Schaeffler inthe fast lane

A peoplebusiness

EfficientE-bikes

Taking thetemperature

IN THIS ISSUE…

ISSUE 8 - JULY 2011

4 6 13 19

HanoverStarring at

NEWS

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COVER STORYSchaeffler at Hanover Fair

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It gives me greatpleasure towelcome you tothe latest editionof SchaefflerUK's corporatenewsletter.

When you readthrough thelatest stories on

product and service innovation containedin these pages, you will see very clearlyjust how important innovation is to theSchaeffler Group. But innovation doesn'tjust happen on its own. It is driven by apassionate workforce striving to supportour customers with improvedtechnologies that fulfill the current andfuture requirements of the markets theyserve. So the articles on innovativeproduct developments or innovative useof service equipment are really about ourpeople and how their passion for problemsolving leads to a better, more cost-effective or more energy-efficient solutionthan was previously available.

So, whether Schaeffler technology helpsto support Team Audi's newly sponsoredA4 to reach the chequered flag first,whether our asset managementtechniques help to safeguard visitors tothe Eiffel Tower, or whether thesustainability of our planet is supportedby innovations in electric vehicletechnology, it is our people that takecentre stage within the global Schaefflerorganisation. This is just as evident herein the UK from the many long serviceawards we present to our employeeseach year, and from the pride that all ourstaff take in their work for Schaeffler. Ourpeople are the reason we can proudlyclaim that Together We Move the World!

I wish you an enjoyable and informativeread, and as always, welcome anyfeedback you may have on any of thearticles contained in this issue.

Kate HartiganManaging Director

PEOPLE TAKECENTRE STAGE

The national award demonstrates thecompany’s ongoing commitment tosustainability.

Schaeffler UK received top honoursin the Sustainability Prize category.Donna Williams-Bevan, TrainingOfficer at Schaeffler UK, acceptedthe prize on behalf of the company atthe annual awards ceremony held atthe City Hall, Cardiff.

The Wales Quality Award is an annualcompetition based on the EFQM(European Excellence Model). Theawards are open to all types ofbusiness operating in Wales, includingmanufacturing firms, financialorganisations, hospitals, service

providers, educational establishmentsand councils.

Winning a Wales Quality Award is anaccolade for any business. Thejudging and assessment process iscarried out by a panel of independentindustry experts from the private andpublic sectors.

In a speech at the awards ceremony,David Phillips, CEO at the WalesQuality Centre, the organisationresponsible for the Wales QualityAwards, commented: “As winner ofthis year’s Sustainability Prize,Schaeffler UK has demonstrated themost significant impact in this areaover a period of time.”

Roger Evans, Plant Director atSchaeffler UK commented: “We arevery pleased to win a Wales QualityAward again. This is the third year insuccession that Schaeffler has won aQuality Award and we believe itacknowledges our ongoingcommitment to continuousimprovement. The award forsustainability recognises the strategyand plans that are being prepared toensure the success of Schaeffler UKin the future. This process hasresulted in the Llanelli plant securinga considerable amount of investmentin new technology during 2011.”

SCHAEFFLERSCOOPS NATIONALSUSTAINABILITYPRIZESCHAEFFLER UK’S AUTOMOTIVE COMPONENT MANUFACTURING PLANT IN SOUTH WALES HAS WON A WALES QUALITY AWARD FOR SUSTAINABILITY.

PRINCE LEARNS ABOUT ENERGY EFFICIENTROLLING BEARINGS AT START WALES FESTIVAL The Prince of Wales met withSchaeffler staff at their exhibitionstand at the Start Wales Festival,held at the National BotanicalGardens in Camarthen, West Wales.

His Royal Highness spoke to RichardGranger, Sales Engineer atSchaeffler UK, about the company’srange of rolling and plain bearingsthat are helping engineers to designmore energy efficient wind, wave andtidal turbines.

Start (www.startuk.org) is a UKnationwide initiative by The Prince’sCharities Foundation aimed atpromoting and celebratingsustainable living. The Prince cut theribbon at the very first Start WalesFestival which featured presentationsand exhibits on the simple steps wecan all take to make better use of

natural resources, including energy,food, transport, buildings and waste –at home and in the workplace.

Schaeffler UK was one of 160exhibitors at the event. A variety ofdifferent rolling bearings and plainbearings were displayed onSchaeffler’s stand, many of themdesigned to support specific types ofrenewable energy systems, includingwind, wave and tidal turbines.

Richard Granger commented: “It wasa pleasure to meet and talk with HisRoyal Highness on such an importantday for the Welsh community andindustry. The Prince took a greatinterest in Schaeffler’s products,particularly our bearing ranges forspecific types of renewable energysystems such as wind turbines, wavepower and tidal energy systems.

“The Prince also showed a keeninterest in Schaeffler’s automotiveengine components plant based inLlanelli.”

KIEV GETS READY FOR EURO 2012

riginally built in 1923, theUkraine’s Olympic Stadium inKiev has been renovated onseveral occasions but is

currently undergoing a thorough,comprehensive modernisation programme inpreparation for the UEFA Euro 2012 footballtournament.

Co-hosted by Poland and the Ukraine, Euro2012 tournament matches are scheduled totake place in various cities in both hostnations with the final being staged in Kiev’sOlympic Stadium on 1st July 2012.

The Olympic Stadium will need toaccommodate more than 83,000 spectatorsfor the final and at the core of itsmodernisation programme is a newretractable, translucent stadium roof, as wellas integrated floodlighting systems.

Schaeffler is playing a leading role in thestadium roof project. The roof is spanned byropes, whose coupling points comprise load-free bearing supports. All rope couplingpoints at the edge of the roof and on the

masts are accommodated by a total of 240spherical plain bearings, which are lined withSchaeffler’s Elgoglide® sliding low frictionlayer. The bearings are dimensioned in sucha way that that they can easily support theloads from the roof acting on the bearingpositions.

A total of 80 radial spherical plain bearingssupport the base plates of the roof columns.These maintenance-free bearings have a160mm diameter bore, are sealed on bothsides and have a corrosion-resistant steelinner ring.

Arranged in pairs, a further 160 radialspherical plain bearings support the loadsfrom the roof structure itself. These bearingshave a 140mm diameter bore and are sealedon both sides. The bearings also have aspecial inner ring bore that is lined withElgoglide®, enabling the bearings to bemounted more easily in the application. Inaddition, the bearings are designed tocompensate for any temperature-related axial expansion.

What is Elgoglide® ?Elgoglide® is a highly wear-resistantsliding layer made from PTFEfabric, which is embedded insynthetic resin and bonded to theouter or inner ring bore. Thislow friction, sliding materialneither expands whenexposed to humidity, nor heat-seals with metal. Elgoglide isalso resistant to most chemicalagents and is ideal for use in rotaryand linear motion applications.

Elgoglide® accommodates loads, transmitsthem and also replaces the lubricationfunction. Relubrication of Elgoglide®bearings is therefore not required.

Elgoglide® bearings offer high load carryingcapacity and long service life combined withsmall installation space and low friction andprovide a number of advantages inapplications that are characterised by highloads and small swivel angles.

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A TOTAL OF 240 MAINTENANCE-FREE SPHERICAL PLAINBEARINGS SUPPLIED BY SCHAEFFLER ARE TO PLAY A VITALROLE IN SUPPORTING A NEW RETRACTABLE ROOF FOR THEOLYMPIC STADIUM IN KIEV IN THE UKRAINE.

In the last two decades, product counterfeitinghas grown substantially across the globe. Whilemuch has been reported about counterfeits inthe music, film, home electronics and designerclothing industries, far greater risks lie incounterfeiting of safety-critical industrialproducts such as tyres, seals and bearings.Here, fake versions can pose a genuine threatto health and safety.

As a result, the World Bearing Association(WBA) has launched a campaign to highlightthe very real safety hazards that come withcounterfeit bearings.

The WBA anti-counterfeiting campaign willreach out to various audiences via e-mail,website banners, social media and thecampaign website, www.stopfakebearings.comwhere interested parties can learn more aboutthreats posed by illegal counterfeiting andwhat is being done to stop it.

The Schaeffler Group withits bearing brands INA andFAG has been fightingcounterfeiting for manyyears. “We are seekingclose contact with publicauthorities and arecooperating closely with associations and otherindustrial companies to draw attention to thisissue”, said Dr. Juergen M. Geissinger,President and CEO of Schaeffler Group.

“We operate a zero tolerance strategy whichmeans that we examine and pursue each andevery case of counterfeiting worldwide, even ifthey seem like petty offences.”

Counterfeiting violates intellectual propertyrights, such as patents and trademarks and,because counterfeits look like and aremarketed as genuine products, it normallytakes a trained expert to identify them untilthey fail..

Where there are doubts about a product, thecompetent authorities and the manufacturer ofthe brand should be contacted.

“Our initiative is aimed at sensitising the publicto the dangers associated with counterfeits,”says James W. Griffith, WBA President andPresident and Chief Executive officer of TheTimken Company. “The WBA is intensifying itsanti-counterfeiting operations – this meansproviding information for customers on the onehand and consistent prosecution of offendersthrough the competent authorities on the other.”

Visit www.stopfakebearings.com tolearn more.

NEW CAMPAIGN AIMSTO PREVENT BEARINGCOUNTERFEITING

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LOOKING AFTERA LANDMARK

THE SCHAEFFLER GROUP HAS RECENTLY EXTENDEDITS LONG-STANDING RELATIONSHIP WITH SETE(SOCIÉTÉ D’EXPLOITATION DE LA TOUR EIFFEL) BYPROVIDING ADDITIONAL SERVICES TO THE COMPANYTHAT OPERATES THE EIFFEL TOWER, ONE OF THEWORLD’S BEST KNOWN LANDMARKS.

chaeffler’s maintenance and assetmanagement division IAM (IndustrialAftermarket) is now providingtechnical support in the selection of

the most suitable rolling bearings together withvibration analysis and bearing mounting servicesto the Eiffel Tower’s operating company.

The extended services agreement with SETE wasbrought about as a result of an urgent need toreplace the bearings in the cabins of thehydraulic elevator in the Eiffel Tower’s westerncolumn. These bearings support a total weight of20 tonnes, which means they are permanentlysubjected to extremely high loads. Furthermore,the axial clearance of the original bearings wastoo large. It was therefore imperative to find analternative solution.

By working in close collaboration with SETE,Schaeffler application engineering expertsselected the most suitable FAG tapered rollerbearings. These bearings meet all requirementswith respect to the radial and axial load ratingsand can be easily integrated in the system. Anexperienced IAM fitter provided on site support tothe maintenance team that mounted the elevatorcabin bearings, a task that took just one day tocomplete.

Later, when the upper pulleys of the elevator inthe eastern column of the Eiffel Tower alsoneeded to be inspected, SETE once againcontacted Schaeffler. Experienced IAM engineerscarried out measurements using an offlinevibration measuring device and provided SETEwith a detailed condition report on the bearingsalong with recommendations regarding futuremaintenance measures that should be taken.

The relationship between Schaeffler and theEiffel Tower started in the late 1980s, whenSchaeffler undertook an extensive project tooverhaul all of the famous landmark’s mechanicalsystems.

At that time, in order to modernise the elevators,the bronze rings in the pulleys were replaced withFAG rolling bearing systems. This significantlyincreased the reliability of the elevators.

In 2002, Schaeffler developed and mounted anINA gear ring, which aligns the revolving

floodlight at the tip of the tower.

Now Schaeffler and SETE areplanning more joint projects.What SETE particularlyappreciates about therelationship with Schaeffler is its portfolio of rolling bearings is capable of meeting customers’ increasing demands for innovation and higher quality.

The product portfolio iscomplemented by the extensiverange of product and servicesolutions for the maintenanceand repair of rolling bearings.These have helped SETE reduce maintenance costs,optimise elevator efficiency andavoid unscheduled shutdowns.

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SCHAEFFLER COLOURSAPPEAR IN THE FAST LANE

A BRIGHT NEW SCHAEFFLERLIVERY, IN LUMINOUS YELLOWAND STRIKING GREEN, MADE ITSFIRST APPEARANCE ON THEGRID WHEN THE GERMANTOURING CAR SERIES – DTM (DEUTSCHE TOURENWAGENMASTERS) - KICKED OFF THE2011 SEASON AT HOCKENHEIMRECENTLY.

he Schaeffler colours, together withthe LuK, INA and FAG logos, arefeatured on an Audi A4 driven by29-year-old Martin Tomczyk from

Rosenheim in Bavaria, who will receive backingas Schaeffler’s brand representative.

While Schaeffler, primarily through LuK, has beenactive in motor sport for over 30 years, the new2011 sponsorship represents a big step forwardin its involvement. Instead of the smaller LuKemblems on the Red Bull Audi and INA emblemson an S-line Audi, seen in previous seasons, thisyear will seen the new fully liveried SchaefflerAudi A4.

“We are pleased to be brightening up DTM racedays with some fresh colours this season,” saidDr Juergen M. Geissinger, President and CEO ofthe Schaeffler Group. “We are continuing ourcommitment to touring car racing in the DTM andwith Audi, and through this new sponsorship weare also raising public awareness of ourcompany.”

The DTM is amongst the most popular touringcar series in the world and has true internationalappeal. Of the ten rounds in this year’s calendar,six take place at German venues with the otherstaking place in Holland, Austria, Spain and theUK.

The UK race will take place at Brands Hatch onSeptember 4th. Starting at 1.00pm, the race willcover 98 fast and furious laps of the Kent circuit.

Adding to the interest in the events is the list ofdrivers who are participating in this year’schampionship such as Ralf Schumacher andDavid Coulthard, the latter one of a very strongBritish contingent.

At the time of writing, three rounds in the serieshad been completed and the Schaeffler Audi had

done brilliantly well – coming in fifth atHockenheim, third at Zandvoort in Holland, andthen taking the chequered flag in first place atSpielberg, with Martin Tomczyk bringing theSchaeffler car home split seconds ahead of RalfSchumacher.

(By the time this edition of ‘In Motion’ ispublished, more races in the DTM calendar willhave been completed. We’ll keep you in touchwith the results in later editions).

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PEOPLE TAKE CENTRESTAGE AT SCHAEFFLERMARIA-ELISABETH SCHAEFFLER, HEAD OF THE SCHAEFFLER FAMILY BUSINESS, WAS INTERVIEWED LIVEIN FRONT OF AN AUDIENCE OF AUTOMOTIVE EXPERTS AT THE RECENT CAR (CENTRE AUTOMOTIVERESEARCH) SYMPOSIUM IN BOCHUM, GERMANY, AND REVEALED THAT A CLOSE RELATIONSHIP WITHEMPLOYEES HAS BEEN A CORE VALUE OF THE BUSINESS SINCE IT WAS FIRST FOUNDED.

he interview was conducted byProf. Dr Ferdinand Dudenhöffer,one of the organisers of the CARSymposium, an event held annually

since 2001 with the aim of investigating theeconomic interrelationships and activities in theworldwide automotive industry.

The motto for this year’s event was“Innovations and Profitable Growth” and thekey message was that the automotive industryhas left the economic trough.

Below are key extracts from the interview withMaria-Elisabeth Schaeffler:

Prof. Dr. Dudenhöffer: The SchaefflerGroup increases its sales by 10 percent,year on year, which is very impressive.

Could you tell us the secrets of yoursuccess? What are your key principles?

Maria-Elisabeth Schaeffler: Schaeffler is a family business established by Georg andWilhelm Schaeffler. When I came from Vienna to Herzogenaurach as a 21-year-old, I found there was nothing as important as thecompany. My husband lived for it seven daysa week. There was a bond with the companyright from the beginning which is impossibleto express in words.

Even back then, the company was our life, our responsibility and our highest priority at all times. This hasn’t changed and includesa very close relationship with employees.When I take journalists or customers round

our plants they can see how the employeesmeet me and how deep human ties can be.This is something very precious; somethingvery binding.

Prof. Dr. Dudenhöffer: How important isit for you to be in contact with largenumbers of staff?

Maria-Elisabeth Schaeffler: I believe thatknowledge about employees and contact withthem is extremely important. It is a specialcharacteristic of a family owned business.People take centre stage at Schaeffler and,because the company has been my life too,seven days a week for many years now, Iknow the people and appreciate that there

are many families where two or threegenerations have worked forSchaeffler. Many started asapprentices and I still meet employeeswhose grandfathers worked here.These special ties motivate peopleand are an important factor in oursuccess.

This is one of the reasons I try totravel as much as possible. I want tomeet the employees at our plantsthroughout the world to get to knowthem and learn about their localsituations. I attach great importanceto this because as a familyentrepreneur it is necessary for me toshow solidarity with all these peoplewho work and achieve for ourcompany.

For a while now, my son hasaccompanied me on these trips whichmakes me very happy.

Prof. Dr. Dudenhöffer: Does ittake a certain level of humility anda down-to-earth approach todemonstrate to your employeesand to the general public thatthese aspects are more importantthan things such as shareholdervalue and the like?

Maria-Elisabeth Schaeffler:Humility has always been important atSchaeffler and this remains the casetoday. My husband always attachedgreat importance to this and, havingcome from a very strict family where Iwas brought up to treasure frugalityand restraint, I also feel this is veryimportant.

Prof. Dr. Dudenhöffer: TheSchaeffler Group has tripled itssales since 1996. How importantare takeovers in the context ofsuch a growth process and whatrole do acquisitions play in thelong term for family ownedenterprises?

Maria-Elisabeth Schaeffler: It allstarted with LuK. Initially we took a50% stake in the company and it wasmy husband’s wish to acquire theremaining 50% at some stage in thefuture. However, we managed thisonly after his death.

Next came the takeover of FAG which,considering our future orientation andgrowth plan, was a real stroke of luck.Now our business is well balancedwith automotive sales accounting for60% and our industrial businessproviding 40%.

Our logo – the LuK, INA and FAGbrands drawn together by theSchaeffler name – reflects the realsituation. We are a family; we make agood match; we have grown together;and we can provide an excellentservice to the market.

Prof. Dr. Dudenhöffer: Howimportant was your entry atContinental AG?

Maria-Elisabeth Schaeffler: Veryimportant and I still support thedecision. Schaeffler is orientatedtowards mechanics – albeit hi-tech –but still mechanics. Continental, onthe other hand, stands for electronics.

The close connection between thesetwo fields will be vital to findingsolutions for future mobility andincreased energy efficiency.

I am convinced that even the greatestsceptics will come to realise that thiswas exactly the right decision –maybe not today or tomorrow, but oneday in the near future.

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INTERVIEW

INNOVATIVE SCHAEFFLERENGINEERING STARS AT HANOVER

isitors to the stand were able toview the latest rolling and plainbearing solutions, together withdevelopments in linear and

direct drive technology and a range of newmechatronic components.

Robert Schullan, President of SchaefflerGroup Industrial, said: “With our wideproduct range, innovative strengths andposition in growth markets, we are able toshape the big future trends in our sectors –energy and energy efficiency, mechatronicsand electric mobility – and to expand theSchaeffler Group’s market position.”

Renewable energyRenewable energies, including wind, solar,tidal and wave power, are a strategic growtharea for Schaeffler Group Industrial, whichworks as a development partner for variousprojects in the sector, creating theprerequisites for the development andeconomic use of regenerative energies withapplication-specific expertise and innovativeproducts.

As an example of its work in this area,Schaeffler featured its strategic partnershipwith British firm Pelamis Wave Power which

has resulted in a decisive breakthrough in thedevelopment of wave energy converters. Theextended performance limits in bearing andseal technology was key to the success of theproject. The Pelamis wave energy converterfloats on the surface of the water like a seaserpent and is anchored to the sea bed. Itsgigantic steel tubes are linked together usingjoints and are located transverse to the waves.Upward and downward wave motion driveshydraulic motors that are linked to generators.

The main steel tube structures are connectedby bearing units containing a combination ofSchaeffler bearings specially developed forthe project.

Rolling and plain bearing supports developedfor use in the tracking systems of solarpowered plants were also featured on thestand. Series AXS angular contact bearingsare particularly suitable for this application,providing maximum efficiency and high cost-efficiency.

MechatronicsMechatronics, which are playing an increasinglyimportant role in innovative rolling bearingsolutions, were also a feature of the Hanoverstand. These newly developed rolling bearings,with integrated sensors and an integrated oradjacent power supply, are improving thereliability and cost-effectiveness of machines bymeans of increased functionality.

One example on show was the new torquesensor bottom bracket for electric bikes (or"pedelecs").

Another was the new grease sensor,incorporating an electronic valuation system, thatenables the condition of the grease in a bearingto be analysed during operation. Developed bySchaeffler in association with the sealingspecialist Freudenberg and lubrication expertKlüber-Lubrication, the system detects anychanges in the condition of the grease beforeany damage to the rolling bearing occurs.

Hanover is one of the world’s biggest engineeringexhibitions and attracted visitors from across the

globe, including many from the UK. In all, over6000 companies exhibited at the show, but, withits raft of innovative developments, SchaefflerGroup Industrial, was definitely amongst the stars.

The latest needle roller bearingsNeedle roller bearings have been a core part ofthe business since its formation in the 1940sand the latest developments in this sector, withthe emphasis on downsizing and frictionreduction, were introduced at Hanover.

Three new needle roller bearing designs, allcarrying the X-life quality brand, were unveiledat the show.

The newly developed, profiled steel cage ofthe new X-life machined needle roller bearingtype D, produced by optimising formingmethods, provides a significantly higher load

carrying capacity. The cagedesign means that

both the number ofneedle rollersand theirload-bearinglength canbeincreasedwithoutanyincrease inoverall

bearing dimensions, opening new designoptions for downsizing. For example, a new X-life NK 55/25-D-XL can achieve a 25% higherload carrying capacity. Previously a needleroller bearing of the size NK 75/25-XL wouldhave been required.

A second development introduced at Hanoverwas the machined needle roller bearing with aTwin Cage made of plastic. Designed toprovide higher efficiency, the developmentallows two short needle rollers to be insertednext to each other in one cage pocket insteadof the usual single long needle roller. The newcombination achieves a significantly lowerfrictional torque in comparison withconventional needle roller bearings.

The third development presented at the showwas a new slimline drawn cup needle rollerbearing which also makes a significantcontribution to lower friction and higherefficiency. This is the first bearing in thediameter range from 15 to 50mm that has asection height of only 1.5mm and is thereforeparticularly suitable for replacing plain bearingsin automatic transmissions. The new bearingsalso reduce friction by up to 60% compared toconventional bearings and simplify the adjacentconstruction considerably.

WITH OVER 230,000 VISITORS THE HANOVER FAIR, HELD FROM APRIL 23 TO 27,PROVIDED AN EXCELLENT LAUNCH PAD FOR THE LATEST INNOVATIONS FROMSCHAEFFLER GROUP WHERE THE FOCUS WAS ON INCREASING EFFICIENCY ANDCONSERVING RESOURCES WHILST IMPROVING PERFORMANCE AND RELIABILITY.

EXHIBITION

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nnovative hybrid bearingtechnology from Schaeffler UKhas enabled engineeringconsultancy and electric vehicle

manufacturer, Delta Motorsport, to designand build from scratch an all-electric road carcapable of 0-60mph in less than 5 secondsand with a top speed in excess of 150mph.

The Delta E-4 Coupe is a stylish4-seater, 2-door coupe thatboasts a class-leadingrange of more than200 miles on a singlecharge.

The vehicle, which can accommodate fouradults, boasts an acceleration comparable toa Porsche 911 Turbo.

The key to the E-4 Coupe's stunningperformance is the direct-drive electric motorthat powers the car. Designed in by DeltaMotorsport in partnership with OxfordUniversity and Oxford Yasa Motors to meetDelta’s performance requirements, the new

design axial-flux electric motorgenerates well over 600Nmof torque while onlyweighing 23kg.

“The bearings were absolutely critical toenabling the modular design of the Yokelessand Segmented Armature [YASA] motor,”said Nick Carpenter, Technical Director atDelta Motorsport. "Ultra Low Energy Vehiclessuch as the E-4 Coupe rely on lightweightcomponents to compensate for the inherentproblem of the low energy density of lithiumbatteries when compared to gasoline.

“When I first came up with the idea of a newbearing arrangement that would help tooptimise the space available for the statorwhile accurately controlling the air gap to therotors, I almost dismissed it due to the factthat standard bearings would have been toobig and too heavy. However, followingdetailed discussions with Schaeffler UK, thecompany’s engineers were able to offer aspecial design of hybrid double-row angularcontact ball bearing, which has a split innerring that was able to meet the demandingcriteria of reduced weight and cross-section."

This was the breakthrough that DeltaMotorsport needed if it was to fulfil itsambition to develop a highly-efficient, plug-inbattery electric 'car for the people’ that isstylish in design, financially viable andcapable of overcoming the 'range anxiety' ofmany potential purchasers of all-electricvehicles.

Stewart Davies, Senior Applications Engineerat Schaeffler UK, said the E-4 project hadpresented some very demanding criteria. “Thechallenge was to keep the bearing as narrowas possible in order to meet the dimensionalconstraints of the design envelope inside theYASA motor, whilst at the same time offeringa commercially viable bearing solution withina very tight timescale.”

Schaeffler UK was able to supply the firstsamples four months after it started work onthe project. Davies continues: “The initialbearing design concept proved to be tooexpensive but, following intensive designcalculations, we were able to offer a singlehybrid bearing that met the key designcriteria and could also be competitivelyproduced in volume.”

One of the problems encountered bySchaeffler’s design team was the high seallip speed. With the bearing rotating at suchhigh speeds, all calculations indicated thatthe seal would wear out and the bearing

would fail prematurely. By specifying anon-contact shield, this problem wassolved. Another advantage of using anon-contact shield is the increased lifeexpectancy of the grease.

According to Davies, “A hybrid bearinghas all the insulation qualities requiredfor use in electric motors, includinglow friction, but the non-contact shielddoubled the life expectancy of thegrease which further enhanced theperformance of the bearing.”

Dr Tim Woolmer, whose DPhil atOxford University led to the creation ofthe YASA motor added: “Thepartnership with Delta and Schaefflerhelped us to create performanceprototypes of the motors very quickly.The design has proven to be so robustat high torque and high speedconditions that Oxford YASA Motorshave adopted it as part of the nextgeneration design being finalised forhigher volume production.”

Delta Motorsport is used toovercoming many challengingengineering problems, having beeninvolved in a wide variety of concept,design and prototype projects rangingfrom sports cars and motorcycle safetyproducts, to hybrid and battery electricvehicles. The company’s work in toplevel motor sport – where vehicleweight, aerodynamics and mechanicalefficiency are key factors – hasenabled Delta to optimise theperformance and handling of the E-4Coupe.

"Problem solving is in our DNA,"states Carpenter. "However, designinga road car is a very different challengeto designing a racing car. It’s not thatany one task is particularly complexbut simply the sheer number ofchallenges involved, from keeping thewater out to making sure the carhandles well.”

Carpenter's enthusiasm for the E-4

Coupe and thefuture ofsustainablevehicletechnology isinspirational. "Wehave learnt somuch just byrolling our sleevesup and having a go.With the motorsportindustry firmly based inthe UK, the culture ofinnovation is in our DNA.There is a great opportunity inthis sector for UK plc, and Deltais looking forward to taking this'Philosophy Transfer' to the nextstage."

"Schaeffler's bearing know-how hasbeen an enabling factor in Deltadeveloping this class-leading product.We wouldn't be where we are nowwithout it," concludes Carpenter.

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AUTOMOTIVE

SCHAEFFLER BEARING TECHNOLOGY FEATURES IN THE NEW DELTA E-4

ALL ELECTRIC AND 0 – 60MPHIN LESS THAN 5 SECONDS

IN MOTION | 10

AUTOMOTIVE

A GROUNDBREAKING NEW SLIM DESIGN OF SPUR GEAR DIFFERENTIAL FOR PASSENGER CARS,WHICH IS 30 PER CENT LIGHTER THAN ITS PREDECESSORS AND WILL ALSO CREATE UP TO 70PER CENT FREE AXIAL SPACE IN THE GEARBOX, HAS BEEN DEVELOPED BY SCHAEFFLER.

E-BIKES

GROUNDBREAKINGDIFFERENTIALWEIGHS 30% LESS

The slim shape of the new differentialenables the use of new bearing conceptswith optimised friction characteristics,which in turn will have a positive effect onfuel economy and CO2 emissions.Ultimately, the lightweight differential willsave space that can be used for largerdual clutches or transfer gearboxes, aswell as making room for electricalcomponents on hybrid electric vehicles.

In the 1950s, a mid-sized car weighed inat around 900kg. 50 years later, this figurehad increased to around 1,600kg due to ahost of new safety and comfort features.Numerous electronic aids were also

responsible for the additional vehicleweight.

Today the need is to reverse the trend andevery kilogram that can be saved from theoverall weight of a vehicle is critical,putting increasing pressure on vehiclemanufacturers and their suppliers tominimise the size and weight of powertrainsystems and engine components.

The new differential is the result of a two-and-a-half year advance developmentproject. It has already been installed in amid-size passenger car and has slippedseamlessly into a variety of other customerprojects.

PRECISION BEARINGS MAKEELECTRIC BIKES MORE RELIABLEAND ENERGY EFFICIENT

ALTHOUGH MUCH OF THE DEBATE ON HOW TO REDUCE HARMFUL EMISSIONS TO THEENVIRONMENT IS FOCUSED ON ALL-ELECTRIC PASSENGER VEHICLES, THE PEDALCYCLE INDUSTRY, WITH THE EMERGENCE OF THE ‘E-BIKE’, IS ALSO NOW A SIGNIFICANTGROWTH MARKET FOR NEW ALL-ELECTRIC DRIVE TRAIN TECHNOLOGIES.

olling bearings are an integralpart of bicycle drive trains andSchaeffler’s experience indeveloping bearing solutions

for bicycles spans more than a century.

More recently, Schaeffler has introduced avariety of energy efficient bearing solutionsfor pedal cycles, including seat pillars,headsets, saddle wing mountings, freewheel hubs, internal gear hubs and bottombrackets.

The BB29 FAG bottom bracket, forexample, has been designed to providesmoother running for city and touringbicycles.

Now, building on the foundations of theBB29 bottom bracket, Schaeffler hasdeveloped a new bottom bracket bearingspecifically for electric bicycles (e-bikes).

With e-bikes, the drive only becomes activewhen the rider is pedalling at a certain force(torque).

However, the drive system must becontrolled and regulated. The data requiredto do this (i.e. the speed, direction and angleof rotation, torque) is ideally measureddirectly on the bottom bracket itself.

Based on the BB29 bottom bracket,Schaeffler’s new compact speed sensorbottom bracket bearing, the BB RS,determines the speed, direction of rotationand angle of rotation using a non-contactmeasurement method.

The system has a much higher resolution

than alternative designs, generating 16pulses per shaft revolution. This enablesmore precise control via shorter responsetimes in activating and deactivating thedrive system. As a result, the drive canrespond with much greater sensitivity toindividual riding characteristics, providingoptimum assistance to the cyclist. Thesystem is also capable of distinguishingbetween forwards and reverse pedallingand can include this information in theoutput signal.

In contrast to traditional speed sensorbottom bracket designs that are normallybased on a magnetic disc with a Hall Effectsensor – which are openly accessible andtherefore sensitive to external influencesand foreign matter – the BB RS sensorbottom bracket bearing is a completelyencapsulated system that can beaccommodated in the design envelope of aconventional bottom bracket bearing. Thismeans that the sensor is optimallyprotected, secure from disruptive influencesand completely maintenance-free.

Once the system is fitted, it is ready foroperation without the need for furtheradjustment. The twin core cabling is locatedwithin the frame, giving optimum protection.The supply voltage is between 5 and 18volts (rated voltage 12V) and is compatiblewith all conventional control systems.

Easy-to-fitMounting is particularly easy due to theconnection preventing reversed polarity andthe dual fix design. The housing profile is

suitable for the use of FAG tools(externally) and Shimano tools (internally).Since the diameter at the centre of thebearing unit is significantly reduced, thisallows space for light cables and otherconnections. The plastic housing with glassfibre reinforcement compensates smallmounting tolerances and makes mountingeasier.

The new BB RS was presented to thepublic for the first time at the Eurobikeexhibition in September 2010, held inFriedrichshafen, Germany. Schaeffler alsounveiled its new torque and speed sensorbottom bracket. A world first, the FAGtorque sensor bottom bracket is able todetermine the total torque from the sum ofthe force from the left and right pedals.Bosch is already using the device in its newhigh-performance drive.

Being able to correctly determine the rider’srequirements for assistance from the motoras riding conditions change and thecorresponding control of the power output,is critical to ensuring that the ride has apositive feel. As well as measuring thedirection of rotation and speed, being ableto measure the precise torque produced bythe rider during pedalling, is a prerequisitefor determining the exact additional powerrequirements.

The additional drive power provided by theelectric motor is controlled principally by thetorque sensor system in the bottom bracket.This means that the rider no longer needsto provide additional ‘pedal power’.

IN MOTION | 13IN MOTION | 12

The SchaefflerGroup’scomprehensiverange of systemsand componentsfor internalcombustionengine-poweredvehicles, hybridvehicles and all-electric vehiclesis detailed in anew brochurefrom SchaefflerUK. Entitled‘DrivingTowards aSustainableFuture’, the

brochure looks at a series of innovativeengineering solutions developed by theSchaeffler Group, which are helpingmanufacturers of traditional internalcombustion engine-powered vehicles toproduce more compact, lightweight vehiclesthat deliver improved fuel consumption andlower CO2 emissions.

Although the internal combustion engine(ICE) is likely to dominate the automotivelandscape for the next decade, the increasingmismatch between energy consumption and

available resources, together with tighter legalrestrictions on pollution, is creating anincreased demand for improvements toexisting automotive technologies and thedevelopment of ‘greener’ alternatives.

Schaeffler is already successfully partnering anumber of major automotive manufacturers todevelop more energy-efficient solutions forICE-powered vehicles. These solutionsinclude a lightweight balancer shaft androlling bearing assembly; UniAir, the world’sfirst fully variable hydraulic valve controlsystem, developed with Fiat Powertrain; theball roller bearing; and the FAG wheelbearing, which provides simplified mountingand is 10 per cent lighter than itspredecessor.

Another development project at Schaefflerinvolves the use of novel, optimised enginecomponents, which together give an overall10 per cent reduction in fuel consumptionand CO2 emissions. Schaeffler’s CO2ncept-10% is a CO2 demonstration vehicle basedon a Porsche Cayenne with a V8 engine.

In addition to tried-and-tested, optimisedengine components, the vehicle is alsoequipped with several new powertrain andchassis components manufactured bySchaeffler. The project achieved an overallsaving of 10 per cent in both fuel

consumption and emissions when comparedto existing production models.

Hybrid and electric vehicles

The brochure also details Schaefflerinvolvement in the ongoing development ofconcepts and components for the nextgeneration of hybrid and all-electric vehicles.

The Group’s new hybrid demonstrationvehicle, the Schaeffler Hybrid, is based on aVauxhall Corsa and is a fully operationalhybrid vehicle. Part of an advanceddevelopment project at Schaeffler, this vehicleenables practical comparisons to be made ofa number of different vehicle configurationsand driving conditions. As well as using aconventional volume-manufactured ICE, theSchaeffler Hybrid also incorporates a centralelectric motor and two wheel hub motors. Thevehicle incorporates every Schaeffler brand,including INA, FAG, LuK, IDAM and AFT(Atlas Fahrzeugtechnik).

The brochure also describes how Schaefflerhas developed innovative hybrid bearingtechnology to support the next generation ofall-electric vehicles. These innovations includehigh speed planetary gear sets, lightweightspur gear differentials, high speed ballbearings for electric motors and highfrequency one-way clutches.

DRIVING TOWARDS A SUSTAINABLE FUTURE R

IN MOTION | 15IN MOTION | 14

his novel, onboard unit enablesinformation relating to thecondition of bearings, wheelsetsand rail tracks to be recorded,

and then transmitted to a higher level controlsystem.

The evaluated data produced by the systemforms the basis for maintenance and repairdecisions and is also critical for railwaysupervisory systems as well as for onlinetimetable generation, routing, process and riskanalysis.

The Train Support System has already wonmany admirers in the rail industry andGermany’s Center for Transportation &Logistics (CNA) recently recognised it with its‘Intelligence for Transportation and Logisticsinnovation’ award.

From Rolling Bearing to Onboard Unit The Train Support System is based onSchaeffler’s FAG axlebox bearing, which canbe used with an integrated GSB (GeneratorSensor Bearing) as a self-sufficient energysource in rail freight wagons. Schaefflerdeveloped the system electronics and softwareand then integrated these in its GSB(Generator Sensor Bearing), forming anonboard unit.

Used in combination with an informationmanagement system, the GSB enables lineoperators and rail companies to improve tracksafety, whilst optimising freight logistics. A widerange of different signals are recorded in theGSB and transmitted to a central computer viaGPS. The evaluated data forms the basis forrail supervision systems, as well as onlinetimetable generation, routing, process and riskanalysis, localisation, length of retention and soon.

Similar to a dynamo, the GSB induces therequired electric power via the rotationalmovement of permanent magnets located onthe wheel axle. This power is typically around100W at a nominal voltage of 24V. Therefore,an independent, self-sufficient energy source isavailable, which, via an electric storage unit,enables additional functions, such as theautomatic opening of train doors or thedetection of switches and sensors.

For the Train Support System, Schaeffler hasnow refined the GSB with a sophisticatedelectronic system into an onboard unit andconnected this with a higher-level informationmanagement system. Now the signals are notonly recorded and processed in the bearing,but are also transmitted via GPS satellitetechnology.

From Onboard Unit to Train Support System In the past, such onboard units were notpossible to develop, particularly in freight trains,because supply of data using satellitetechnology only works with an independent,self-sufficient energy supply system.

This is now available due to Schaeffler’sGenerator Sensor Bearing. Communication ofmessages via satellite opens up newpossibilities for optimising freight haulagelogistics and for enhancing transport safety..

The sensors integrated in the bearing recorddata on the condition of the axlebox bearing,such as wear or excessive heat, and alsodetermine and monitor other characteristicssuch as mileage, speed, temperature and noise.This data enables conclusions to be made

about the condition of wheels, bogies and railtracks. Even the condition of butt joints andswitches in the rail network can be monitored.

The evaluation of the data recorded in thebearing also enables the monitoring andoptimisation of traffic and goods flow, as wellas wagon availability, location tracking and thecalculation of track utilisation costs, taking intoaccount the loads, number of axles, time anddistance.

“The great innovation for transportation andlogistics is achieved via the combination of theself-sufficient energy generation in theGenerator Sensor Bearing and the sensor data with the respective onboard units and the higher level information and control system. This makes the Train Support System a groundbreaking solution for rail traffic in terms of safety and communications, as well as transportation and logistics management,” emphasised Simone Purbs, Head of the Schaeffler Group’s Railway Sector Management.

AN AWARD-WINNING TRAINSUPPORT SYSTEM HAS BEENDEVELOPED BY THESCHAEFFLER GROUP.

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RAIL IN

DUSTRY

TRAIN SUPPORT SYSTEM IMPROVESRAIL SAFETY AND EFFICIENCY

The two handheld FAG Detector IIIvibration monitoring systems suppliedby Schaeffler UK paid for themselveswithin just two months, by minimising

disruption costs to rail operators and by significantlyreducing the number of traction motor repairs due tobearing deterioration.

“If we detect early signs of wear to traction motorbearings, we can repair or replace that motor at ourown convenience before more significant damageoccurs,” said Peter Ridgway, Production SupportEngineer at Siemens Mobility, Rolling Stock. “Thecost of repairing a damaged traction motor would bemany times the cost of a standard overhaul.”

Prior to investing in the FAG Detector III handheldvibration monitors, Siemens had been experiencingbearing deterioration problems on some tractionmotors, fitted to the Desiro electrical multiple units.The bogies on these trains are all driven by the sametraction motor. What Siemens needed was a methodof monitoring the condition of the traction motorbearings in order to predict their remainingoperational life and enable appropriate correctiveaction to be taken before damage was caused to themotor.

“In theory, these traction motors have a service lifeapproaching one million miles before they needoverhauling, but we were experiencing some bearingissues earlier than this. In March last year, I thereforestarted to search for a suitable solution and cameacross Schaeffler’s UK website, which was veryhelpful,” said Peter Ridgway.

After talking to Schaeffler UK’s Engineering ManagerDr Steve Lacey, Peter Ridgway decided to work withSchaeffler to develop a suitable condition monitoringsolution.

Schaeffler carried out a comprehensive program tomeasure vibration from around 100 traction motors.This involved measuring vibration on the tractionmotor housing and assessing the condition of thebearings and other associated mechanicalcomponents.

The vibration measurements were carried out whilstthe trains were positioned over an Underfloor WheelLathe at two of Siemens’ rail maintenanceworkshops in Southampton and Ilford.

As Dr Steve Lacey states: “At the onset of theinvestigation, I wasn’t very hopeful that simple

vibration-basedparameters could beused to give a reliableindication of motorcondition. However,after carrying outdetailed vibrationmeasurements on thetraction motor housing,it became apparent thatsimple characteristicvibration parameterscould be used to give avery reliable indicationof the condition of themotor, even in thepresence of highbackground vibrationfrom other sources.

We believe this novelsolution for assessingthe condition of railtraction motors is an industry first and we’re veryexcited about the potential benefits that our FAGDetector III can bring to rail operators.”

Following in-depth analysis and reporting, Schaefflerdeveloped special software for its FAG Detector IIIwith the aim of providing Siemens with a device thatwould be easy to use and that didn’t require avibration monitoring expert to interpret the results.

The modified Detector III now enables maintenanceengineers at Siemens to implement vibration checkson a routine basis. The device now has a new ‘Rail-Measurement’ menu option with pre-set limits for theDesiro traction motors.

“We collected vibration data using our FAG BearingAnalyser. The results demonstrated that, evenamongst the very high background noise andvibration levels, it is possible to detect vibrationfrequencies that are related to the drive end bearing,”added Dr Lacey.

Peter Ridgway concluded: “Siemens is committed toundertaking maintenance to the highest standards ofintegrity. We have been extremely impressed withSchaeffler’s commitment to this project and cannotfault the company’s drive and dedication to finding areliable and practical solution for us.”

“We can now properly survey the fleet of trains to

assess the condition of their traction motors and tomake more informed decisions as to when tooverhaul a particular motor.”

A NOVEL, HANDHELD VIBRATION MONITORINGSYSTEM HAS BEEN DEVELOPED TO ENABLEMAINTENANCE ENGINEERS AT SIEMENS MOBILITYTO CHECK TRAIN TRACTION MOTORS FOR EARLYSIGNS OF DAMAGE TO THE BEARINGS.

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AN INDUSTRY FIRST FOR SCHAEFFLER AND SIEMENS

NOVEL HANDHELD VIBRATION MONITORFOR TRAIN TRACTION MOTORS

y working closely with themanufacturer, the SchaefflerGroup has optimised bearingsused in newly developed Sauer-

Danfoss H1 series of axial piston pumps andmotors.

As a result of the new optimised X-lifecylindrical and tapered rolling bearings, overallefficiencies of the H1 pumps and H1 motorshave increased by around 2 per cent, resultingin significant improvements in energyefficiency levels.

Energy saving potential for the end users ofthe pumps and motors is significant. Forexample, by utilising a new H1 hydraulic pumpand two H1 hydraulic motors, a wheel loaderthat has a drive power of 140kW can savearound 9kW. Projected onto 1,000 wheelloaders operating for eight hours a day, annualsavings potential could reach 26,000MWh.This is equivalent to the average energyconsumption of more than 6,500 households.

This results in approximately savings ofaround 5 million Euros (0.21 Euros/kWh) andaround 16,000 tonnes of CO2 per year. Thelatter is roughly equivalent to the annualemissions of 4,200 compact cars, each

traveling 25,000km per year.

Increasingly stringent emissions regulationsand rising energy costs are boosting demandfor more efficient machines and drive systems,including the optimisation of power traindesigns for diesel engines in order to reducevehicle fuel consumption.

In non-automotive applications, various typesof hydraulic units are now replacing traditionalpower transmission systems. Configurableaxial piston pumps and motors, for example,are specifically designed for use with electricalmachine controls.

In developing the H1 series, as well asoptimising and improving the electro-hydraulicsystem itself, Sauer-Danfoss also focused onoptimising the base components within thehydraulic pumps and motors. The variousbearing positions on the pumps and motorswere scrutinised down to the last detail inorder to identify where any improvementscould be made. New, low friction, optimisedrolling bearing solutions from Schaeffler had asignificant influence on reducing power loss,installation space and weight across the H1range.

A new option for an H1 axial piston pump inswashplate configuration was achieved byusing new swashplate cradle bearings. Here,compact, low friction cylindrical roller bearingswere used to support the drive shaft.Compared to the previous version, theinstallation space and weight weresubstantially reduced and efficiency wasincreased by around 2 per cent.

IMPROVING ENERGYEFFICIENCY IN AXIALPUMPS

ENERGY EFFICIENCYew rolling bearings for

household appliances havebeen developed that reduceenergy consumption in

refrigeration compressors by up to five percent improving the energy efficiency ratingof the compressor by one class.

The new FAG axial ball bearings fromSchaeffler are specifically matched toeccentric shaft bearings in refrigerationcompressors, replacing the plain bearingsthat are normally used.

Four types of FAG axial ball bearings areavailable, which can be freely combined.Both bearing washers can be supplied withor without raceways. Bearing cages aresupplied in either sheet steel or plastic,matched to the operating environment. Thebearing materials offer excellentcompatibility with coolants and areresistant to varying temperatures.

The sheet steel cage has a special ‘filigree’(twisted wire) design, which not onlyprovides high rigidity, but is even moresuitable than plastic cages for the hightemperatures that occur in these bearingpositions. In addition, coolant compatibilitytests are no longer necessary.

The raceways in the axial washers provideeven more secure guidance for the ballsand improve load distribution and ballrotation. Overall, these characteristics

result in a bearing that offers reducedwear and which has a longer operating life.Bearings with raceways on both sides arealso available, which provide increasedmounting security.

In the basic design, the axialbearing washers arepunched, through-hardened and polished,and both sides can beused as raceways. Thesize of the bearingcan be adapted to suitindividual mountinglocations.

ENERGY CONSUMPTIONIN HOUSEHOLDAPPLIANCES CUT BY 5%

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IN MOTION | 17IN MOTION | 16

WIND POWER

A new high capacity cylindrical rollerbearing for wind turbine gearboxes offers a20 per cent increase in rating life.

The bearing, which features a new bearingcage design, also provides higher loadratings and reduced friction.

The basic static and dynamic load ratings ofthe new bearings are 6 per cent higher thanthose of a conventional cylindrical rollerbearing with solid brass cage, resulting in a20 per cent increase in rating life.

These new FAG high capacity cylindricalroller bearings feature a new sheet steelcage, which enables a much more compactdesign compared to a conventional solidbrass cage. The slimline cage leaves spacefor at least one additional rolling element inthe bearing, which increases the load ratingsignificantly.

There are other advantages too. Due to thenew cage, the high capacity bearing has asignificantly lower friction than fullcomplement cylindrical roller bearings withmaximum basic load rating. The ‘self-retaining’ cage also simplifies bearingmounting because the rolling elements areretained even when the ring is removed.

Today, most planetary stages of windturbine gearboxes use full complementcylindrical roller bearings. These bearingshave no cage, the function of which is toguide the rolling elements and to maintain aset distance between them. These fullcomplement bearings have the highest loadratings, since more rolling elements arefitted to bearings that have no cage.

However, full complement roller bearingshave relatively high friction because therolling elements are in direct contact witheach other. These kinematic conditionscause higher friction losses. In contrast,cylindrical roller bearings with conventionalsolid brass cages have significantly lowerfriction, but often do not achieve therequired load ratings due to the reducednumber of rolling elements.

Schaeffler’s new FAG high capacitycylindrical roller bearings incorporate thenewly developed sheet steel cage, whichensures low friction and provides sufficientspace for an additional roller in the bearing(due to very narrow crosspieces).

The cage comprises two cage rings lyingone inside the other and joined together.The crosspieces of the inner cage guide the

rollers and retain them in the bearing, evenwhen the bearing ring is removed. Thismeans that the bearing is much easier tomount, as no separate device is required tohelp prevent the rollers from falling out.Meanwhile, the outer cage providesincreased rigidity.

In addition, the special geometrical shape ofthe cage pockets improves lubricant flow,which reduces friction and prevents damageto the bearing.

EXTENDED RATING LIFE FOR TURBINEBEARINGS

A novel designof rollingbearing forwind turbinegearboxes hasbeen developed

by Schaeffler. Notonly is it resistant to

the effects of slippage,but actually prevents slippage from occurringin the first place.

The new FAG tube roller bearingincorporates three tube rollers that are ofslightly larger diameter than the other rollersand thus rotate at all times in contact withthe inner and outer ring, preventing slippageeven when the bearing is under very low load.Due to the design of the tube rollers, theybecome slightly compressed under higherload and the full set of rolling elements thencomes into contact with the bearing rings,supporting the load in the same way as aconventional bearing. The load rating and

rating life of the bearing are thus unaffected.

Slippage is the natural enemy of all rollingbearings. The life and performance of arolling bearing will suffer if it is overloaded orunderloaded. This is because rolling bearingsare designed with a minimum loadrequirement in order to function optimally. Ifthis minimum load is not met, slippage willoccur. This means that the rolling elementsnot only rotate, but also slide on the bearingraceways. Eventually, this can lead to surfacedamage such as increased wear or smearing,particularly in critical lubrication conditions.

In wind turbines, rolling bearings have tomeet special performance requirements. Thebearings must be designed to withstandextremely low and high loads that act on thebearing during calm or strong windconditions. The risk of damage to a bearingincreases significantly when the roller set ofa rolling bearing with high slippage issuddenly subjected to extremely highacceleration forces. For this reason,

Schaeffler has developed the tube rollerbearing, which completely eliminates theproblem of slippage.

The tube roller bearing is not available fromSchaeffler’s standard catalogue but is customdesigned for specific customer projects andapplications.

PREVENTING SLIPPAGE

IN MOTION | 19IN MOTION | 18

ENSURING THEACCURACY ANDRELIABILITY OF DMGMILLING CENTRES

n the machine tool industry,system partnerships and co-development projectsbetween OEMs and

component suppliers are increasinglyimportant.

Machine tool manufacturers prefer to focuson their core competences, whilst sourcing‘ready-to-fit’ components and sub-systemsfrom high performance technology partners.

German machine tool manufacturerDECKEL MAHO GILDEMEISTER (DMG)for example, is working closely with TheSchaeffler Group’s INA Linear Technologydivision on a number of new machine tooldevelopments.

DMG relies exclusively on Schaeffler’s highperformance RUE-E linear recirculating rollerbearing and guideway assemblies for itslarge and super-sized milling centres.

The RUE-E system provides smooth,uniform running characteristics and highdynamics, ideal for precision linearmovement of heavy loads. The range ismodular and so customers can select from a

range of accessories to suittheir application.

The range also benefits from Schaeffler’spatented injection moulding technology,which enables perfect rolling elementguidance in the load and return zones,optimised transitions and the best possiblerunning characteristics with very low strokepulsation. Schaeffler has also reduced thenumber of components in the design,resulting in more robust, reliable rollingelement guidance.

Labyrinth seals on the rolling elementrecirculation system improve protectionagainst contamination. Uniform lubrication isalso guaranteed due to a completely closedand sealed lubrication duct.

The design of the guides incorporates anefficient sealing concept, comprisingstandard seals: single lip upper seals, doublelip lower sealing strips, as well as double lipend wipers. The end plates, fitted asstandard in front of the contact end wipers,provide extra protection against coarsecontaminants, which means the contact end

wipers retain their full performance capabilityeven in environments with fine, oftenaggressive contaminants.

DMG has been working with Schaeffler todevelop linear guidance systems for itsDMU/DMC 200 to 340 milling centres,including 5-axis machining centres.Depending on the size of the machine tooland the loads acting on the main axes, linearrecirculating roller bearing and guidewayassemblies in sizes RUE 35, 45, 55 and 65are specified. In addition, in order to meetspecific customer requirements, DMG usescovering strips; double lip wipers andcustomised sealing kits from Schaeffler’smodular KIT system. These are pre-assembled at the factory. Load calculationsare carried out using Schaeffler’sBEARINX® calculation software,complemented by DMG’s own designcalculations for further system refinements.

Optimised distribution of lubricant for theRUE-E units ensures minimal flow greaseconsumption of just one litre per year usingmachine lubrication intervals of four hours.Additional components are not required.

I

The Schaeffler Group has expanded its closeworking partnership with Italian machine toolmanufacturer The BIGLIA Group. In addition tosupplying ball and roller monorail guidancesystems for BIGLIA’s range of lathes and multi-spindle machine tools, Schaeffler is nowsupplying its super precision FAG spindle andcylindrical roller bearings to the Italian company.

This technical and commercial collaboration withSchaeffler means that BIGLIA now has a reliablepartner that supports the Group on a global level,offering long-term application engineering advice,premium quality products and fast deliveries.

Established in the 1950s, The BIGLIA Group isbased in Incisa Scapaccino, a small town locatedin the famous Italian wine-growing region ofPiedmont. The company initially focused on themanufacture of sawing and special purposemachines, but in recent years, has seen steadygrowth in the lathe sector. Today, the Group,which has manufactured more than 10,000machines since its foundation, employs 170 staff.

BIGLIA first selected the Schaeffler Group as itspreferred supplier of ball and roller monorailguidance systems in 2004 to ensure that the

company’s range of lathes and multi-spindlemachine tools would continue to meet customers’high expectations in terms of quality, reliabilityand performance.

Today, the majority of main axes in BIGLIAturning machines are equipped with ball androller linear recirculating bearing and guidewayassemblies, such as the KUVE 35 guidancesystem, from Schaeffler.

The KUVE range of four-row monorail guidancesystems offers high accuracy, rigidity and loadcarrying capacity, as well as other specialcharacteristics. KUVE guides have integrallubricant reservoirs adjacent to the rollingelements and provide long operating life, withmaintenance-free operation in certainapplications.

The full complement KUVE-B guidance system isideal for applications where the emphasis is ondynamic characteristics as well as maximum loadcarrying capacity and rigidity. A wide range ofcarriages are available, including standard, long,low, high, short and narrow, all of these runningon the same modular guideway.

A speciallow noise KUVE

design is alsoavailable for applications

in which quiet running hasa higher priority than load

carrying capacity. This version incorporates plasticelements called ‘Quad-Spacers’, which guide andseparate the balls, preventing collisions andreducing running noise.

BIGLIA now offers a comprehensive range ofmulti-functional lathes and multi-spindle machinetools, with two or three automatic turning heads.Available in 25 different versions with between 2and 12 axes, these machines are suitable foruniversal turning operations and for machiningcomplex assemblies in a single set up.

The company also manufactures a variety oflathes, including vertical lathes with inclinedspindles, lathes with three automatic toolchangers and multi-tasking lathes.

MACHINE TOOLS

TECHNICAL COLLABORATION WITH BIGLIA

FAST LEAD TIMES ONLINEAR SYSTEMS…

lobally, Schaefflermanufactures inexcess of 10km ofshafting for

customers every day and theshafting comes off the linearproduction line in Germanycontinuously at walking pace, 24hours a day, seven days a week.

A large stock of shafts is availablefrom Schaeffler’s UK Linear Quick-Centre, located at the company’sUK manufacturing plant in Llanelli,South Wales. This facility enablesSchaeffler to offer UK customersrapid deliveries on linear systems,rails, shafts, cages and carriages, aswell as customer-specific machinedshafts.

John Loonam, Linear ProductSpecialist, comments: “No othermanufacturer of linear guides orbearings has a facility like thisbased in the UK. The Linear Quick-

Centre has enabled Schaeffler toreduce UK customer lead timessignificantly over the past twoyears, especially on low volumelinear products and shafts.

“It means we can offer customers48-hour emergency support oncut-to-length shafts. Custom,machined shafts are generallyavailable on 3 to 5 day lead times.”

The Linear Quick Centre canmachine shafts up to 6m in length,with diameters between 5mm and80mm. Monorails can also bemachined up to 6m in length.Materials include induction-hardened steel, stainless steel andaluminium support rails.

...AND RAPID DELIVERIES ONLINEAR GUIDES AND SHAFTS

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LINEAR

chaeffler UK is now able to offerUK customers fast lead times onits RUS and PR linearrecirculating roller guidance

systems.

The RUS and PR linear recirculating rollerguidance systems have been part of theSchaeffler range for many years, but theyremain popular with many UK customers,particularly machine builders and machine toolretrofitters. Now, Schaeffler UK can supplythese units on fast lead times, typically 1-2months.

“We are the only supplier in the UK that holdsa comprehensive stock of these types oflinear guide,” said John Loonam, LinearProduct Specialist at Schaeffler UK.

Schaeffler offers one of the mostcomprehensive ranges of linear guidanceproducts in the world. Linear recirculatingroller guidance systems comprise INA linear

recirculating roller bearings, with guideways and adapters. The units can be used as locating/locating or locating/non-locating bearings. In a closed arrangement, the bearings can support loads from all directions andmoments about all axes.

The RUS and PR versions are popular withmachine tool retrofitters and machine builders, as they offer very high load carryingcapacities, and require little installation space. The units also provide extremely high rigidity under preload.

“The RUS and PR units come with adjustinggibs, which facilitate mounting and provideuniform distribution of the preload over theentire length of the linear recirculating rollerbearing, enabling the preload to be set veryeasily,” explains Loonam.

The RUS..KS version offers very smooth, lownoise operation due to seals on the end faces.

This unit can be lubricated through the endpiece, and can operate in temperatures from –30 deg C to +90 deg C.

The PR model is a full complement cylindricalroller set and is suitable for high operatingtemperatures, high speeds and highaccelerations. Due to its all-metal construction,the PR can operate in temperatures from –40 deg C to +120 deg C.

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IN MOTION | 21IN MOTION | 20

HELPING TO MAKETRACTORS ANDGRADERS GREENER

NEW ROLLING BEARINGSDEVELOPED BY THESCHAEFFLER GROUP FORTRACTORS AND GRADERSPROVIDE GREATER DRIVETRAIN EFFICIENCY WITHRESULTANT REDUCTIONS INFUEL CONSUMPTION ANDVEHICLE EMISSIONS.

ractors and graders require highdrive power and operate at highspeeds. As well as providingoperational reliability under

every conceivable load or speed condition, thedesign engineers responsible for the newgeneration of these machine are looking todevelop more environmentally friendlymachines with reduced fuel consumption andmore energy efficient drive trains.

Many of the latest tractors offer more than100kW drive power, with some capable ofachieving road speeds of up to 80km/h. Mostgraders operate under full load at speeds ofup to 40km/h. The high drive power requiredfor these applications is transmitted via thegearbox and differential and significant fuelsavings can be achieved by focusing onimproving the efficiency of these two keydrive train systems.

Low Friction BearingsThe terms ‘rolling bearings’ and ‘energyefficiency’ are almost synonymous with oneanother. Rolling bearings are generallyspecified in order to save energy. Wheremechanical work is required or componentsare in motion, rolling bearings ensure reducedfriction and therefore increased energyefficiency. This is why the rolling bearing – auniversally accepted machine component – isand will remain one of the key components inreducing energy consumption.

The continuous improvement of modelling,simulation and design calculation software isthe main prerequisite for developing evenbetter bearings, tailored more precisely tomatch customer requirements and to provideeven higher energy efficiencies.

It is not only the selection of themost suitable bearing that plays akey role here. The internal design ofa rolling bearing, for example thedesign of the cage, will also have amajor impact on the bearing’s

performance and friction. Other designapproaches involve the use of friction-

reducing, wear-resistant materials andcoatings, as well as applying further surfacequality improvements in the functional areasof the bearing during volume production.

Low Friction Tapered Roller Bearings

Low friction tapered roller bearings areoptimised in terms of their geometry, surfacestructure and materials, as well asdimensional and running accuracy. As a result,the basic dynamic load rating is increased byup to 20 per cent and the basic rating life isextended by up to 70 per cent. This meansthat it is now possible to select morecompact, lighter bearings, leading to a furtherreduction in friction. The use of premiumgrade materials and special heat treatmentsalso provides the bearing with a higherresistance to solid particulates andcontaminants such as sand, dirt, dust andheavy clay soil.

In addition, an improved logarithmic profilehas been developed for the bearing racewaysand roller surfaces, which compensates forstress peaks during high loads ormisalignment. Due to the optimised rollersurfaces and contact geometry, an elasto-hydrodynamic lubricant film is created, even atvery low speeds. This film allows high loadson the bearings during initial start-up andreduces frictional torque by up to 75 per centcompared to conventional bearings.

Friction-optimised Tandem Angular Contact Ball BearingsSchaeffler’s INA and FAG tandem angularcontact ball bearings prevent the loss ofpreload and also reduce friction losses.Therefore, the bearings increase theefficiency of the gearbox and enablesignificant fuel savings to be achieved.

Similar to tapered roller bearings, angular

contact ball bearings can support axial andradial loads. However, due to their pointcontact, angular contact ball bearings produceless friction and (unlike tapered rollerbearings) have no roller/rib sliding contact,which would adversely affect friction.

Point contact is easier to lubricate than linecontact of tapered roller bearings. This meansthat angular contact ball bearings operatewith lower friction than similar-sized taperedroller bearings. The use of double-row angularcontact ball bearings ensures that therequired load carrying capacity can beachieved and, at the same time, the frictionaltorque is lower than single-row angularcontact ball bearings with the same loadcarrying capacity. Another benefit of angularcontact ball bearings is the preservation ofpreload, which provides consistently highrigidity.

Friction-optimised Tandem Ball Roller BearingsThis innovative “ball roller bearing” is based onan ingenious idea and novel rolling elementcombined with new assembly methods.

All areas of a conventional rolling element or“ball” that are not under load are removed.This means that 15 per cent of the balldiameter is cut off on both sides of the ball.The result is the ‘ball roller’, a ball that isflattened on both sides and is 30 per centnarrower than a conventional ball. This savesvaluable design space. Furthermore, the veryslim shape of the ball roller, together withspecially developed assembly methods,enable an increase in the number of rollingelements, so that a filling capacity of up to 90per cent can be achieved.

More rolling elements in the same designspace results in much higher load ratings andcorrespondingly longer service life.

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AGRICULTURE

CONDITION MONITO

RING

he new TempCheck PRO is ahandheld infrared temperaturemeasurement device that offersengineers a genuine, low cost

alternative to thermal imaging cameras. Thedevice requires little training as the user simplyaims the device at the target object andpresses a button. The temperature is thendisplayed on a coloured LCD display.

The device is extremely simple to operate andworks in a non-intrusive manner. It deliversprecise results within seconds. Users can carryout safe inspections on hot components orobjects in hazardous areas, and sources ofproblems can be located without removing orexchanging parts. Valuable time and money canbe saved by detecting weak points before theybecome a real production problem.

The TempCheck PRO can be used as part ofthe preventive maintenance regime for rotatingmachinery and components, as well as forlocating ‘hot spots’ on bearings, gearboxes,motors, valves, HVAC systems, electricalconnectors, fuses, electrical wiring and controlcabinets.

The device is supplied as standard with asurface sensor for situations where contactmeasurement is the preferred method, and animmersion sensor for measuring thetemperature of fluids, making it ideal for use inchemical, pharmaceutical or food processingapplications. The integrated data logger canstore up to 20 recorded values.

High resolution, small spot size

TempCheck PRO offers a very widetemperature measurement range and is able tomeasure surface temperatures from -32°C to+760° C. The optical resolution of the unit is40:1, which provides an accuracy of ±1% (or±1 deg C between 0 °C and 760 ° C). Thishigh resolution, combined with the unit’sconsistently small infrared measuring spot sizeof 13mm up to a distance of 260mm,minimises measurement errors and ensuresthat the device is capable of accuratelymeasuring smaller targets (down to 13mm) thatare further away.

TempCheck PRO’s 300ms response time alsoallows the user to ‘sweep’ the unit around aroom or control cabinet looking for ‘hotspots’.The user can even programme the device to

compensate for the emissivity of differenttarget materials.

TempCheck PRO comes with acoustic andvisual HIGH/LOW alarm functions and a USBinterface. The integrated reporting softwareenables the user to set parameters and recordtemperatures. The unit is also supplied with anadapter for a photographic tripod and aprotective pouch and storage case.

The TempCheck PRO also benefits from aslimline, ergonomic design and is no larger orheavier than a standard TV remote controldevice, fitting neatly into an engineer’s pocket.

Emissivity and temperaturemeasurement

The emissivity of an object depends on thematerial, the type of surface, the temperature,wavelength and sometimes on the measuringarrangement. While an ideal emitter can emit allthe radiation it receives and is known as a‘black body’, this does not exist in nature andbodies emit radiation to varying extents at thesame temperature. The emissivity defines theratio between the radiation emitted from themeasured object and that emitted by a blackbody and is therefore a value between one andzero. Infrared sensors receive the radiationemitted from the object surface, but may alsoreceive reflected radiation from the

surroundings and in some cases, radiation fromother sources transmitted through themeasuring object.

When selecting an infrared measurementsensor, it is therefore crucial that thewavelength band over which it measures isknown and that the correct wavelength band isused for the object to be measured. Manyobjects consisting of non-metallic materialsshow a high and relatively constant emissivity,irrespective of their surface consistency, atleast in the long-wave spectral range, typically8-14µm.

The FAG TempCheck PRO is the latest devicein Schaeffler’s TempCheck family of contactand non-contact temperature measurementproducts.

This range includes the FAG TempCheckPLUS, which is similar to the FAG TempCheckPRO, but is a lower cost version that offers areduced temperature measurement range (-32 deg C to +530 deg C) and a reducedoptical resolution of 20:1.

A NEW, LOW COST, EASY-TO-USE NON-CONTACT (INFRARED) TEMPERATUREDEVICE THAT MEASURES THE SURFACE TEMPERATURE OF COMPONENTS IN AWIDE VARIETY OF APPLICATIONS HAS BEEN LAUNCHED BY SCHAEFFLER.

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TEMPCHECK PRO – THE NEW, LOWCOST, EASY-TO-USE ALTERNATIVETO THERMAL IMAGING

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IN-HOUSENEWS

Like virtually everyoneelse in the country whohas any interest in books,I got hooked on StigLarsson’s addictiveMillennium Trilogy and hiswonderful anti-heroineLisbeth Salander. Icouldn’t put the booksdown and finished allthree over a couple ofweeks.

And there lies the problem. I wanted more, but because StigLarsson’s books were published after his death from a heart attack,there aren’t any.

It was a bit of a literary void. But then, just before flying off for aholiday in sunnier climes, I was introduced to Jo Nesbo, anotherScandinavian author, and his alcoholic hero, Detective Harry Hole.

Hooked again!

Nesbo’s books are genuine page turners and only constant naggingfrom family to ‘do things’ persuaded me to put them down. I managedto finish two on holiday.

‘The Redbreast’ opens in the German lines on the frozen RussianFront during the Second World War – did you know that a hugenumber of Norwegians volunteered to join the Wehrmacht – butcomes right up to date with neo-Nazi sympathisers in modern-dayOslo. The two narrative threads cleverly intertwine throughout the bookuntil it reaches its gripping climax.

‘The Redbreast’ was over 600 pages long, but they passed in a flashand then it was on to ‘Nemesis’, the second in Nesbo’s ’Oslo Trilogy’.It starts with a bank robbery when the teller is given 25 seconds tohand over the money. It takes 31 seconds and the robber cold-bloodedly shoots his female hostage in the head. The start of another450+ pages of suspense and shocks.

Nesbo is a brilliant thriller writer with the talent to surprise and shockfrom the first page to the last. Blood and horrific violence featurethroughout the books, but so does a fair smattering of dark humour.Hole (which is actually pronounced ‘Huller’) may seem like thestereotypical fictional detective, but he’s actually completely originaland engaging.

I’m about to start my third Nesbo book, ‘The Devil’s Star’, and the goodnews is that there are three more left when I’ve finished this one.

Ray Hirst, Trinity Marketing, July 2011*From a review in ‘The Independent’

For the past seven years MatthewAnthony, a member of the team atthe Llanelli plant, has been studyingat Coleg Sir Gar in Swansea andrecently all his hard work paid offwhen he received his BSc Hons inComputer Aided Engineering andMechanical and ManufacturingEngineering.

Matthew first enrolled at the collegein 2004 on a National Diploma butthen moved on to an HND and,finally, the BSc.

“I found the course enjoyable and interesting,” he said. “But there werea lot of late and restless nights doing course work and revision.

“I hope the qualifications will give me a good grounding for futuredevelopment and enable me to further my career with the SchaefflerGroup.”

MARATHON CHARITY BIKE RIDE FROM NORTH TO SOUTH WALES

Long serving staff at Schaeffler’sUK Head Office in Sutton Coldfieldwere honoured at a special dinnerheld at Moor Hall Hotel. Pictured atthe event are (l to r), Roger Evans,Plant Director, Martin Ryan (15years service), Richard Oldfield (25

years service), Richard Hall (15years service), Kate Hartigan,Managing Director, Adrian Horne(15 years service), Siobhan Griffin(15 years service) and DesPattinson, Director and GeneralManager, Industrial Division.

THE NEXT STIG LARSSON’

o raise funds for Ysgol GrugGlas, a school for children withspecial needs, a group ofcyclists, supported by the

Schaeffler manufacturing plant at Llanelli,took part in a marathon bike ride fromCaernarfon Castle in North Wales toSwansea.

The 160 mile ride started on Friday, June 3and finished on Sunday, June 5, with a largereception party at a local rugby club.

As the team photograph shows, the eventwas blessed with hot, sunny weather allweekend enabling the riders to enjoyspectacular views of the Welsh countryside.

To date the team has raised over £2,000 forthe school with donations still coming in.

Many thanks from all the staff and pupils ofthe school to all those who have sogenerously donated to such a worthy cause

Many friends and colleagues attendeda special farewell lunch to wish BrianFox, Engineering Manager at theLlanelli manufacturing plant, a longand happy retirement after over 41years of dedicated service to thecompany.

Brian started working for INA inGermany as a product technician in1970. “Back in the early days when Istarted work in the metal-formingdepartment in Herzogenaurach I feltprivileged to have worked alongsideDr Schaeffler on the factory floor andto have been involved in thedevelopment of new deep-drawingtechnology used in the production ofneedle roller bearings,” he said.

“Now, at the end of my career withSchaeffler, I have again been involvedwith this precision technology to deep-draw mechanical tappets, as well ascommissioning the exciting newinvestment in the South Wales plant."

Brian paid tribute to his colleagues,past and present, who have helpedbuild the successful team that hascontributed to the outstandingachievements of the Llanelli plant."These are really exciting times foreveryone at Llanelli and I am pleasedto have been a part of them.”

Brian is pictured being presented witha new cycling jersey and a cake tomark his wonderful achievements.He is now looking forward tospending more time with his familyand three grandchildren, and tocontinuing his fundraising efforts forlocal charities.

FAREWELL TO BRIANAFTER 41 YEARS

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Two other members of the Minworthteam were also recently presentedwith Long Service Awards byManaging Director Kate Hartigan.

Alan Owen (left), Customer ServicesCo-ordinator has completed 40 yearswith the company and Steve Boyle

(below),Regional SalesEngineer andDistributorNationalAccounts Co-ordinator, hasworked withSchaeffler for25 years.

Having won the League Title at Under16’s, the Schaeffler (UK) sponsoredMarston Green Girls took the brave stepahead of the 2010/11 season ofjumping up two age groups to Under18’s.

Competing in the Central WarwickshireGirls Football League – one of thelargest Girls Football Leagues in the UK– the Girls set about their task with thecommitment and desire that had carriedthem to that League title just a fewmonths earlier.

Starting in early September, so positive

was their start to the season, that by theend of October the girls had won 5 anddrawn 1, scoring 36 goals and concedingjust 1.

Even when they finally tasted defeat, a 5 – 0 reverse against eventual leaguerunners-up RPS Dynamos, the girlsimmediately bounced back by puttingStratford Town to the sword the followingweek – the result… 16 – 0 !!!!!

As well as great success in the League,the girls also embarked on a fantasticcup run, ending only when, due to injuryand absence, just 8 players took to the

field for the semi final againstLeamingtom Lions, a game theyeventually lost just 1 – 0.

The girls would taste defeat only twicemore during the season - both timesagainst eventual League ChampionsWyrley Juniors - on their way to securinga third place finish – a remarkableachievement considering the girls wereplaying a year above their own age groupagainst the very best sides the Midlandshas to offer.

“It truly is a pleasure to work with theseplayers,” said Glenn Hughes, team coachand Sector Leader for Distribution, F’ISand MRO at Schaeffler UK. “Put simply,they enjoy what they do. They have apassion for the game and anunderstanding that great success is notachieved through individual brilliance, butthrough TEAMWORK.

“On behalf of myself, my coaching teamand the players I would like to thankSchaeffler UK for their fantastic supportthis season. Marston Green Girls andSchaeffler are two teams with a similarethos based on commitment and co-operation.

“Together, we may not move the world,but we are making a mark in ladiesfootball !!!!”

MARSTON GREEN GIRLS MAKE THEIR MARK WITH SCHAEFFLER HELP

Pictured left to right Back:- Mike Barber, Jason Merrifield, Rob Edwards, Brian Fox, Les ‘The Driver’ Evans, Steve Peters,James Phillips, Richard Davies; Middle:- Barry Fox, Paul Leaker; Front:- Christian Fox (Organiser),Charles Phillips

Graduation day for MatthewAnthony (second left)

REVIEW

LONG SERVICE AWARDS

BSC FOR MATTHEW

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