ISSUE 9 - DECEMBER 2011

Major new investment at Llanelli plant

IN THIS ISSUE… 3 6 10 12

Innovation Minister tours Getting to the ‘Magic’ Award Schaeffler stand slopes safely bearings COVER STORY Major investment in Llanelli

SCHAEFFLER POSITIVE SIGNS IN A RECEIVES 2011 CHALLENGING YEAR SUPPLIER AWARD FROM It gives me great pleasure to welcome you to the last issue of GERMAN LUXURY CAR MAKER PORSCHE HAS AWARDED THE SCHAEFFLER In Motion for GROUP ITS 2011 SUPPLIER AWARD IN RECOGNITION OF THE CONTINUED 2011. SUCCESSFUL COLLABORATION BETWEEN THE TWO COMPANIES. Globally, it has The most important components in Porsche’s latest valve train components were first tested in the Porsche been another variable valve control system, the Porsche VarioCam Plus, 917 Le Mans racing car. challenging but were amongst Schaeffler products praised by Porsche In the mid-1980s, as Porsche launched its technologically positive year for the Schaeffler Group, during the award ceremony. with many encouraging signs of growth advanced Porsche 959 model, Schaeffler was again selected as one of the company’s high-tech development and investment in all regions around the Prof. Peter Pleus, President of Schaeffler Group partners. One of the developments was Schaeffler’s world. It is therefore all the more pleasing Automotive, passed the 2011 Supplier Award on to hydraulic chain tensioner which proved to be extremely for me and my fellow directors to witness Schaeffler’s Engine Systems Business team. “We are very effective in what was considered the most innovative the significant investment that is being proud of this award because it is recognition of our sports car of its time. made here in the UK. Our manufacturing innovative capabilities and manufacturing qualities,” said Prof. Pleus. plant in Llanelli is benefitting from the With Schaeffler’s support, Porsche is now setting the single largest investment in new Various rolling bearing solutions used in the Porsche 356 benchmark in variable valve train technology. Switchable processes in its 50 year history. Thanks have laid the foundations for the long-standing partnership bucket tappets and camshaft phasing units are key to the commitment of all our employees between the two companies. Porsche was one of components of the Porsche VarioCam Plus valve train to the successful installation of new plant Schaeffler’s first customers as the company began to system, a highly efficient, powerful engine technology. and machinery, our UK automotive produce its novel, LuK-branded diaphragm spring clutches Examples of successful collaboration projects between customers will benefit from the latest in the mid-1960s. In the same decade Schaeffler built up Porsche and Schaeffler in engine, transmission and innovative components and processes its expertise in combustion engines and its high precision chassis systems are numerous. from the Schaeffler Group.

However, it is not only the automotive sector that is benefiting from Schaeffler's TWO SUPPLIER AWARDS ongoing investment strategies. FROM SIEMENS MOBILITY Renewable energy sectors such as wind, ROLLING STOCK wave and tidal power are welcoming our investment in new bearing technologies Siemens Mobility Rolling Stock has presented The and condition monitoring solutions. And Schaeffler Group with two supplier awards in the the investment doesn't stop there. “Competitiveness in Mechanical Engineering” and “Logistics” categories. These growth opportunities are having a A total of 271 companies from 10,000 suppliers were positive impact on the recruitment sector The highest possible level of quality is essential for nominated for the awards and of these, just 21 made it as the Group looks to the next generation Siemens and Schaeffler to survive in a global market in through to the final round. of young engineers to support its global the long term and to form long lasting business expansion plans. As you will see from the Each of these 21 suppliers received an invitation to attend relationships with customers. articles in this issue, it is never too early the “Our Stars for Mobility Rolling Stock” award ceremony “To achieve these goals, we need partners like The to start a career in engineering. in Berlin. Schaeffler Group, which has the same high standards and I hope you will agree there are some “I am extremely proud of the fact we’ve received this commitment to success as Siemens,” explained Joern F. exciting developments which will benefit award from Siemens for Schaeffler’s successful Sens, Director of Siemens Mobility Rolling Stock. us all in the coming months and years. collaboration with the company in railway engineering The Schaeffler Group and Siemens Mobility have a long- during the last few years,” said Simone Purbs, Director of standing and successful partnership. Amongst other Kate Hartigan Railway sector management at Schaeffler Group Industrial. projects, The Schaeffler Group recently became Managing Director Schaeffler was the only company to be nominated in three development partner and sole supplier for the axlebox separate categories and was the only supplier to receive bearings in Siemens’ Velaro high-speed trains, which are awards in two different categories. used in China and Russia at speeds of up to 350 km/h.

IN MOTION | 2 3 | | MOTION MOTION

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School, Coedcae and Glan y Mor. y Glan and Coedcae School, Director Plant from presentations Following UK Schaeffler and MBE Evans Roger Williams-Bevan, Donna Manager Training guided a given were teachers and pupils the factory. the of tour compete to teams into split then were Pupils involved which Challenge Engineering an in an read correctly to having pupils a devising before drawing engineering fo method suitable The event was part of a nationwide a of part was event The the improve help to initiative Government people, young to manufacturing UK of image and brightest the attracting of aim the with manufacturing in career a into talent best engineering. and 2011 November in place took day open The 14 – 13 (aged 9 Year 60 of total a and local six from event the attended pupils) John St Valley, Amman including schools Quee Bryngwyn, Lloyds, that team the was winner The bearing. the in hub idler their assembled correctly time. fastest MORE THAN 60 PUPILS FROM LOCAL SECONDARY SCHOOLS TOOK INPART A PUPILS GIVEN A TASTE OF A CAREER IN MANUFACTURING MANUFACTURING IN CAREER A OF TASTE A GIVEN PUPILS INSIDE MANUFACTURING COMPONENT MANUFACTURING PLANT IN LLANELLI, SOUTH WALES. “The award for the lightweight balancer shaft balancer lightweight the for award “The lightweight designs are key f key are designs lightweight “Modern technologies, innovative products and products innovative technologies, “Modern President of Schaeffler Group Automotive. Group Schaeffler of President detailed work,” said Prof. Peter Pleus, Peter Prof. said work,” detailed demonstrates the significance of innovative of significance the demonstrates internal combustion engines. combustion internal rolling bearing supports used in modern in used supports bearing rolling Schaeffler’s lightweight balancer shaft with shaft balancer lightweight Schaeffler’s The international jury’s focus this year was on was year this focus jury’s international The innovations from automotive suppliers. automotive from innovations PACE Awards honour outstanding product outstanding honour Awards PACE Transportation Research Center (TRC), the (TRC), Center Research Transportation consulting firm Ernst & Young and the and Young & Ernst firm consulting News Presented annually since 1994 by by 1994 since annually Presented PACE Award for outstanding innovation. outstanding for Award PACE shaft with rolling bearing supports has won a won has supports bearing rolling with shaft The Schaeffler Group’s lightweight balancer lightweight Group’s Schaeffler The EMISSIONS

PACE AWARD FOR AWARD PACE LOWERING CO LOWERING THE MOST IMPORTANT INVESTMENT IN OUR HISTORY NEW PLANT AND MACHINERY MAKES LLANELLI A WORLD BEATER

A MAJOR INVESTMENT BY THE SCHAEFFLER GROUP IN ITS AUTOMOTIVE ENGINE COMPONENT PLANT IN SOUTH WALES WILL MAKE LLANELLI A WORLD CENTRE OF EXCELLENCE FOR THE MANUFACTURE OF MECHANICAL TAPPETS

components in the engine, resulting in lower fuel consumption and reduced CO2 emissions. The applied coating material is either in the form of a solid (PVD – Physical Vapour De position) or in the form of a gas (PACVD – Plasma Assisted Chemical Vapour Deposition). In contrast to conventional coating methods, this new technique will enable Schaeffler to produce unique compositions of materials and coatings using an environmentally friendly (no CO2 is produced) vacuum process. The new coating machines require components to be thoroughly cleaned before entering the vacuum chambers. Th e new plant therefore includes new special purpose washing machines for each coating machine. 315-tonne deep drawing press

The installation of the 315-tonne deep drawing and blanking press is also now complete. The multi-million pound press is one of only four of its kind in the world and will enable the UK plant to produce up to 20 million mechanical tappets per year for its automotive customers.

“Without doubt, this investment is the single most The press will produce highly repeatable, superior important investment in this factory’s history,” said quality mechanical (shimless) tappets to ‘near net Roger Evans MBE, Plant Director. shape’. The Schaeffler Group has invested several million Ken Poolman, Tool Design Manager at Schaeffler euros in new plant and machinery for the Llanelli UK commented: “The press was delivered to the manufacturing plant. The new investment was plant in October and more than 30 people were supported by the Welsh Government. required to install the machine. We’ve now completed internal trials, tooling sign-offs and Established in 1955, the Llanelli plant factory acceptance tests and the press is now manufactures high precision engine components operational.” for the and currently employs 230 people. The Llanelli plant is now the lead Schaeffler production plant in Europe for mechanical The new machinery – which includes a state-of- tappets. the-art surface coa ting machine and an enormous, deep drawing press – will enable The new deep drawing press stands at a Schaeffler UK to produce highly repeatable, towering 5.5 metres tall and incorporates a total superior quality mechanical tappets and other of 12 production stations, including associated Ulta-thin Tiondur® coating will be automotive engine components. applied by the new coating machine. blanking press and other feed-in equipment. The press required special foundations to be prepared The new coatings plant, which currently and is sunk in a purpose built pit below factory comprises of one coating machine but with the floor level. It is capable of producing forces of up with an ultra-thin Tiondur® + DLC, extremely possibility of more to follow, was installed in June to 315 tonnes. 2011. hard, multi-layer coating that is applied via special, vacuum-controlled chambers. The Each of the 12 press stations functions as a The new coating machines will enable Schaeffler function of the extremely wear- resistant coating progressive stage in the manufacture of a tappet. UK to coat the surface of engin e components is to minimise friction between mating These stages involve blanking, four or five

IN MOTION | 4 NEWS

“By embracing these advanced coating and deep drawing technologies, we will be able to produce superior quality components that meet the specific needs of our automotive customers. This, in turn, will help safeguard the long term future of this factory. “Introducing the deep drawing press has required a comprehensive re-training programme for our wor kforce, including machine operators, tool designers and production engineers. More than 25 of our staff have received training in readiness for the new press. In fact, the training element is just as important as the machine itself as our workforce needs to adapt and embrace these significant changes in machinery and new technologies,” he added. Edwina Hart, The Welsh Government’s Minister for Business. Enterpr ise, Technology and Science, said it was good to hear that the significant investment by Schaeffler in the Llanelli plant would support its long-term future and give the company a competitive advantage. different forming processes, followed by new tappet coating machine in June this “In these challenging trading conditions, it cropping and coining. year, the arrival of the new deep drawing is vital that businesses remain ahead of press is the second important stage of this the game and this The press will operate round the clock for plant’s machinery investment programme, investment will 6 days a week across three continuous which will help us to improve plant enable Schaeffler to shifts. productivity and secure future business remain highly competitive within a In terms of technical advantages, the press from our automotive customers. global market. I am enables Schaeffler UK to press tappet “This significant investment in new plant pleased it ha s been blanks to ‘near net shape’, i.e. as close to and machinery represents a tremendous supported by the the finished product as possible. By deep shift in the way this factory will produce Welsh Government.” drawing the tappets, the plant will be able automotive components in the future,” to manufacture a more cost effective he said. Welsh Government alternative to the traditional ‘forged and Minister Edwina Hart turned’ design, resulting in less wastage. The press is also fitted with the latest advanced sensors and monitoring technology to ensure zero defects and a high quality finished product. These technologies include movement detection systems and vision cameras that look for any performance and quality issues or product marking and surface defects. Roger Evans commented: “Followin g the installation of the

Plant Director Roger Evans, MBE IN MOTION | 5 ENERGY EFFICIENT MOBILITY SOLUTIONS AT FRANKFURT MOTOR SHOW

THE SCHAEFFLER GROUP RECEIVED SOME VERY PROMINENT VISITORS TO ITS EXHIBITION STAND AT THE RECENT INTERNATIONAL MOTOR SHOW IN FRANKFURT, WHICH ATTRACTED CLOSE TO 1 MILLION VISITORS OVER 10 DAYS

ederal Chancellor Dr. Angela Merkel visited Schaeffler’s 500 metre- F square stand as part of her tour of the exhibition halls. The Chancellor was welcomed by Schaeffler Group partner Maria-Elisabeth Schaeffler, Georg F.W. Schaeffler, Chairman of the Supervisory Board and Dr. Juergen M. Geissinger, President and CEO of Schaeffler Group. The Chancellor was able to gain valuable insights into current developments in energy-efficient vehicles. transmissions (see separate article on page 8) braking by using a wheel-selective flow of forces. Frau Schaeffler explained the underlying intention of the IAA participation to Dr. Merkel: “With our Innovation on show at Frankfurt “The potential fields of application for the eDifferential range from sports cars with product presentation we have demonstrated A four-wheel driv e battery-electric vehicle (BEV), extremely high driving dynamics, to conventional impressively that we are a source of innovation for based on a Skoda Octavia Scout, the Group’s passenger cars and agricultural vehicles,” the vehicles of tomorrow. Continuous research and latest electric vehicle concept, was unveiled at explained Dr. Tomas Smetana, Senior Manager development enables us to produce forward-looking the show. solutions and set new standards in automobile Advance Development Power Transmission manufacturing.” This new ACTIVeDRIVE complements two other Systems at Schaeffler Automotive. existing vehicle concepts from Schaeffler - the An important delega tion from the UK also visited The eDifferential system integrates two water- Schaeffler Hybrid and the CO2ncept-10%. These cooled permanent magnet synchronous motors the Schaeffler stand. This group included Prof. three vehicles together represent Schaeffler’s (PMSM) of different dimensions, a planetary gear, Richard Parry-Jones, Co-Chairman of the UK future strategy and product portfolio for the a gearbox for active torque distribution, and a Automotive Council, and Mark Prisk MP, Minister automotive industry. of State for Business & Enterprise. central element - Schaeffler’s lightweight Prof. Dr.-Ing Peter Gu tzmer, President Technical differential. The electric motors were developed The UK delegation was welcomed by Richard Development at Schaeffler, commented: “These by Schaeffler’s IDAM (INA Drives & Hall, Director & General Manager, Automotive three cars are full of new ideas and function as Mechatronics) division. Division, at Schaeffler (UK) Ltd. During the tour platforms for the testing of various components Other novel features of the ACTIVeDRIVE include of the stand, Mark Prisk was introduced to a and systems under realistic conditions.” number of key Schaeff ler innovations that are an integrated electromechanical parking lock; a helping to optimise the drive train of internal The innovation behind the ACTIVeDRIVE is its new forced lubrication system for the gearbox combustion engines and to meet the demands active electric differential (eDifferential), which is that requires no oil pump; sheet metal planetary for global energy-efficient mobility. He was given installed on both the front and rear axles. carriers; plus various high speed, friction- a guided tour by Prof. Peter Pleus, President of optimised bearing solutions. The electronic “The eDifferential enables active intervention Schaeffler Group Automotive. in driv ing dynamics via well-directed power Schaeffler’s stand highlighted a number of supplies – rather than braking intervention innovative products and solutions for the and therefore power reduction, as is the case automotive industry. These included efficient drive with ESP (Electronic Stability Programme). trains for internal combust ion engines, new The active electric differential significantly components for hybrid vehicles, and advanced improves power transmission when driving on solutions for electric mobility. surfaces with different friction coefficients. It also assists steering and has a clearly positive One particularly novel solution unveiled at effect on driving dynamics, safety and Frankfurt was a new thermal management comfort. module that reduces fuel consumption and CO2 emissions by up to 4 per cent by optimising and “ This means that the vehicle can be controlled controlling the temperature of engines and virtually without the use of steering and

IN MOTION | 6 AUTOMOTIVE

controls for the ACTIVeDRIVE are development project that enables practical supplied by AFT (Atlas Fahrzeugtechnik comparisons of a wide range of electric GmbH), Schaeffler’s automotive drive train mobility options. Schaeffler CEO Dr. Jürgen M. Geissinger mechatronics and vehicle testing division. summed it up: “With our motto of ‘efficient The driving modes represented on the future mobility’, Schaeffler continues to Because of the use of two active electric vehicle range from conventional operation consistently pursue its traditional path. differentials, the four-wheel drive using an internal combustion engine, to Schaeffler is in an excellent position in this ACTIVeDRIVE has an overall output of up parallel and serial hybrid operating modes respect. Activities such as setting up the to 210kW. using a range extender, as well as all- eMobility Systems Division enable us to electric driving modes. further develop our capacities in research Due to its performance and traction and development as well as in capacity, the 1,900kg test vehicle Together, the ACTIVeDRIVE, CO2ncept- manufacturing and allow us to orientate accelerates from 0 to 100km/h in just 8.5 10% and Schaeffler Hybrid, provide a an ourselves towards the demands placed on seconds. The vehicle has an electronic overview of Schaeffler’s broad automotive us by the automobile of today and tomorrow. maximum speed regulation of 150km/h. product portfolio, which ranges from With a view to our innovative product range In this configuration, the vehicle’s cruise energy-efficient solutions for conventional and the demands of global energy-efficient range is up to 100km. internal combustion engines, through to mobility, Schaeffler will gain more than systems for hybrid vehicles and all-electric The CO2ncept-10% proportional benefit from the growth in vehicles. worldwide Based on a Porsche Cayenne, Schaeffler’s automobile CO2ncept-10% vehicle impressively demonstrates the improvements that can be achieved through consistent, detailed work on vehicles that are powered by internal combustion engines. In the case of the CO2ncept-10%, these optimisa tion measures cover detailed solutions that are already available on the market or are close to series production, but do not touch or alter the basic vehicle configuration. Furthermore, the optimisation of the classic drive train also includes the use of electrical components manufacturing. rather than the previous hydraulically- Schaeffler is actuated elements. a global Schaeffler Hybrid

Based on a compact Vauxhall Corsa, the supplier Schaeffler Hybr id is a versatile advance

IN MOTION | 7 AN OAP THAT’S STILL GOING STRONG

comprehensive modular OAP (overrunning alternator pulley) A system has been developed by Schaeffler that offers many different custom designs for diesel and petrol engines, passenger cars, commercial vehicles and motorcycles. These include an OAP manufactured partly to aircraft specifications, which is used in the Schaeffler A4 DTM.

The Schaeffler Group currently manufactures more than 400 different types of belt pulley with OAP. In fact, during the combustion engines – including a one-way clutch are clear. The reduction in last 15 years, around 140 million of these turbocharged versions – are significantly the force level in the belt drive extends the unsung heroes have rolled off the higher than those indicated to the vehicle’s life (typically by a factor of 10) of individual production lines at Schaeffler. driver by the tachometer needle. components, while ensuring an increase in In modern internal combustion engines, the the generator speed and a reduction in In a vehicle’s accessory drive, the alternator OAP is an important component that often noise. In addition to smoother engine is the component with the greatest mass gets overlooked, particularly when you running, the OAP also contributes towards AUTOMOTIVE moment of inertia and the highest speed. consider the positive effects it has on the reduction of fuel consumption and This means that the acceleration and improving the energy efficiency of an therefore CO2 emissions. deceleration forces acting on the alternator engine. resulting from the rotational irregularities Its important contribution towards improving The OAP is the functional interior of the belt have the greatest effect on the belt energy efficiency also explains why the OAP pulley mounted on the alternator and its transferring these forces. The OAP has been so successful in both diesel and function is to decouple the alternator from therefore ensures that, at many operating petrol engines. The OAP is now also the rotational irregularities of an internal points, only the accelerating proportion of included in the extensive list of measures for combustion engine. This task is a critical the crankshaft forces that are transferred to optimising the fuel consumption of internal one, particularly as the rotational the belt drive are used to drive the combustion engines. irregularities that occur in the latest internal alternator. The advantages of the OAP with

NEW THERMAL MANAGEMENT

SYSTEM WILL REDUCE CO2 EMISSIONS

A new temperature control system for engine start up when the engine is automotive engines and transmissions has been cold, the pump continues to developed by Schaeffler. operate – which is inefficient.

The system can reduce CO2 emissions by up to Schaeffler’s Thermal Management 4 per cent for both internal combustion engines Module precisely maintains the and hybrid electric components and batteries. temperature of all drive train The system is also ideal for use on engines with components, according to start-stop functionality. requirements, by electronically controlling cooling water The new Thermal Management Module is distribution. This enables the Thermal Management Module. actually an innovative temperature control unit engine to operate at the optimum temperature for the entire vehicle drive train. The module The sensor-controlled Thermal Management in response to changing engine load and driving combines numerous functions into a single Module enables the speed of the electronic conditions. For example, the cold running phase compact, integrated unit housed in a high- water pump to be increased or decreased can be significantly reduced by switching off the strength plastic enclosure. depending on the driving conditions. At full water pump at engine start up. Individual speed, the temperature of the engine can be Up to now, the temperature of almost all internal components can also be run at higher decreased by the control module so that the combustion engine-driven vehicles has been temperatures than is possible in a thermostat- fuel mixture doesn’t need enriching, which in controlled by a thermostat mounted on the controlled engine. Engine temperature can be turn reduces fuel consumption. Driving at part- engine block. The engine is typically cooled by reduced under full load and the tendency for load means the temperature of the engine can circulating water from a pump which operates ‘knocking’ or having to enrich the fuel mixture be increased by the control module, enabling continuously regardless of engine load. Even on under full load is also reduced using the the optimum fuel mixture to be achieved.

IN MOTION | 8 9 | | MOTION MOTION MOTORSPORT IN om. Ekstrom and Rockenfeller. He took the took He Rockenfeller. and Ekstrom didn’t he front, in once and 11 lap on lead chequered the took and wrong a foot put Ekstr of ahead seconds two flag n in the wet. Canadian wet. the n in the first race, third at Zandvoort, at third race, first the fifth in in fifth at third Lausitz, at first Spielberg, at first at again first Nurburgring, at fifth Norisring, Oschersleben, at second Hatch, Brands final the at second and Valencia at third eight achieved He Hockenheim. at race races, ten of out finishes podium 20 a full points, 72 of a total accumulating rival. nearest his of ahead a was Hatch Brands at round UK The ru race, fantastic took Audi, another in Rockenfeller Mike two- by followed closely pole from lead the and Ekstrom Mattias champion time Paffett. Gary champion, ex-DTM another had Tomczyk Martin 2, lap by However, down hunting was and Paffett passed ring

try between him and him between try

TM (Deutsche Tourenwagen (Deutsche TM popular most the is Masters) series. car touring international of consisted season 2011 The

ircuits and the other four at circuits in circuits at four other the and ircuits D The Schaeffler-sponsored Audi came in came Audi Schaeffler-sponsored The back to Hockenheim. to back Hatch, Valencia and then, for the final race, final the for then, and Valencia Hatch, Norisring, Munich, Nurburgring, Brands Nurburgring, Munich, Norisring, Zandvoort, Spielberg, Lausitzring, Spielberg, Zandvoort, Hockenhiem, before travelling on to on travelling before Hockenhiem, The DTM series kicked off in May at May in off kicked series DTM The success. right and this played a major part in the in part a major played this and right Jurgen Jongklaus and the whole team was team whole the and Jongklaus Jurgen outset the chemis the outset engineer race Moser, Ernst principal team could get to know each other. From the From other. each know to get could then organised a barbeque party so they so party a barbeque organised then names of all the mechanics by heart and heart by mechanics the all of names the start of the season, Martin learned the learned Martin season, the of start the New to the Phoenix Audi Sport team at team Sport Audi Phoenix the to New real champion too.” champion real driver and a great guy – and now he’s a he’s now – and guy a great and driver proved he’s a winner. He is a strong race a is strong He a winner. he’s proved fought hard and, especially this season, this especially and, hard fought this time. He never hung his head, always head, his hung never He time. this and he’s had many ups and downs du downs and ups many had he’s and of our Audi DTM family for eleven years eleven for family DTM Audi our of happy for Martin. He has been a member been has He Martin. for happy was delighted with the win: “I feel so feel “I win: the with delighted was Audi motorsport boss Dr Wolfgang Ullrich Wolfgang Dr boss motorsport Audi sensational. sensational. favourites and his win is considered is win his and favourites season Martin was not amongst the amongst not was Martin season It has to be said that at the start of the of start the at that said be to has It triumph. Audi motorsport, the 2011 season was a was season 2011 the motorsport, Audi Tomczyk and the back-up of his team at team his of back-up the and Tomczyk And, thanks to the determination of Martin of determination the to thanks And, INA and FAG. and INA logos of its three primary brands, LuK, brands, primary three its of logos the Schaeffler name together with the with together name Schaeffler the in vivid yellow and green colours featuring colours green and yellow vivid in emphasis with the being liveried being A4 Audi the with emphasis the 2011 season saw a change in a change saw season 2011 the motorsport for over 30 years through LuK, through years 30 over for motorsport Whilst Schaeffler has been involved in involved been has Schaeffler Whilst Holland, Austria, Spain and the UK. the and Spain Austria, Holland, c ten races, with six taking place at German at place taking six with races, ten THE SCHAEFFLER BRAND TOOK A STARRING ROLE THE AT HOCKENHEIM RACE CIRCUIT

TRIUMPHS IN THE DTM THE IN TRIUMPHS SCHAEFFLER AUDI SCHAEFFLER

AT THEAT END OF OCTOBER WHEN 29-YEAR-OLD MARTIN TOMCZYK, DRIVER OF THE SCHAEFFLER-SPONSORED AUDI A4, WAS CROWNED DTM CHAMPION 2011 GETTING TO THE SLOPES SAFELY

IN COLD OPERATING ENVIRONMENTS LIKE SKI RESORTS, MATERIAL ROPEWAYS AND GUIDE PULLEY SYSTEMS RELY ON PRECISION BEARINGS TO ENSURE THAT MAINTENANCE, SERVICING AND BREAKDOWN COSTS ARE KEPT TO A MINIMUM LEISURE

trong winds, snow and Most of these systems use pulley wheels, For ropeways, accelerators and guide condensation are a constant guide pulleys or rope pulleys and each will pulleys, Schaeffler supplies manufacturers S challenge for machine normally require a bearing arrangement to such as Leitner and Doppelma yr with its operators in ski resorts, and support the loads. In material ropeways, single row deep groove ball bearings. rolling bearings and plain bearings both for example, design loads can be up to 40 These bearings are provided with lip seals play important roles in ensuring that tonnes. Line inclination is up to 45° with on both sides made from nitrile butadiene material ropeways, guide pulleys, cable spans of 1,500m over often-difficult rubber (NBR). The bearings are suitable cars, ski lifts, mountain railways and other terrain. Aerial tramways or cable cars are for moderate speeds and axial loads, but critical transportation systems remain in used to transport either heavy goods or are lubricated for life using a high quality operation at all times and require little or passengers, with some catering for up to grease. no maintenance. 2,000 passengers per hour. Schaeffler’s single row deep groove ball The Schaeffler Group is working with a The guide pulley bearings must therefore bearings are capable of withstanding number of manufacturers whose be capable of withstanding the required operating temperatures from –30°C up to equipment is required to operate in loads, as well as the harsh environmental 70° C, are designed to deal with the temperatures as low as –30°C and in high conditions. accumulation of condensate and offer altitude locations where snow and high longer operating life. The operator of the ski lift or tramway will winds are a constant threat. These want to minimise maintenance and Bearings in vertical mounting manufacturers produce ski lifts, inclined servicing costs and will certainly not wish configurations are often required for elevators, detachable and fixed chairlifts, to replace bearings more then once ropeways and pulley wheels and for these gondola ropeways, aerial tramways and during a skiing season. types of applications, spherical roller funiculars (cable trams or light railways).

IN MOTION | 10 bearings are the recommended choice. Schaeffler’s standard spherical roller bearings with metal cages can also be used at temperatures down to – 30°C.

Spherical roller bearings are double row, self- retaining units that comprise solid outer rings with a concave raceway, solid inner rings and barrel rollers with cages. The inner rings have cylindrical or tapered bores.

The symmetrical barrel rollers position themselves freely on the concave outer ring raceway. As a result, shaft flexing and any misalignment of the bearing seats are compensated for.

Spherical roller bearings can support axial forces in both directions as well as high radial loads. The bearings are designed with the maximum possible number of large and extremely long barrel rollers, which means they support heavy loads. Due to the narrow osculation between the rollers and raceways, uniform stress distribution is achieved in the bearing.

Schaeffler’s spherical roller bearings are also available in the premium X-life quality standard, which represents improvements in product design, product performance and service life that far exceed current standard values. As a result, under identical operating conditions, the basic dynamic load rating and basic rating life of these bearings are significantly improved. In certain applications, this means that a smaller bearing arrangement is possible. GE..SW bearings are complete units comprising radial loads and so are suitable for alternating an inner ring with a convex outer slideway and an dynamic loads. The bearings can also be used in In applications such as funiculars or cable outer ring with a concave inner slideway that has pairs as preloaded units. Just as important, the railways, liquid and solid contaminants can cause a hard chromium Elgoglide® low friction sliding bearings, which are available for shafts from vertically mounted rolling bearings to fail contact surface. 25mm up to 200mm, are maintenance-free prematurely. Schaeffler’s GE..SW angular contact throughout their operating life. spherical plain bearings are therefore used as a These bearings can support axial loads as well as plain bearing alternative to tapered roller bearings. What is ELGOGLIDE®? layer can be classed as maintenance-free because they replace the lubrication function. Elgoglide® is a highly wear-resistant sliding Relubrication of Elgoglide® bearings is layer made from PTFE fabric, which is therefore not required. In fact, relubrication of embedded in synthetic resin and bonded to the bearings would destroy the carefully the outer or inner ring bore. This low friction, matched tribological system. sliding material developed by Schaeffler Elgoglide® bearings offer a number of neither expands when exposed to humidity, advantages for applications requiring high load nor heat-seals with metal. Elgoglide® is also carrying capacity and small swivel angles, long resistant to most chemical agents and is ideal service life, small installation space and low for use in rotary and linear motion friction. These maintenance-free bearings also applications. minimise downtime and service costs, whilst Spherical plain bearings with the Elgoglide® eliminating the need and cost of lubricants.

IN MOTION | 11 IN 54and 60mm diameter. The most frequently skatersprefer smaller wheel sizes ofbetween diametersbetween 74and 90mm, while stunt discipline.Most skaters move onwheels with Thechoice ofwheels depends onthe specific downhill,Alpine and speed skating. skating,aggressive skating, night skating, footballand basketball, freestyle slalom, street sincedeveloped, including street hockey, in beginningofthe 1990s. Many variations have Inlineskating became newa trend sport atthe performanceofinline skates. touringbikes, arenow helping toboost the originallydeveloped asbearings forcity and maintenance-freehybrid bearings that were Corrosion-resistant,low friction, lightweight, ‘MAGIC’ BEARINGS FOR INLINE SKATERS MOTION usedwheel size inspeed skating is 100mm. | 12 Schaeffler’ maintenance-freeFAG technologyishelping toprovide Cronitect®hybrid bearings have Now,this innovative bearing wheelhub bearings inbikes. attentionasbottom bracket and beenattracting considerable IS BEING USED TO SUPPORT TOP-LEVEL SPORT TOP-LEVEL TOSUPPORT USED BEING IS SCHAEFFLER GROUP’S TECHNOLOGICAL EXPERTISE TECHNOLOGICAL GROUP’S SCHAEFFLER developedinto longera term cooperation. “Wearepleased th bearingsforextreme environments. steelthat isnormally used inrolling materialforthe blades using high-techa Schaefflerintroduced speciala lightweight developednewa blade forice skates. Theyhave, forexample, already co- specialmaterials. tribologicalinvestigations and ondeveloping surfacecoatings forcomponents, basic bearings.Both parties will work together on developmentand supply ofrolling Thecooperation isnot restricted tothe activitiesofathletes. measurementsystems used tomonitor the projectsforsports equipment and willcollaborate onfuture development DevelopmentofSports Equipment (FES) andthe Institute forResearch and Undercooperationa agreement Schaeffler LEVELSPORTS HOWSUPPORTS TOP SPORTKNOW- ENGINEERING s news low-friction, atthis collaboration has line andplain side.Together, all these improvements offer fittedwith non-contact plastic seals onone onthe market. The hybrid bearings arealso comparedtoother bearings currently available Inaddition, friction isreduced by49% 12%less than conventional bearing solutions. resultisbearinga that weighs just 10.5g – combinationwith only andhigh corrosion resistance. Used in offersextremely high load carrying capacity Cronitect®isuniquea bearing steel that Developedand patented bySchaeffler, 12%lighter, 49% less friction fittedwith conventional bearings. andcompetitive edge over skates that are providesskaters with technicala advantage resistant,hard Cronitect® raceways. This plasticcages onwear- whichrotate inhig performanceceramic balls, bearingsuse high TheCronitect® hybrid skatingperformance. moredynamic and smoother impetusthey require fora inlineskaters with the extra withdecisivea advantage fewofatenths of equipmentan improvethe smooth running ofsports “Ourlow-friction products, inparticular, can GroupIndustrial. ofProduct Development atSchaeffler commentedDr.Arbogast Grunau, President sportwith our products and expertise,” valuablecontribution tosupporting top-level “Wearereally pleased that wecan make a skatesand summer bobsleighs. Examplesinclude racing bikes, inline speed competitivesports and train importantcomponents inmany types of linearguidance systems arealready Rollingand plain bearing solutions and HaraldSchaale, Director ofthe FES. amongstthe world’s top performers,” said ofinspiration and help athletes tostay expertisewill provide uswith new sources TheSchaeffler Group’s technological h-tech fiveceramic balls, the d therefored provide athletes ingequipment. anadd-on kit(FAG 608 Cronitect® PS12). isavailable in‘Powerslide’ inline skates and as inlineskates. setA consisting of16bearings insize 608, the most frequently used size for FAGCronitect® hybrid bearings areavailable runningcharacteristics. Bearings”due totheir noticeably smooth someeven referring tothem as“Magic showingkeena interest inthe bearings with medals.Asresult,a professional skaters are bearingshelped skaters towin numerous InlineSkating Championships where the professionalspeed skating atthe European theirunique qualities during initial tests in FAGCronitect® hybrid bearings demonstrated weight. inlineskates byminimisin excellent,smooth-running characteristics for fishingreels. protectedbearings and roller clutches for trainingequipment, and special corros speedhub gear bearings forfitness and developedcomponents forRohloff’s 14- electric-bikes.Schaeffler has also bracketsfordrive control systems on andtouring bicycles; and sensor bottom bearingsused inthe bottom brackets ofcity racingbicycles; Cronitect® Hybrid roller bottombracket units and wheel hubs of haveincluded rolling bearings forthe Schaeffler’smost recent performancelimits. developmentmethods forpushing extremeconditions and todefine theopportunity totest products under partnershipwith the FESoffers Schaeffler developmentofsports equipment. The reliabilityarekey objectives during the Lowermass, longer life and maximum seconda during competitions.” g bothg friction and developments er ion- CONDITION

NEW IMPROVED ONLINE CONDITION MONITORING SYSTEM FOR INDUSTRIAL MACHINERY

chaeffler Industrial Aftermarket end user or by Schaeffler Industrial Aftermarket Services has launched an Services. This means that operators can make S improved version of the FAG changes to system parameters remotely from DTECT X1 online condition anywhere in the world. monitoring system which is suitable for a wide The FAG DTECT X1 s is designed for use in a range of industrial vibration monitoring wide range of industrial environments, including applications. the monitoring of rotating components and The updated version is more compact than its machines such as bearings, gearboxes, predecessor and offers increased functionality compressors, fans, pumps, rolling stands, paper and flexibility. mills and drives.

The FAG DTECT X1 s can save up to 16 All commonly used acceleration, speed and separate monitoring tasks and execute these displacement sensors can be connected to the automatically. The system is protected to IP67 FAG DTECT X1 s system, enabling process MONITORING and can therefore be installed in harsh parameters such as speed, temperature, torque environments, in ambient temperatures from and pressure to be monitored. –20ºC to + 70ºC. The monitoring system has an integrated GSM Applications in Paper Manufacturing modem that enables direct communication The system monitors vibration conditions which, In the paper industry, FAG DTECT X1 s is between the user and the device. Automatic if left undetected, can cause costly unplanned already helping to keep plant availability high. alarms can therefore be set up and shutdowns of plant and machinery. These Here, the system is suitable for monitoring measurement data provided for further analyses. conditions include damage to bearings and complex machinery, including suction press gears, as well as shaft misalignments. If a The user can choose whether to outsource the rollers and pick-up rolls on paper machines. specified threshold value or alarm limit is monitoring of the machine completely to exceeded, the system triggers an alarm. The FAG DTECT X1 s monitors the vibration Schaeffler Industrial Aftermarket Services or vibration monitoring data can be analysed behaviour of the rolls and the bearing positions. whether the machine operators should receive directly on site at the central control station or FAG DTECT X1 s is easy to retrofit to existing special training that qualifies them to carry out this data can be retrieved via a TCP/IP paper machines and machine operators require the monitoring independently. communications link and analysed by either the no specific knowledge or skills. GROUNDBREAKING GREASE MONITOR planned precisely into maintenance This is referred to as ‘demand-based’ rather than schedules. Any changes in the ‘time-based’ relubrication. The result is a reduction condition of the grease are detected in the cost of lubricants, replacement parts and early, long before any damage can be maintenance. In addition, operational downtime of caused to the bearings. plant and machinery will be reduced, whilst process efficiencies and machine utilisation will A new, groundbreaking sensor has been Grease operating life is key to also improve. developed that enables the online condition maintenance monitoring of grease in rolling bearings. In preventive maintenance regimes, the operating How does it work? life of the grease is critical, particularly if the life of The grease sensor, which has a diameter of just The sensor is ideal for monitoring critical plant and the grease is less than the expected life of the 5mm and a length of 40mm, is able to detect four machinery located in difficult-to-access areas, bearing. In this case, the bearings would normally parameters of the grease: water content, such as wind turbines and automated assembly be relubricated halfway through the grease cloudiness (opacity), wear (thermal or mechanical), lines. Its value is that it will signal if there is a operating life. The disadvantage here is that the and temperature. From these parameters, the problem, but equally importantly can prevent any grease is replaced without knowing anything sensor’s electronic evaluation system utilises unnecessary change of grease. about the actual condition of the grease. For complex software algorithms to generate an Developed by Schaeffler in conjunction with example, it may have been possible to continue analogue signal (4-20mA), which then displays Freudenberg Dichtungs- und using the grease for a longer time period without the condition of the grease. By setting alarm Schwingungstechnik GmbH & Co. KG and affecting the performance of the bearing. thresholds (limit values), digital signal outputs can lubricants specialist Klüber Lubrication, the new Conversely, perhaps damage has already also be generated, indicating whether the grease grease sensor incorporates a unique electronic occurred to the bearing due to ingress of water or quality is ‘poor’ or ‘good’. evaluation system which enables the condition of high temperatures and so the grease should have Schaeffler, Freudenberg and Klüber have the grease to be monitored whilst the bearings been replaced earlier. validated the measurement method for around 95 are operating. The sensor is positioned directly in The new grease sensor enables grease to be per cent of greases currently available on the the rolling bearing immersed in the grease. replaced according to the actual operating market. A future solution, currently being This is a significant breakthrough, as the schedule requirements of the bearing and not according to developed, is for integration of the sensor in for replacing rolling bearing grease can now be any pre-defined time periods. rolling bearing seals. IN MOTION | 13 COMPOSITE PLAIN BEARINGS FOR WIND, WAVE, TIDAL AND SOLAR ENERGY SYSTEMS

RENEWABLE ENERGY SYSTEMS, INCLUDING SOLAR, WIND, WAVE AND TIDAL POWER, ARE IDEAL APPLICATIONS FOR COMPOSITE PLAIN BEARINGS

he Schaeffler Group now offers a Each bush comprises two layers of wound rapidly expanding range of plain (twisted) material. The inner, sliding layer is made T bearings for renewable energy from synthetic fibres and PTFE fibres in epoxy systems. In addition to its Metal- resin, whilst the outer layer comprises continuous Polymer Composite Bearings range, Schaeffler glass fibres (filaments) in epoxy resin. This also recently launched ELGOTEX® plain bearings. combined, double wound material is stabilised by applying a specific winding angle to the glass In solar energy systems, for example, plain fibres, which significantly increases the strength of bearings are particularly suitable to the operating the bush. conditions, which often involve slow swiveling movements with high loads. In addition, plain The result is a host of technical advantages, bearings are also suitable for operation in media including extreme robustness, compactness and such as water (hydro power) and for dry running Metal-polymer composite bearings are a cost- low wear (due to consistent friction levels). In applications. effective alternative for applications with minimum addition, ELGOTEX® plain bushes are lighter than their bronze equivalents. Metal-polymer composite plain bearings available space and a comparatively high sliding speed. The plain bearings are available as bushes The product is available with integrated seals and Schaeffler’s metal-polymer composite bearings are and flanged bushes, as well as thrust washers and is resistant to corrosive media. The bushes also particularly effective in oscillating applications, strips. The material can also be easily formed to perform well in applications where swivel or axial where the bearings achieve a higher basic rating specific customer requirements for rotary, linear movement is requir ed. Good vibration damping life than conventional bearings. and oscillating movements. All Schaeffler’s metal- properties is a further benefit of ELGOTEX®. polymer bearings are lead-free. The metal-polymer composite material provides INA plain bushes with ELGOTEX® are available low-wear sliding characterist ics, as well as a high ELGOTEX® plain bearings with bore diameters from 20-200mm, outside load carrying capacities and high thermal Schaeffler’s ELGOTEX® range of plain bushes diameters from 24-220mm, and widths of 15- conductivity. Static load carrying capacities of up to provides a variety of technical advantages that 250mm. Custom versions with outside diameters 250 N/mm2 can be achieved. Composite materials stem from the product’s uniq ue, entwined double- up to 1,200mm are also possible. can also be used in water or other media due to its layer design. high moisture resistance.

COMPACT ONLINE CONDITION MONITORING FOR WIND TURBINES

An improved version of the FAG WiPro online 260 x 150 x 90mm, enabling easy installation in changes to system parameters remotely from condition monitoring system has been launched control cabinets. The integrated multiplexer anywhere in the world. by Schaeffler Industrial Aftermarket (IAM). enables the recording of signals from up to eight The FAG WiPro s is specially developed for the different sensors. The new system – the FAG WiPro s - is more wind power industry. Wind turbine drive train compact than its predecessor and offers It can save up to 16 separate monitoring tasks (main bearings, gearboxes, couplings and increased functionality and flexibility. and execute these automatically. The system is generators) and tower vibration can be monitored protected to IP67 and can therefore be installed as a function of the operating parameters. The new individual modules – the monitoring unit in harsh environments and in ambient Integration of oil quality (particles) as part of the and the multiplexer – are now integrated in a temperatures from -20ºC to + 70ºC. monitoring is also possible. FAG WiPro s can also single, compact unit that offers a high degree of analyse measurement signals already installed in flexibility for end users and is ideal for permanent The system monitors vibration conditions, which if the wind turbine nacelle. condition monitoring of wind turbines. left undetected, can cause costly unplanned shutdowns of wind turbines. These conditions Due to its integrated overvoltage protection Unlike its include damage to bearings and gears, as well as device, the WiPro s can be adapted to customers’ predecessor, the shaft misalignments. If a specified threshold value specific requirements. The system is based on its new system or alarm limit is exceeded, the system triggers an predecessor, the FAG WiPro, which was certified combines all alarm. The vibration monitoring data can be by Germanische and acknowledged by control modules analysed directly on site at the central control German insurance company Allianz Zentrum für into a single station or this data can be retrieved via a TCP/IP Technik (AZT). This will enable insurance compact communications link and analysed by either the companies to offer customers of the FAG WiPros housing, which end user or by Schaeffler Industrial Aftermarket more favourable insurance terms for wind turbine measures just Services. This means that operators can make installations.

IN MOTION | 14 RENEWABLES

SINGLE BEARING DESIGN CONCEPT FOR MULTI-MEGAWATT WIND TURBINES

A SINGLE BEARING DESIGN CONCEPT FOR MULTI-MEGAWATT WIND TURBINE ROTOR SHAFTS, HAS BEEN INTRODUCED BY SCHAEFFLER. THIS NOT ONLY IMPROVES THE ENERGY EFFICIENCY AND RELIABILITY OF THE TURBINE BUT ALSO ELIMINATES DRIVE TRAIN COMPONENTS, THEREBY HELPING TO REDUCE THE OVERALL WEIGHT OF THE TURBINE

sing its in-house advanced rolling bearing calculation U software, BEARINX®, in combination with Finite Element Analysis tools and multi-body simulation (MBS) models, Schaeffler engineers can assist customers during the initial stages of wind turbine design with the aim of improving the reliability and efficiency of the turbine under a wide variety of load conditions. Schaeffler is able to develop bearing desi gns that are tailored to specific wind turbine requirements, including turbines for both onshore and offshore wind farms. This powerful combination of software enables Schaeffler to evaluate various load conditions and to accurately assess all relevant, critical load conditions for wind turbines. The use of ‘moment’ bearings in single bearing designs enables a high level of system integration, resulting in extremely bearings can be utilised, which prevent compact, less complex wind turbine axial clearance and small axial designs. The preloaded bearing also misalignments. This controlled guidance of prevents the transfer of negative axial the rotor shaft means that fewer loads to the wind turbine drive train. movements act on the system, reducing the nega tive effects on the gearbox and With single bearings, the wind turbine rotor generator. is supported by a single, double row tapered roller bearing (or ‘moment’ Schaeffler supplies moment bearings that bearing), typically in a back-to-back are individually designed to match specific arrangement that supports all forces and turbines. These bearings are supplied with moments. This concept can take many classic steel pin cages or with plastic different forms, for example, with a shaft (PEEK) segmented cages. PEEK is a and gearbox and a high-speed generator, lightweight, high-strength plastic with low as a hybrid solution with shortened wear characteristics, which is also able to gearbox and medium-speed generator, or support high forces. The plastic segmented as a direct drive without a gearbox. cage reduces friction and increases the efficiency of the turbine. This cage also Single bearings always result in more improves the guidance of the rolling compact designs. For example, the wind elements, whilst optimising lubricant supply. turbine nacelle can be fully integrated with Moment bearings can also be supplied with the bearing-gearbox-generator unit. This integrated anti-corrosion protection, which means that it is possible to eliminate drive is achieved by applying a zinc flame- train components and reduc e weight. This sprayed surface coating and multi-layer in turn reduces the head weight of the painting. Special hardening processes wind turbine, allowing smaller foundations enable custom material characteristics for to be used and simplifying logistics. integrated functions such as seals or connections to adjacent structures. Another advantage of the single bearing design is that preloaded tapered roller

IN MOTION | 15 SYSTEM SOLUTIONS FOR MEDICAL AND LABORATORY AUTOMATION

sing a wide range of linear guidance systems, radial U components, direct drive systems and complex bearing assemblies, The Schaeffler Group has developed a number of system solutions for laboratory automation applications. Schaeffler’s engineering field service team ensures close collaboration with the customer from early on in the development process. When conceiving customised components and system solutions, LINEAR Schaeffler engineers use a range of modern CAD/CAM software tools. For bearing calculations and selection, they use Schaeffler’s own bearing calculation software program, BEARINX®. This enables detailed analyses of bearing loads and life calculations, ensuring the selection mounting plate. The customer was the decision to outsource the hardware of the most appropriate bearings for the delighted to receive a cost-effective, low- development and production to Schaeffler, application. In the design and modeling maintenance solution and was particularly the client was able to a chieve significant stages, the latest methods such as Finite satisfied with the simplified installation cost savings in R&D, production and Element Analysis (FEA) software is used in procedure. purchasing. order to optimise system solutions. In another application that involved a DNA Surface Coating sequencer, the customer required a direct- Blood-testing and Schaeffler’s engineering and technical drive X-Y-Z (three-axis) unit with very high diagnostics devices support services also include positioning accuracy and repeatability, recommendations on surface coatings that In a recent example, a customer required a smooth running, low displacement impact a whole range of bearing bearing solution for a new blood-testing resistance, and maintenance-free properties. These include the durability, device. Quiet operation, low maintenance oper ation. Schaeffler’s solution comprised corrosion and media resistance, and and corrosion resistance were specified as a ready-to-fit direct drive for a running-in behaviour of the bearings. key attributes for the compact design. mechatronics system with monorail guidance systems, miniature linear Schaeffler’s solution consisted of a four- Corrotect®, Triondur®, Protect A® and guidance systems, a PCB direct drive row linear ball bearing and guideway Protect B® are just a few examples of motor, stepper motors, encoder and assembly (KUVE- B) with Corrotect® coating solutions provided by Schaeffler. housing. The customer benefited from coating for the X-axis, as well as Depending on the customer’s Schaeffler’s comprehensive engineering corrosion-resistant miniature linear requirements, special materials such as support, which resulted in a direct drive guidance systems for the Y- and Z-axes. Cronidur 30, ceramics, PEEK heavy-duty solution that significantly improved the In addition, the solution incorporated a plastics and hardened non-magnetic performance of the DNA sequencer. spindle bearing with semi-locating bearing steel can be combined to achieve functionality. Due to comprehensive Samp le Changers optimised solutions. engineering support and by procuring all rolling bearings from a single source, the Schaeffler has also developed customer received a maintenance-free a system for a laboratory blood-testing device with improved sample changer. In addition to performance and longer service life. smooth running and low maintenance requirements, the Analysis Devices customer specified that the and DNA sequencers sample changer should be compact and robust. In another customer application – a Schaeffler’s medical analysis device - the principal solution requirements were high degree of comprised positioning accuracy and repeatability. In miniature this case, engineering support and medical linear technology specialists from Schaeffler modules, developed a ready-to-fit module that housings and consisted of four miniature linear guidance motors. Due to systems, two toothed racks and a

IN MOTION | 16 NEWPRODUCT

NEW ANGULAR CONTACT ROLLING BEARINGS FOR LIGHTER, MORE COMPACT MACHINE BUILDS

IN APPLICATIONS SUCH AS INDUSTRIAL ROBOTS, MECHANICAL HANDLING SYSTEMS AND INDUSTRIAL GEARBOXES, DESIGN CHARACTERISTICS SUCH AS HIGH PRECISION, LIGHT WEIGHT AND COMPACTNESS ARE OFTEN THE MOST IMPORTANT. AT THE SAME TIME, THERE IS ALSO A DRIVE TOWARDS INCREASING RIGIDITY, POSITIONAL ACCURACY AND RATING LIFE

n order to fulfil these combines low mass and a compact demanding requirements, The design envelope with impressive basic I Schaeffler Group has load ratings. With a bearing ring launched two new ranges of thickness of just 1.2mm and radial angular contact rolling bearings – the AXS section heights of 7mm and 10mm, the application need to be increased further. and SGL series. AXS offers great potential for design The SGL is therefore a suitable alternative, miniaturisation. for example, to crossed roller bearings AXS and SGL bearings provide extremely under higher requirements. lightweight bearing solutions capable of The roller and cage assemblies comprise supporting significant loads and high tilting c ylindrical rollers, snap fitted into high Applications moments. The reduced design envelope of strength polymer cages with the smallest Used in the hand of a paint robot, AXS these bearings opens up new opportunities possible pitch. The high basic load ratings bearings open up new possibilities in terms for even more compact machine builds and enable additional preload, for conditions of cost optimisation for supporting several automa tion systems. such as swivel operations, in order to axes in extremely thin-walled designs. The further increase the tilting rigidity. low weight of the bearings, combined with Similar to thin disc springs, AXS bearings its relatively large diameter, enables have a conical bearing ring, produced by AXS bearings can be mounted very easily lightweight designs with high load carrying forming technology and a roller and cage and securely. As the bearing rings are capacities to be produced, which in turn assembly runs between these two geometrically identical, there is no risk of leaves more space for the passage of paint hardened rings. Bearing diameters are mix up during fitting. The bearings can be hoses. The bearings are maintenance-free, currently available from 8-175mm. fitted easily with the roller and cage lubricated for life with special grease. assembly without requiring specialist skills The high precision of the SGL bearings is or knowledge. AXS bearings are also being used in achieved by the machined, ground bearing tracking systems on solar power SGL – accurate and rigid rings, which have a triangular profile. The plants. Here, the small cross-section, high cylindrical rollers are guided by a cage, SGL series bearings are the preferred load carrying capacity and high rigidity of which is made from a wear-resistant choice where high load carrying capacity, the bearings are critical. polymer. accuracy and rigidity are required. The precision machined, ground triangular In medical equipment, AXS bearings are AXS – lightweight with high load profile bearing rings – in combination with being utilised in ceiling mounts for carrying capacity the line contact of the cylindrical rollers – operating theatres, where they are The AXS angular contact rolling bearing enable highly precise, rigid bearing replacing wire raceway ball bearings. solutions. High precision gearboxes are SGL bearings have significantly higher constantly undergoing design refinements tilting rigidity than conventional angular and optimisation. Due to increasing contact ball bearings and the use of dema nds for reduced design envelopes, quadratic rolling elements provides less friction, lower temperatures, smooth significantly improved kinematics. The running and high tilting rigidity, the rolling behaviour of SGL bearings is almost capabilities of the bearings within ideal. The bearings run uniformly with low gearboxes are subjected to constant friction and so are suitable for high speed analyses. applications. Increasingly, conventional angular contact SGL bearings are used predominantly in ‘O’ ball bearings or crossed roller bearings arrangements. The resulting large support used in gearbox output bearing designs distances increase the rigidity of the are being replaced by SGL angular contact bearing design. rolling bearings. The rigidity and accuracy achiev ed with line contact and an ‘O’ The SGL bearing is best used where the arrangement make a strong case and also rating life and tilting rigidity in the increase the rating life.

IN MOTION | 17 DIRECTING DEBUT FOR SIOBHAN

ongratulations to Siobhan the script in Griffin, New Business Co- anticipation. ordina tor, Marketing Services, C “ After reading on her successful debut as through the script I Director of the latest play produced by the could see it was Alrewas Dramatic Society. still very relevant

NEWS Siobhan's idea, to take the script of today but wanted 'Teechers', which was written by John our version to be Godber in 1987, and give it a contemporary set in Liverpool, even though the play is not theme, certainly paid off. written with any given accent in mind. So I main three actors was superb and had the just had to knuckle down and re-write a audience laughing from start to finish. Siobhan, who has been a loyal member of couple of bits as I wanted it t o be set 'in the Credit must go to the actors and to Siobhan the Alrewas Dramatic Society for a number now' ." Griffin, the Director, who recognised the of years, said of her recent achievement: potential of the script and stage managed "I began think ing about doing 'Teechers' According to a review in the local press: the cast of only five to create a play with 15 following other John Godber plays I had "The performance of 'Teechers' was one of characters and many scene changes". either seen or heard about and sent off for their best in recent years. The acting of the

THE EGG CHALLENGE

Llanelli, supported by John Bailey, Press Technologist and Matthew Anthony, IN-HOUSE Health and Safety Officer. The school children were split into six groups and final entries were judged by Kate Hartigan, Managing Director, Roger Evans, Plant Director and Adrian Roberts, Schaeffler UK's goal to develop young design and build a system that will allow HR Director. The winning team's people's interest in everything the safe transp ortation of two eggs submission was forwarded to The Young engineering took another step closer across chasms and up cliff faces without Engineers for recognition on their recently when an engineering design and damaging the eggs, and using only website. build challenge was successfully adopted limited items to create the mechanisms'. by a local primary school in Llanelli. Derrick said: “It has been great to see the The project, which took place over a enthusiasm shown by all pupils for our Thirty 11 year old pupils from Penyrheol number of weeks, was managed by activities and we look forward to working Primary School took part in a variation of Derrick Lewis, Technology Manager at with this and other local schools in the the Young Engineers' Egg Challenge, 'to Schaeffler UK's manufacturing plant in future". TEAM WORK hen his keen footballing son wasn’t getting enough ‘game time’ with his team, Derrick Lewis, Technology W Manager with Schaeffler UK in Llanelli, decided to do something about it. He started a new team. Between June and September he completed a coaching course, recruited team members, roped in his father-in-law to help and launched Pengelli football team. They now have 17 lads on the books and thanks to Schaeffler, who sponsored the kit, Pengelli has entered a local league and have been playing since September. “I did it for my lad,” said Derrick, “but also with the aim of getting kids off their playstations and DS gaming machines. We’ve yet to get that first win, but it is getting closer.”

IN MOTION | 18 LONG SERVICE AWARD

total of fourteen members of staff at Schaeffler UK’s plant in Llanelli were A presented with long service awards recently. The awards were presented by Plant Director Roger Evans and HR Director Adrian Roberts. Our picture shows (l to r): Paul McGowan (15 years), Jamie Davies (20 years), Gavin Thomas (10 years), Paul Issac (20 years), Andrew Pritchard (15 years), Gary Morris (15 years), Barrie Kelley (15 years), Roger Evans, Mark Thomas (25 years), Mark Williams (15 years), Phillip Griffiths (20 years), Desmond Williams (15 years), Tony Bowen (15 years), Ian Sadler (20 years), Adrian Roberts, and Meirion Thomas (15 years).

taff and guests enjoyed the celebrations at this year’s Annual Presentation Dinner Dance for S Sutton Coldfield employees, held at the Moor Hall Hotel in Sutton Coldfield recently. The picture shows recipients of Long Service Awards with members of the UK management team. (L to R): Adrian Roberts (15 years), Richard Hall, Mike Barber (15 years), Richard Shand (10 years), Kate Hartigan, Roger Evans, Paul Gi bbons (15 years), Janet Pelly (15 years), Des Pattinson and Paul Healey (10 years).

THE LONDON 2012 QUIZ

THE OLYMPIC GAMES ARE JUST A FEW MONTHS AWAY SO HERE’S A QUICK QUIZ TO SEE HOW MUCH YOU KNOW ABOUT THE EVENT. SEND YOUR ENTRIES BY EMAIL TO [email protected]. ALL CORRECT ENTRIES WILL BE ENTERED IN A DRAW AND THE WINNER WILL RECEIVE A SELECTION OF 2012 MEMORABILIA! What do you know about the London 2012 Olympics and Paralympics

1. What sport will take place around Hampton Court Palace? 6. Which special Olympic facility has been built near Waltham Cross?

2. Where will the equestrian events take place? 7. How many people will carry the Olympic Torch on its relay round the country? 3. On what date do the Paralympics start? 8. How many different sports will feature at the London Olympics? 4. What will start and finish in The Mall? 9. How many years is it since London last hosted the Olympics? 5. The Olympic Football Final will take place at Wembley. Can you name two other venues that will be used for matches? 10. What has the film ‘Slumdog Millionaire’ to do with the Olympics?

IN MOTION | 19 IN MOTION | 20