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Success Stories

Success Story

Industry: Quarrying, Mining & Construction

Application: Autoclave Bogie Wheel Assembly

Cost Savings: € 138 382

Introduction

A customer was experiencing constant bearing failure within an Autoclave bogie wheel assembly, using Deep Groove Ball Bearings. The failures resulted in damage of surrounding hardware (housings and axles) and high labour and parts cost, as components  needed regular replacement. NSK Engineers examined the application and determined that ingress of hard particulates and moisture, combined with excessive load was the root cause of premature bearing failure. NSK recommended changing to NSKHPS Spherical Roller Bearings, which gave better service life and greater reliability, as NSKHPS roller bearings carry greater loads and operate at higher temperatures. This resulted in eliminating continuous ongoing contractors maintenance and substantially reducing colateral damage to surrounding components.
Quarry, Mining , Construction, Autoclave Bogie Wheel Assembly
  • Autoclave Bogie Wheel Assembly
NSKHPS Spherical Roller Bearings
  • NSKHPS Spherical Roller Bearing

Key Facts

  • Autoclave Bogie - wheel Assembly
  • High loads and high temperature combined with contaminated environment causing standard deep groove ball bearings to fail prematurely
  • Constant bearing failure resulted in damage to surrounding hardware and high labour 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 200° C
  • 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

Product Sheet >>

Cost Saving Breakdown
Before Cost p.a. NSK Solution Cost p.a.
Bearing Costs: Bearing Costs:
Deep Groove Ball Bearings		 € 15.142 Bearing Costs: Bearing Costs:
NSKHPS Spherical Roller Bearings		 € 3.120
Engineering Costs: Annual Maintenance Costs:
2040 hours @ €26/hour		 € 53.040 Engineering Costs: Annual Maintenance Costs: € 0
Engineering Costs: Annual Hardware Costs:
Replacement of damaged bearing housings and axles		 € 77.220 Engineering Costs: Annual Hardware Costs:
Bearing housings and axles		 € 3.900
Total Costs € 145 402 € 7 020

Reference:SS-E-2036