Posts Tagged ‘industry advances’

Koyo KTV Truck here until 2:00 pm CST today

Thursday, April 12th, 2012

An impressive show of technology on wheels is parked in our parking lot today. KTV Truck (Koyo Training Vehicle) on the inside is as impressive as it is on the outside.  The gentleman enjoying the coffee is Mr Cox, VP of Bearings Incorporated, and movtivator to bring the truck to our facilities at Bearings Incorporated.

The Baldor-Reliance Super-E

Friday, August 19th, 2011

In the mid-1970s, a southeastern tire manufacturing plant asked Baldor if it were possible to increase the operating efficiencies of motors in their plants. Baldor engineers determined that considerable energy savings could be gained from a better motor design. By adding more copper to the windings, upgrading the laminations to a higher premium-grade steel, designing precision air gaps between the rotor and stator, and reducing fan losses in the motor, Baldor was able to supply the plant with the premium efficient motors it needed.

This was the birth of the Baldor Super-E®. Today’s upgraded and expanded Super-E product line offers some of the highest levels of efficiency in more than 600 stock motors rated from 1/2 to 15,000 horsepower. Super-E, severe duty, close-coupled pump, IEEE 841, washdown, and explosion-proof models are also available with a three-year warranty or better. (Our IEEE 841 motors have a five-year warranty.) Called a “key breakthrough” by the Consortium of Energy Efficiency, the Baldor Super-E was recognized by the CEE in 1998 as the first premium efficiency motor line to meet their stringent efficiency criteria citing, “For the first time, one manufacturer will carry all qualifying products.” In 2001, the CEE efficiency levels were adopted as the NEMA Premium® efficient levels and expanded to 500 horsepower.

 Premium Efficiency Pays for Itself

To understand what a motor really costs, compare initial purchase price with the cost of theelectricity it uses over its working lifetime. Often, too much attention is paid to purchase price. For most motors, this initial cost represents less than two percent of its lifetime cost. Electricity accounts for about 97 percent. Baldor Electric Company’s motors and drives save customers money every minute they operate. Whether it’s lower energy costs or greater reliability, these savings go straight to the bottom line. Baldor is the industry leader in overall efficiency ratings. Better than 96 percent of the energy used by some of Baldor’s Super-E motors is converted to mechanical work. The Baldo•Reliance Super-E runs cooler and longer with greater reliability than any other industrial motor. When you consider that a typical 50 horsepower motor costs over $36,000 to operate continuously in a year, it’s easy to see how just a few percentage points of higher efficiency can quickly reduce electricity costs. Even seemingly modest percentage point differences in efficiency ratings can yield substantial electricity cost savings when the motor is operating continuously every day.

Baldor Electric Company — First in Energy since 1920

Tuesday, August 16th, 2011

The history of energy efficiency in industrial motors is really the story of Baldor Electric Company. For almost 100 years, Baldor has led the industry in developing products that deliver greater performance and reliability while using less electricity. From the company’s founding in the 1920s through today, Baldor has introduced one efficiency enhancing advancement after another. In fact, many of the advancements initiated by Baldor have later been adopted as industry standards.

The issue of energy efficiency for electric motors and drives is becoming increasingly relevant as electricity costs continue to rise. Companies are now competing in an environment of rising energy costs and the uncertainty of available electricity. These dynamics require the kind of forward-thinking industrial motor, drive, and generator supplier that anticipates customer needs and delivers products that save money and improve productivity. That company is Baldor.

 

Why is Energy Efficiency Important?

Electric motor-driven systems used in industrial processes consume some 679 billion kWh or 63 percent of all electricity used in U.S. industry, according to a Department of Energy report published in 1998. The report goes on to reveal that industrial motor electricity consumption could be reduced by up to 18 percent if companies were to apply “proven efficiency technologies and practices.” Specifically, the DOE recommends motor efficiency upgrades and application improvements. The purpose of this brochure is to show you the energy saving opportunities from using premium efficient motors and drives. The opportunities are real.

In 1992, the Energy Policy Act (EPAct) established minimum efficiency standards for industrial electric motors built after October 1997. Yet, only about 10 percent of all motors in use today comply with the minimum efficiency levels the Act mandates. When you factor in the savings potential of using adjustable speed drives in many applications, it’s easy to see that the environment, along with your profitability, stand to benefit significantly.

Timken Primary Processes / Thermal Treatment Processes

Wednesday, July 6th, 2011

PRIMARY PROCESSES

HOT ROLLING

Hot rolled tubing has a surface finish comparable to hot rolled bars, plates or sheets of equal thickness. Light mill oxide covers both the outside and inside surfaces. Hot rolled tubing can be produced to outside diameter and wall dimensions with stated tolerances.

When a quotation for this highly specialized product is requested, we work closely with the customer to gain as much knowledge as possible about the end use. This enables us to apply materials with optimum dimensions to reduce costs.

COLD DRAWING

Cold drawn tubing is produced from hot rolled tubes that have been carefully inspected and properly surface-conditioned. Cold drawing consists of pulling a tube through a die and over a mandrel, reducing the diameter and wall thickness. Tubing is cold drawn for one or more of the following reasons: closer dimensional accuracy, better surface finish, smaller sizes than can be hot rolled, or to achieve certain mechanical properties. Cold working also imparts higher strength to the tubing and tends to improve machinability of carbon and lean-alloy steel.

ROTOROLLING®(Cold Pilgered)

Rotorolled tubing is produced from hot rolled tube shells that are conditioned for further reducing. Rotorolled tubes are produced on a machine designed to make large reductions of the cross-sectional area in one pass of the tube. The machine operates by cold swaging the tube between semicircular dies containing tapering grooves. The dies rock back and forth while the tube is advanced and rotated between rocking cycles over a long tapering mandrel. The developed contour of the die grooves forms a tapering circular pass that ends in a constant-diameter ironing section that establishes the OD of the finished tube.

Rotorolled tubing is a premium product with a surface condition superior to those obtained by cold drawing. Machinability is excellent. Dimensional tolerances are very uniform. Our ability to obtain large reduction ratios allows superior mechanical properties to be achieved.

Wall thickness of up to one-third of the outside diameter can be produced.

  

ROUGH TURNING                           

 Turned tubing is produced by machining the outside surface of the hot rolled tubing. This process removes surface defects and decarburization from the outside, but the inside diameter surface retains the hot rolled finish. This is accomplished in a machine where the tools are mounted in a ring and rotated around the tube. The only motion of the tube is lateral, through the ring and past the rotating tools. Turned tubing is used extensively in automatic screw machines for manufacture into ball and roller bearing races and for special applications where advantages can be taken of the close outside tolerance or clean outside surface. Any hot rolled size up to 8 inches OD can be rough turned. Surface finish approaches 125 RMS or better.

 

THERMAL TREATMENT PROCESSES

 ANNEALING

Annealing is heating uniformly to a temperature within or above the critical range and cooling at a controlled rate to a temperature under the critical range. This treatment is used to produce a definite microstructure, usually one designed for best machinability. It is also used to remove stresses; induce softness; and alter ductility, toughness or other mechanical properties.

HOT BED COOLING

This is the standard process of air cooling the tubing immediately following piercing on a special table or hot bed that continuously advances the tubing as additional tubes are finished. Tubing that is hot bed cooled may require additional thermal treatment to obtain optimum machinability or required mechanical properties.

MILL ANNEALING

Mill annealing is a controlled cooling of the tubing immediately following piercing which produces – in some low and medium carbon alloy grades – the optimum hardness and microstructure for machinability.

NORMALIZING

In this process, steel is heated uniformly to a temperature at least 99° F (37° C) above the critical range and cooling in air to room temperature. This treatment produces a recrystallization and refinement of the grain structure and gives the product uniformity in hardness and structure.

PROCESS TEMPERING

Process tempering is performed to improve subsequent fabrication of the material (machining, cold working, etc.). See Tempering.

QUENCHING (QUENCH HARDENING)

This processes heats steel uniformly to a temperature above the critical range and cools it rapidly in a liquid medium.

SPHEROIDIZE ANNEALING

This special type of annealing requires an extremely long cycle. Spheroidize annealing is used to produce a globular condition of the carbide and maximum softness for best machinability in some analyses or to maximize cold formability.

STRESS FREE

This designates tubing that has been hot rotary straightened. Minimal straightening stresses develop in hot rotary straightening, so stress relief tempering is not needed. Cold rotary straightening and stress relieving can substitute for hot rotary straightening.

STRESS RELIEVING

Stress relieving is a final thermal treatment used when stress-free material is desired. Its purpose is to restore elastic properties and minimize distortion on subsequent machining or hardening operations. This treatment is usually applied on material that has been heat treated (quenched and tempered). Normal practice is to heat to a temperature 99° F (37° C) lower than the tempering temperature used to establish mechanical properties and hardness.

TEMPERING

Tempering heats uniformly to a temperature under the critical range, holding at that temperature for a designated period of time and cooling in air. This treatment is used to produce one or more of the following end results:

  • To soften material for later machining or cold working. Also referred to as a Process Temper.
  • To improve ductility and relieve stresses resulting from prior treatment or cold working.
  • To produce the desired mechanical properties or structure in the second step of a double

NSK 6205 DDUC3 Electric Motor Quality Ball Bearing

Tuesday, May 24th, 2011

GIVE AN ELECTRIC MOTOR THE SILENT TREATMENT

Selecting bearings for electric motors can make a big difference when you want to ensure long life and quiet operation.  The design, manufacturing and quality measures NSK incorporates throughout production minimise electric motor noise and ensure years of problem-free operations.

Cleaner Steel

If there was ever an opportunity to cut corners, this would be it; use a steel of marginal quality, sell at a reduced price and hope no one notices the difference

An innovator in bearing steel, NSK uses SUJ-2 steel for balls and rings.  SUJ-2 steel is ultra-clean, vacuum-melted bearing steel, much cleaner than typical industry standard steel.  With an oxygen content lower than 9 parts per million coupled with the proper treatment, NSK electric motor bearings have nearly double the fatigue life.

Superfinished Raceways and Maximum Sphericity

A super finish on both raceways means less wear at start-up, better performance out of the lubricant and smooth, quiet operation.  NSK accomplishes this through a proprietary method of honing the raceways to finishes at the sub-micron level.  For added value, NSK tests every bearing for low noise and vibration characteristics before the “quiet” rating is applied.

Rough bearing raceways inhibit lubrication and can lead to increased noise.  At NSK, raceways for electric motor bearings are finished to a super-smooth condition using a custom honing process they developed specially for this purpose.  This finish guarantees excellent lubrication and extends bearing life.  To enjure the smoothest possible operation, NSK uses high-grade steel balls manufactured using a proprietary process.  The result is an extremely quiet running bearing.

The ball set plays an integral role in the smooth and efficient operation of a bearing.  Not only do they need to be extremely close in size and tolerance, but are required to be nearly perfect in shape. At least by NSK standards.

Cage Advancements

It’s the small things that sometimes make the difference.  Like the close tolerances NSK achieves by coining the cage pockets.  The results are better distribution of the lubricant, less noise and reduced internal friction.  The benefit is a strong cage with a lower operating temperature and higher speed limits and ultimately it means longer bearing life. 

NSK also provides molded polyamide cages with optimized ball pocket designs.  Their conformance with the rolling elements reduces friction for quieter operation with improved grease life.  Bearings with polyamide cages also have lower torque at high speeds and are more tolerant of misalignment.

High-Temperature Grease

NSK offers a variety of lubricants to suit a wide range of applications.  When it comes to electric motors, the AS2 and NS7 greases are superior quality grade lubricants formulated to deliver low starting torque and extended service life. 

This grease offers high-temperature capability with low-noise characteristics in its electric motor bearings.  The wide temperature range prolongs the life of the grease, which in turn extends the bearing life.  You get smoother and quieter operation throughout the life of the bearing.

Quality from Start to Finish

In the manufacturing process, NSK uses the latest in automated equipment to achieve superior consistency.  At each step in the process, the latest  Statistical Process Control (SPC) techniques are applied.  NSK builds in quality you can count on, with thorough in process gauging.  Each bearing is tested for noise and vibration levels, using side-by-side Anderometer in the manufacturing line.  The Anderometers measure the degree of geometric and surface protection.  Any bearing that does not pass the low, medium and high-frequency tests is automatically rejected.

The Right Clearance

To accomplish that goal NSK identified the optimum RIC for electric motor bearings: CM.  NSK believes this range provides the right amount of clearance to meet the goal while controlling the air gap between rotor and stator, delivering quiet operation and increased efficiency.  NSK also provides bearings with CN and C3 clearances used in electric motors. The results create a much quieter running motor.

Shields, Seals and the VV

Bearings with two enclosures are pre-greased at the factory and are classified as “greased for life”.  This simply means that the type and amount of grease is sufficient to outlast most general applications, with the exception of temperature extremes, contamination, high load and high speed.

Enclosures are defined as either contact or non-contact and refer to any gap at the inner ring.  The popular Z metallic shield does a good job of keeping the grease in place and larger contaminants out of the bearings. NSK applies an anti-corrosive coating to their Z shield in the event of moisture and because they are non-contact, their operating speed and starting torque are unaffected.

For more arduous service conditions, the DU seal is in full contact with the inner ring, increasing grease retention and excluding a wider range of contaminants from entering the bearing but generate more head and therefore have reduced operating speeds.  Enter the V seal from NSK. Zero drag, low staring torque, maximum operating speeds, no excessive heat and increased grease retention and contaminant protection over the shield design.  The V seal from NSK delivers an alternative that’s fast becoming the standard in election motor bearings.

Guaranteed Results

You can depend on NSK for quieter running electric motor bearings with the design, manufacturing, and built in quality  that you need.

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Check out our

NSK 6205DDUC3 EMQ Ball Bearing sale going on  .. located in our ON SALE section of our website

NSK 6205DDUC3 EMQ
Electric Motor Quality Ball Bearing
Regular price = $12.45 each
Sale price …. $6.12 each
Until 6/30/11

 

The Timken ISOCLASS Bearing Spectrum

Tuesday, May 24th, 2011
  • Standard IsoClass Bearings

The 30000 series bearings included in the original ISO/R355 standard, often referenced as DIN720, now constitute the core of the IsoClass line of metric bearings.

  • IsoClass Spacer Assemblies

A wide range of spacer assemblies is available for numerous applications in the original-equipment and replacement markets.

Most single-row standard IsoClass bearings can be supplied as a two-row, pre-set, ready-to-fit assembly by adding spacers machined to pre-determined dimensions and tolerances.

  • Customized IsoClass Bearings

Modified and flanged IsoClass bearings are indicated by prefixes and/or suffixes to the basic part number.  These bearings are not interchangeable with bearings sharing the same basic part number.

  • Modified IsoClass Bearings
    • Timken has developed modified ISO 355 bearing designs to meet specific application requirements.  These bearings have a modified external configuration or internal geometry.
    • Flanged IsoClass Bearings
      • A variation on standard IsoClass bearings, the flanged outer race facilitates axial location and accurately aligned seats in a through-bored housing.
  • ISO STANDARDS

The ISO 355 international  metric standard defines dimensions and cup angles for single-row tapered roller bearings.  Originally intended to replace the ISO/R 355 standard, the new ISO 355 standard defined additional bearings and created new designation codes for the entire dimensional codes for the entire dimensional spectrum of ISO 355 metric bearings.

Because new designation codes for bearings that were in accordance with both the old and new standards.

With the Challenges ….

Thursday, May 19th, 2011

…. Of a new millennium, striking a balance among innovation, quality, performance and economics could be a formidable task for some bearing suppliers.  But not for The Timken Company.

For the past century, Timken has worked to blend these essential elements to create enduring value for their customers.  This focus, and the synergy between Timken’s steelmaking and bearing manufacturing organizations, adds up to a degree of product knowledge that is unsurpassed in the world.

Today, the measure of Timken’s success can be stated quite simply; Timken is the world’s largest manufacturer of tapered roller bearings.  They have led the bearing industry in nearly every significant technological advancement, manufacturing evolution, and material enhancement since Henry Timken first patented the tapered roller bearing in 1898.

Of course, maintaining this leadership position requires a full measure of dedication.  Stemming from the core of the Timken organization is a passion for quality in all that they do and a steadfast commitment to offer a spectrum of bearings and related services that add value to your own end product.

You will find this particularly true when it comes to our line of metric tapered roller bearings.

  • AN EXTENSIVE SELECTION OF 30000 SERIES METRIC BEARINGS

The Timken IsoClass brand was developed to encompass and expand Timken’s range of metric bearings – and provide you with outstanding value now and in the future.  The result is an extensive line of ISO bearings with more than 170 part numbers in the 30000 series readily available.

A closer look will show that Timken IsoClass bearings represent a commitment that reaches far beyond adopting a new brand.

For example, since 1996, Timken has invested more than $60 million in new plants and people to support the IsoClass product line.  They have added 30 part numbers to allow them to provide a full line of products to meet this important market’s needs.

In research and development, Timken has invested more than 50,000 hours to evaluate and develop  new and existing designs and 500,000 hours in performance testing.  They have expanded their metric manufacturing capacity with facilities in Italy and Poland joining our other plants in Brazil, Canada, China, France, Great Britain, Romania, and the United States.