Scha­ef­fler bear­ings and ad­vanced tech­nol­ogy im­prove re­li­a­bil­ity

DEMM Engineering & Manufacturing - - BEARINGS & LUBRICANTS -

Scha­ef­fler is us­ing over 30 years’ ex­pe­ri­ence pro­duc­ing bear­ings for wind tur­bines to fur­ther op­ti­mise the cost­ef­fec­tive­ness and re­li­a­bil­ity of its wind power prod­ucts, tech­nolo­gies and main­te­nance ser­vices for the Aus­tralasian mar­ket.

Wind power is show­ing con­tin­ued growth in Aus­tralia ac­cord­ing to the Clean En­ergy Coun­cil’s lat­est re­port. In 2014, wind ac­counted for over 30 per­cent of all re­new­able en­ergy and 4.2 per­cent of Aus­tralia’s to­tal en­ergy gen­er­a­tion.*

“Rolling bear­ings play a key role in wind tur­bines, and down­time or main­te­nance work can be costly, es­pe­cially on off­shore sys­tems,” says Ben Kang, Power Trans­mis­sion and Wind En­ergy Sec­tor Man­ager, Scha­ef­fler Aus­tralia. “De­mand for greater re­li­a­bil­ity in the wind power sec­tor has greatly in­creased in re­cent years – for both on­shore and off­shore in­stal­la­tions,” he said.

To meet the in­creas­ing de­mands for re­li­a­bil­ity in wind power sys­tems and com­po­nents, Scha­ef­fler cre­ated the Wind Power Stan­dard ( WPOS). In or­der to achieve the high stan­dards, Scha­ef­fler re­lies on co­or­di­nated and trans­par­ent pro­cesses, de­fined change man­age­ment, strict qual­ity mon­i­tor­ing, and ex­ten­sive doc­u­men­ta­tion across the en­tire process chain in close co­op­er­a­tion with cus­tomers and sup­pli­ers.

“WPOS is de­signed to make sure we’re al­ways de­sign­ing bear­ings with op­ti­mum qual­ity and re­li­a­bil­ity in mind,” says Kang. “Scha­ef­fler de­vel­ops the best so­lu­tion for ev­ery bear­ing po­si­tion by work­ing to­gether with its cus­tomers from start to fin­ish.”

To fur­ther ex­tend the ben­e­fits of WPOS, Scha­ef­fler takes fur­ther qual­ity and re­li­a­bil­ity as­sur­ance mea­sures for all prod­ucts and tech­nolo­gies it engi­neers for the wind power sec­tor. Th­ese in­clude:

Op­ti­mum De­sign with state- of-the-art cal­cu­la­tion and sim­u­la­tion pro­grams: Along with many years of ex­pe­ri­ence and ex­ten­sive sys­tem ex­per­tise, the spe­cial­ists at Scha­ef­fler en­sure the op­ti­mum de­sign of wind power bear­ings with es­pe­cially state- ofthe-art cal­cu­la­tion and sim­u­la­tion pro­grams. Scha­ef­fler takes the en­tire sys­tem into ac­count, from in­di­vid­ual rolling bear­ings and their com­po­nents to the ad­ja­cent struc­tures and the com­plete drive train, which is de­picted

and op­ti­mised with multi- body sim­u­la­tion pro­grams de­vel­oped in-house.

Re­al­is­tic tests on Scha­ef­fler ASTRAIOS: The cal­cu­la­tions are en­hanced and val­i­dated on pow­er­ful test rigs. Bear­ings up to 3.5 me­tres in out­side di­am­e­ter can be tested on one of the most state- of-the-art and big­gest large- size bear­ing test rigs in the world. ASTRAIOS sim­u­lates the real loads and torques that oc­cur in a wind tur­bine. Scha­ef­fler uses th­ese re­al­is­tic sim­u­la­tions to con­trib­ute de­ci­sively to a faster and more re­li­able de­sign of wind tur­bines and in­creases their cost­ef­fec­tive­ness and safety.

Asym­met­ric FAG spher­i­cal roller bear­ings for in­creased ax­ial load car­ry­ing ca­pac­ity: Asym­met­ric FAG spher­i­cal roller bear­ings fea­ture a larger con­tact an­gle on the bear­ing row sub­ject to ax­ial loads and a smaller con­tact an­gle on the bear­ing row sub­ject pri­mar­ily to ra­dial loads. The asym­met­ric con­tact an­gles re­duce slid­ing move­ments in the drive train through an even higher ax­ial rigid­ity of the bear­ing. A lamel­lar, amor­phous hy­dro­car­bon coat­ing, Trion­dur C, pro­vides the bear­ings with re­duced fric­tion and high wear

pro­tec­tion un­der mixed fric­tion con­di­tions.

In­no­va­tive so­lu­tions against white etch­ing cracks ( WEC): Scha­ef­fler has ex­ten­sive test­ing op­tions to cre­ate WEC, in­ves­ti­gate their causes, and de­velop so­lu­tion con­cepts for re­duc­ing the dan­ger of WEC. Th­ese could, for ex­am­ple, be an op­ti­mised de­sign of the bear­ing, the se­lec­tion of a WEC-re­sis­tant ma­te­rial, or even an im­proved lu­bri­ca­tion con­cept. The prod­uct so­lu­tions rec­om­mended by Scha­ef­fler are through-hard­ened, black ox­ide coated rolling bear­ings. Along with other ad­van­tages, the Duro­tect B coat­ing of­fers in­creased pro­tec­tion against WEC, which is sta­tis­ti­cally proven through ex­ten­sive field ex­pe­ri­ence.

High sys­tem avail­abil­ity thanks to con­di­tion mon­i­tor­ing: Scha­ef­fler of­fers com­pre­hen­sive ser­vices and prod­ucts for con­di­tion mon­i­tor­ing, such as re­mote mon­i­tor­ing and di­ag­no­sis, off­line mea­sure­ments, en­doscopy, ther­mog­ra­phy, and torque mea­sure­ment. Th­ese tech­nolo­gies al­low the costs for main­te­nance mea­sures to be re­duced and the avail­abil­ity of wind tur­bines in­creased.

ASTRAIOS, one of the most pow­er­ful large-size bear­ing test rigs in the world, sim­u­lates the real loads and torques that oc­cur in a wind tur­bine, left, and on­line con­di­tion mon­i­tor­ing, right Scha­ef­fler tech­nol­ogy is backed by com­pre­hen­sive ser­vice in Aus­tralia and New Zealand, with re­search and bear­ing ap­pli­ca­tion and main­te­nance train­ing from Scha­ef­fler op­er­a­tions es­tab­lished for more than 35 years Down Un­der. Scha­ef­fler of­fers a wide range of ser­vices in Aus­trala­sia and glob­ally in­clud­ing sup­port, di­ag­nos­tics, and main­te­nance and assem­bly for rolling bear­ings and sys­tems.

*Based on fig­ures in the Clean En­ergy Aus­tralia Re­port 2014.



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