities in North America, Europe and Asia, adds Pigott. The $400 million investment in Paccar s newest facility complements the $2.5 billion invested over the last ten years to accelerate award-winning product development, Six Sigma implementation, customer after-sales support and dynamic information technology programs in our capital goods and financial services markets. According to the company s press release, construction of the facility will begin in mid-2007 and is targeted for completion in Tom Plimpton, Paccar president, says, This will be Paccar s most technologically advanced facility and reinforces our efficient manufacturing platform that builds the highest-quality products in the industry. february 2007 powertransmissionengineering 39

42 industry news Bison Gear APPOINTS NEW PRESIDENT Bison Gear & Engineering Corp. announced the appointment of Martin Swarbrick as president and chief operating officer. Most recently, Swarbrick was vice president and director of business excellence for Motorola. During that period, Motorola was awarded the Malcolm Baldrige National Quality Award in 2002 and the Balanced Scorecard Hall of Fame award in Martin s track record as a leader in the disciplines of Performance Excellence, Quality, Customer Advocacy and Six Sigma will drive Bison Gear s continued growth by offering the best overall value package to customers, says Ron Bullock, Bison Chairman and CEO. Swarbrick s 27 years as a business leader began in Ireland as a manufacturing engineer for General Electric, where, over a seven-year period, he progressed to manufacturing manager. He spent the next seven years with Verbatim (Kodak) as operations manager. In 1991, he became operations director for Motorola s Land Mobile Products sector, and shortly after became vice president and general manager with responsibility for manufacturing operations and distribution for Europe, the Middle East and Africa. Bison Gear & Engineering Corp. designs and produces gearmotors in parallel shaft and right-angle configurations, as well as AC and DC motors, for OEMs worldwide. Timken SELLS AUTOMOTIVE STEERING BUSINESS The Timken Co. completed the sale of its automotive steering business, which operates facilities in Watertown, CT, and Nova Friburgo, Brazil, to DriveSol Worldwide, Inc. Terms of the sale were not disclosed. The sale of this business, which has not been profitable in recent quarters, is part of the structural changes we are pursuing to improve our ability to create shareholder value, says Timken president and CEO James W. Griffith. The steering components business employs approximately 600 people at the Watertown plant and about 300 people in Brazil. It had sales of $110 million in DriveSol, an affiliate of Sun Capital Partners, Inc., will continue to manufacture steering tilt shafts, intermediate shafts and steering components at the Watertown plant, and steering columns at the Nova Friburgo plant. Production at both facilities is focused on tube forming, coating, painting and precision assembly. As a result of our focus on driving innovation in the core areas of friction management and power transmission, we have decided to exit this nonstrategic business, said Jacqueline A. Dedo, president of Timken s Automotive Group. In addition to our previously announced restructuring programs, we are continuing to examine and implement further actions to improve financial performance in our Automotive Group. Messinger Bearings AWARDED CHICAGO GEAR CONTRACT Messinger Bearings has been awarded a contract to provide 40 large bearings to Chicago Gear for use in eight Babcock & Wilcox coal pulverizers for Texas Utilities. Babcock & Wilcox was awarded the contract to supply eight identical, supercritical coal-fired boilers as part of TXU s solid-fuel power generation program in Texas. According to Messinger Bearings press release, the eight boilers, each with a capacity of 858 MW, will be the largest of this kind under construction in the U.S. to date. Messinger was selected to provide the diameter thrust roller bearings because of the company s previous experience supplying this type of bearing for other B&W pulverizers. Messinger will begin shipments to Chicago Gear in April and will complete delivery in November Sumitomo Drive ANNOUNCES THREE PROMOTIONS Sumitomo Machinery Corp. annzounced the promotion of Ronald Smith to CEO/president. He has 25 years of power transmission experience. Smith has worked for SMA for the past 16 years, advancing through numerous sales and management positions. In 2004, he became the company s COO. In other news, Randy Satterfield was promoted to vice president of sales for the eastern division. According to a company press release, Satterfield joined Sumitomo in 1985 as a field sales engineer. He has held various positions with the company, most recently as regional vice president of the southeast region. Lastly, Steven Leins was promoted to western division vice president of sales. He has worked at SMA for 22 years. Most recently, Leins held the position of regional vice president. 40 powertransmissionengineering february

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44 events At Hannover Fair 2007, Bigger is Better Hannover Fair 2007, the largest exhibition of industrial technology on the planet, is set to run April in Hannover, Germany. Now approaching its 60th year, Hannover Fair is the ultimate industrial show for sellers and buyers of industrial automation for process, production and building automation; a full range of energy technologies; April Hannover, Germany 42 powertransmissionengineering february subcontracted components and systems for the production industries; industrial software and services; microsystems and nanotechnology; and research & development. Fair organizer Deutsche Messe anticipates nearly 6,000 exhibitors this year, comprising 2.15 million square feet of floor space. Recognized through the years as a prime resource for stand-alone machinery and components, the venue is now widely attended for its display of fully integrated, latest-technology manufacturing solutions. Another benefit of Hannover Fair is its focus on expanded applications for existing technology. Too, Hannover Fair offers easy access to industrial sector experts from around the world, affording attendees the opportunity to gain insights and ideas they might otherwise have been unaware of. The fair, along with its customary roster of leading industrial nation exhibitors, also boasts access to a growing number of emerging industrial nations (Turkey is this year s show s Partner Country), both exhibiting and attending. As always, Hannover Fair 2007 will feature an impressive array of corporatesponsored lectures and symposiums addressing such topics as new products, procedures, market developments and trends, and solutions. In advance of the fair, Power Transmission Engineering surveyed a few companies that regularly exhibit at Hannover. We asked them what they ll be showcasing, what are the central benefits of Hannover, and how do they compare Hannover with other shows. Following are their responses. SEW-EURODRIVE GmbH&Co KG Stefan Brill Manager Public Relations At Hanover Fair SEW-EURODRIVE will provide drive solutions for each customer, starting with components like geared motors or frequency inverters, decentralized drive technology or a new series of industrial gears (gears beginning with 500,000 Nm), followed by systems for the drive automation technology based or focused on branches. Last, but not least, we will show a complete EMS system (Electric Monorail System). With this system, OEMs and end-users are able to optimize flexible transport and logistic processes. The Hanover Fair in general is one the important trade fairs for SEW. It s where we meet OEMs and end-users. Nevertheless, small and focused fairs are becoming even in Germany more interesting; like the SPS/IPC/DRIVES in Nuremberg, in November, or the FachPack. For more information: SEW-EURODRIVE USA 1295 Old Spartanburg Hwy. P.O. Box 518 Lyman, SC Phone: (864) Fax: (864) Website: SEW-EURODRIVE EUROPE P.O. Box 3023 D Bruchsal Germany Phone:

45 events Fax: Website: HANSEN TRANSMISSIONS Reinhard Huck European Sales Manager Apart from its standard product range of Hansen P4 gearboxes, Hansen will present Hansen Services a new department for servicing of gearboxes that was launched in the spring of Hansen Services will be part of the Hansen booth for industrial gearboxes in Hall 26. A second booth in Hall 13 will cover the Hansen business unit for wind energy, with gearboxes for wind turbines. Hannover Fair is an international event that is well-organized, and thus attracts interested visitors for each part of the show. It is a good opportunity to have a big number of customer contacts in a very short time frame. The Hannover show is bigger and more international than other shows. For more information: Lena De Wachter Communication & Product Promotion Hansen Transmissions International NV Leonardo da Vincilaan 1 B-2650 Edegem Antwerp - Belgium Phone : +32 (0) ; Direct: +32 (0) Direct fax : +32 (0) LDeWachter@hansentransmissio ns.com Http : demonstrate our product range in two of our main customer industries wind energy, and minerals and mining. One wind gear unit will be a 1.5 MW, which will be delivered to our customer after the show. It is an example of the volume product at our Jyvaskyla (Finland) production plant, where the entire production capacity is in use for wind turbine gears. Today, around 50% of our net sales comes from the wind turbine gear production. The second exhibit is a planetary gear coal mill drive unit, which was custom-made at our Wuppertal(Germany) plant for a customer-specific need. The third gear unit will be a Duetto gear unit, representing our modular gear series. The unit at the exhibition is modified according to the needs in mill drives for the minerals industry. What is completely new is our condition management system for wind turbine gears. Instead of just monitoring the condition and measuring the vibrations, Moventas solution processes a wider range of information about a gear unit s condition. Thus we are able to carry out the needed maintenance operations before any damage occurs. There will be an online demo. At Hannover, we can contact all the players in the field of mechanical power transmission; not only the ones that operate in the same customer segments as we do in wind, mining and minerals, and pulp and paper but the entire audience. Honestly, we cannot afford to stay away. All the main players will be there, but it is a remarkable investment and every time we wonder whether the investment pays back. This is more of a general show. We do meet a lot of our existing customers at Hannover. But instead of reaching potential customers or co-operation partners like in industry-specific shows,(e.g., Husam Wind, PulPaper and ABTCP), at Hannover we reach the public interested in mechanical power transmission in general suppliers, press, students and competitors. For more information: Moventas Oy P.O. 158, Martinkatu FIN Jyvaskyla Finland Phone: +358 (0) Fax: +358 (0) Website: MOVENTAS OY Kati Pesola Communications Manager As we are exhibiting at Hannover for the first time as Moventas, our main interest is in exhibiting the new company name. Previously known as Valmet, Metso and Santasalo, we changed our company name due to an ownership change in Spring One of the main goals at the show is to make Moventas known as a player in the mechanical power transmission industry. We will exhibit three gear units to february 2007 powertransmissionengineering 43

46 calendar February Pacific Design & Manufacturing Show. Anaheim Convention Center, Anaheim, CA. Features suppliers and products in engineering, automation technology, lasers, motors, drives, packaging, rapid prototyping, components, electronics, computer-aided design and manufacturing, production, machinery and networking. Combined with MD&M West, WestPack, Electronics West and Automation Technology Expo West. Registration is free if you pre-register online or bring show materials with you. The on-site expo-only registration is $55. For more information, visit the show s website at expo/pac07. February Gearbox CSI. Lake Buena Vista Resort, Buena Vista (Orlando), FL. Forensic analyses of gear and bearing failures demonstrate that few gearbox failures are the result of true fatigue (B-10 or basic gear rating). The course evaluates of the results of forensic analysis given in the design of gearboxes to achieve the best gear and bearing performance possible. Forensic analysis has become an important gearbox designer s tool. Presented by Ray Drago, chief engineer at Drive Systems Technology and Joseph Lenski Jr., a technical fellow at Boeing Rotorcraft s Space and Defense Group. $1,895 for American Gear Manufacturers Association members, $2,395 for non-members. For more information, contact the AGMA by telephone at (703) or on the Internet at February International Conference on Powder Injection Molding of Metals, Ceramics and Carbides. Royal Plaza Hotel, Lake Buena Vista (Orlando), FL. Highlights include presentations on the latest PIM standards and the Global Powder Metallurgy Property Database, the current status of research and development in PIM, and a keynote luncheon with an address that focuses on the use of PIM in the consumer electronics industry. An optional one-day PIM tutorial precedes the conference. Registration is $895 for MPIF members and $995 for non-members. (The optional one-day tutorial is $495.) For more information, contact MPIF by telephone at (609) , at mpif@mpif.org or on the Internet at March 5 Fundamentals of Mechanical Seals Basics Course. George R. Brown Convention Center, Houston, TX. The course is designed to give the attendee the necessary information to select and apply mechanical seals in various applications. The course will focus on the effects of equipment types and pump operation on the performance of seals, including the selection and performance of piping plans and support systems. Attendees will also be introduced to failure analysis techniques and life cycle costing implications. All students will receive a copy of HI s Mechanical Seals for Pumps: Application Guidelines by attending this course. Registration for Fundamentals of Mechanical Seals Basics is now open and forms are available on both the Hydraulic Institute and Texas A&M Turbomachinary Laboratory websites. For more information, contact the Hydraulic Institute on the Internet at March 6 9 UTS Gear Design and Manufacturing Course. Universal Technical Systems facility, Rockford, IL. The course aims to provide a fundamental understanding of spur and helical involute gear geometry, teach attendees to apply gear design concepts, and to develop a working knowledge of UTS software tools. Other topics to be covered include gear fundamentals, gear tooth forms, gear geometry, standard proportions, quality, gear modifications, gear design considerations and the gear design process. Students also have the opportunity to tour Gleason Cutting Tools and Forest City Gear. An optional Basic TK Solver course is offered on March 5 to familiarize students with the program for equation solving, manipulation of units and creation of tables and plots in math models. The TK Solver Course is $295 and the Gear Design Course is $1,250. For more information, contact UTS by phone at (815) , by at sales@uts.com or on the Internet at March WESTEC Los Angeles Convention Center, Los Angeles, CA. Exhibitors include advanced machine tool, cutting tool and accessories, manufacturing technology, and emerging technology companies. The event is sponsored by the Society of Manufacturing Engineers and showcases automation and assembly solutions for the aerospace, automotive, biotechnology, chemical, computer, cosmetics, defense and electronics industries. Registration is free. For more information, contact the Society of Manufacturing Engineers by phone at (800) or on the Internet at April 1 3 Plastic Parts Innovations Conference and New Products Design Competition. Peabody Hotel, Memphis, TN. The Alliance of Plastics Processors (APP) is accepting abstracts or proposals for technical presentations, panels, or workshops. The APP seeks papers on topics that include the latest uses of materials; case studies; emerging business issues; new market developments; lowpressure structural foam; creative design/tooling; innovative new process technologies; time or cost-reducing product development methods; and production innovations to advance attendees knowledge of the plastics processing arena. For more information, contact the Society of the Plastics Industry by telephone at (202) or on the Internet at April Hannover Messe World Trade Fair for Industrial Technology. Hannover fairgrounds, Hannover, Germany. The 2007 exhibit program includes Industrial Automation; Motion, Drive & Automation; Digital Factory; Subcontracting; Energy; Pipeline Technology; FM Solutions; Comvac; Surface Technology; Microtechnology; and Research and Technology. For more information, visit the show s website at 44 powertransmissionengineering february

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48 classifieds Heat Treating Forgings TAKE A BITE OUT OF YOUR GEAR COSTS WITH TEETH LIKE THESE. Cutting Tools YOUR AD HERE YOUR AD HERE YOUR AD HERE Presrite Corporation Phone: (216) Gear Manufacturing Gear Manufacturing YOUR AD HERE Gear Manufacturing YOUR AD HERE Cutting Tools YOUR AD HERE Heat Treating YOUR AD HERE YOUR AD HERE 46 powertransmissionengineering february

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50 advertiser index A/W Systems Co. Page 47 (248) Arrow Gear Co. Page 46 (630) B&R Machine & Gear Corp. Back Cover (731) Bourn & Koch Page 16 (815) Cadillac Machinery Co. Inc. Pages 31, 39 (847) Clifford-Jacobs Forging Co. Inc. Page 17 (217) Comtorgage Corp. Page 9 (401) kgradolf@comtorgage.com Fässler Corp. Inside Back Cover (414) usa@faessler-ag.ch Gleason Corp. Inside Front Cover (585) dmelton@gleason.com Kapp Technologies Page 3 (303) info@kapp-usa.com A/W Systems Co. Page 47 (248) Arrow Gear Co. Page 46 (630) B&R Machine & Gear Corp. Back Cover (731) inquiry@brgear.com Bourn & Koch Page 16 (815) bournkoch@worldnet.att.net Cadillac Machinery Co. Inc. Pages 31, 39 (847) sales@cadillacmachinery.com Clifford-Jacobs Forging Co. Inc. Page 17 (217) sales@clifford-jacobs.com Comtorgage Corp. Page 9 (401) kgradolf@comtorgage.com Fässler Corp. Inside Back Cover (414) usa@faessler-ag.ch Gleason Corp. Inside Front Cover (585) dmelton@gleason.com Kapp Technologies Page 3 (303) info@kapp-usa.com A/W Systems Co. Page 47 (248) Arrow Gear Co. Page 46 (630) B&R Machine & Gear Corp. Back Cover (731) inquiry@brgear.com Bourn & Koch Page 16 (815) bournkoch@worldnet.att.net Cadillac Machinery Co. Inc. Pages 31, 39 (847) sales@cadillacmachinery.com Clifford-Jacobs Forging Co. Inc. Page 17 (217) sales@clifford-jacobs.com Comtorgage Corp. Page 9 (401) kgradolf@comtorgage.com Fässler Corp. Inside Back Cover (414) usa@faessler-ag.ch Gleason Corp. Inside Front Cover (585) dmelton@gleason.com Kapp Technologies Page 3 (303) info@kapp-usa.com 48 powertransmissionengineering spring

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52 CUSTOM BEVEL GEAR MANUFACTURING Per Your Specifications and/or Sample Providing Inverse Engineering to Make a Clone of Your Sample Spiral Bevel Gears: 66" PD Straight Bevel Gears: 80" PD Spurs Helicals Spline Shafts Gearbox Repair/Rebuilds In-House Steel Material Warehouse Full Heat Treating Services EDM Wire Burning BREAKDOWN SERVICES Machine and Gear Corporation 4809 U.S. Highway 45 Sharon, TN Toll Free: (800) Ph: (731) Fax: (731) inquiry@brgear.com Internet: Family owned and operated since 1974