Sealing technology for roller bearings
Energy savings can primarily be achieved by an optimized bearing design. There is potential for the improvement of components, for example, in the material and surface quality of rolling elements and rings, raceway profile and geometry, the ball or roller set, and its interaction with special cage designs. Smoother running due to reduced friction or lower inertia thanks to a lightweight design – energy consumption can be lowered in a variety of ways without compromising on performance and service life.
Crucial details
Using the right machine elements makes it possible to achieve, for example, more energy-efficient power transmission technology that not only saves consumption costs but also reduces CO2 emissions due to their low energy needs. However, users often don’t know the details surrounding the options they have here. “For detailed information on bearing design, components and accessories, design engineers often turn to the respective manufacturers, which share their in-house knowledge. However, you are better off utilizing multi-manufacturer expertise because you have more comprehensive comparison options for the available products,” emphasizes Klaus Findling, Findling Walzläger GmbH’s Managing Director. Findling offers advice for the various details as well as their effects on the respective application.
Sealed and lubricated is the way to go
Seals and lubricants are other design elements that influence a bearing’s energy efficiency. They too are available in a wide variety of designs. “Roller bearing manufacturers can usually only manufacture a limited number of seal forms economically and therefore have a limited selection,” says Findling. “By working together with a large number of specialized ABEG® technology partners, we not only supply the largest possible variety of bearing technology variants, but also sealing elements.” For example, non-contact labyrinth seals result in less power dissipation. They therefore save a lot of energy while providing an effective seal. Deep groove ball bearings with low-friction, non-contact seals can significantly reduce the operating consumption of a system. Compared to a Premium solution with a contact seal (mass-produced product), a Supra solution with non-contact seals not only enables more energy efficient and lower-wear operation of the system, but it is also a more cost-effective solution, which is another argument for using the ABEG® method when looking for savings potential. The same applies to the lubricants used, which play a key role in mechanical power transmission technology with respect to the bearing’s performance, functionality and service life. Findling holistically and competently provides consultation for bearings, lubricants and seals. In this way, users get powerful and energy-efficient bearing solutions for their respective applications.
Whether they’re used at extreme temperatures, in environments with aggressive substances or under “normal” operating conditions, the requirements for seal materials and forms are becoming increasingly demanding. Users expect maintenance-free products with ever longer service lives. The importance of seals often only becomes apparent when not everything is sealed and the functionality of a machine is threatened. This may result in downtimes and considerable costs, meaning that the economic feasibility calculation done with regard to lower process costs when purchasing no longer adds up. For proper, efficient and low-wear function, it is therefore recommended to take into account the different products with their respective installation dimensions and framework conditions early on in the design and construction phase both for mating structures and within components. For roller bearings, this also includes sealing technology.
Good advice or the right product do not need to be expensive. With Findling Wälzlager’s ABEG® method, users can determine the optimum component from a wide range of sealed bearing technologies based on technical and economic criteria. While manufacturers can only produce a limited number of seal forms economically, working together with a large number of specialized ABEG® technology suppliers makes it possible to have the largest possible diversity in all four ABEG® performance classes.
The necessary competent personal consulting on the advantages and disadvantages of different sealing technologies and lubricants against the background of the respective application is the norm for the roller bearing specialist. A bearing point’s seal should not only prevent contamination from the outside but also keep the lubricant in the bearing. Friction must also be minimized in order to ensure efficient energy use. Until now, non-contact labyrinth seals were used whenever good sealing characteristics were desired at high rotation speeds and ZZ covers (non-contact gap-type seals, capped) were not sufficient. They cause low power dissipation and are therefore particularly energy efficient.
A disadvantage is that they are significantly more expensive to produce than standard contact seals. In order to make this sealing technology suitable for mass production, the overall system must be technically and economically optimized. The ABEG® product range makes it possible, for example, to combine the three performance classes, Premium (for the most demanding high-tech applications), Supra (performance-oriented for almost universal application possibilities) and Eco (cost-conscious, solid base technology), with the following seal variants:
- Z (non-contact gap-type seal),
- LB (non-contact, single-lip rubber seal guided in a groove),
- RS (contact, single-lip rubber seal),
- D (contact, single-lip rubber seal guided in a groove), and
- LU (contact, double-lip rubber seal guided in a groove).
Compared to a Premium solution with a contact seal (mass-produced product), a Supra solution with non-contact seals not only enables more energy efficient and lower-wear operation of the system, but it’s also a more cost-effective solution. A large number of customized solutions such as triple-lip seals or seals with a face pane can be offered in addition to these seal variants. Solutions made of Teflon or Viton are also available in addition to the standard NBR seal material.
- New products
- Rolling bearings
- ABEG