Success Story
Industry: Quarrying, Mining & Construction
Application: Autoclave Bogie Wheel Assembly
Cost Savings: $148,297
Introduction
A customer was experiencing constant bearing failure within an Autoclave bogie wheel assembly utilizing Deep Groove Ball Bearings. The failures resulted in damage of surrounding hardware (housings and axles) creating high labor and replacement parts cost. NSK Engineers examined the application and determined that ingress of hard particulates and moisture, combined with excessive load was causing premature bearing failure. NSK recommended upgrading to NSKHPS Spherical Roller Bearings, which offered greater service life and reliability, as NSKHPS roller bearings carry greater loads and operate at higher temperatures. This solution resulted in eliminating continuous ongoing maintenance and substantially reduced colateral damage to surrounding components.
- Autoclave Bogie Wheel Assembly
- NSKHPS Spherical Roller Bearing
Key Facts
- Autoclave Bogie wheel Assembly
- High loads and temperature combined with contaminated environment caused standard deep groove ball bearings to fail prematurely
- Constant bearing failure resulted in damage to surrounding hardware and high maintanence costs
- Bearings within 10 axles replaced every 2 - 3 weeks
- NSK Solution: NSKHPS Spherical Roller Bearings
- Extended lifetime resulted in zero maintenance requirements and significant reduction in hardware colateral damage
Value Proposals
- The customer experienced constant failures in a Autoclave Bogie wheel assembly
- NSK engineers performed a Failed Bearing Analysis which showed ingress of contaminants from the production process, moisture and excessive load as the cause
- An Application Review showed that the existing Deep Groove Ball Bearings were inadequate
- NSK recommended NSKHPS Spherical Roller Bearings
- Since introduction, the bearing life has significantly improved, which has resulted in significant reduction of Hardware damage and eliminating maintenance, providing a large cost saving for the customer.
Product Features
- Highest load rating SRB's which enables downsizing
- Optimum raceway design & surface finishing
- Brass cage design (CAM) or strengthened steel cage (EA)
- High cleanliness Z-steel
- Temperature stability: up to 392° F
- 40 mm to 260 mm bore size
- Up to twice the operating life
- Up to 20% higher limiting speed
- Dynamic load rating: 25% higher
- Lower maintenance cost and improved productivity
Cost Saving Breakdown
| Before | Cost p.a. | NSK Solution | Cost p.a. | |
|---|---|---|---|---|
| Bearing Costs: Bearing Costs: Deep Groove Ball Bearings |
$16,226 | Bearing Costs: Bearing Costs: NSKHPS Spherical Roller Bearings |
$3,343 | |
| Engineering Costs: Annual Maintenance Costs: 2040 hours @ $28/hour |
$56,840 | Engineering Costs: Annual Maintenance Costs: | $0 | |
| Engineering Costs: Annual Hardware Costs: Replacement of damaged bearing housings and axles |
$82,753 | Engineering Costs: Annual Hardware Costs: Bearing housings and axles |
$4,179 | |
| Total Costs | $155,819 | $7,522 | ||
Reference:SS-E-2036
Share