Bearings for Railway Transport 70 Years — Proven Solutions for You
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Proven solutions for you BEARINGS FOR RAILWAY TRANSPORT 70 YEARS — PROVEN SOLUTIONS FOR YOU Kharkov Bearing Plant (HARP) is one of the largest CIS manufacturers of bearing products and the only Ukrainian manufacturer of bearings for railway transport. Today HARP holds leading positions in the production of railway bearing units for the entire «1520 space» and bearings for some market segments in the CIS: agricultural machinery, electrical engineering, automotive industry, mining and metallurgical complex, and others. The main development trends are: producing of new types of radial roller bearings with short cylindrical rollers and bearing units, strengthening of its position as a manufacturer of bearings for railway rolling stock, development of ball bearings of higher accuracy class, producing of hot-stamped and turned semi-finished products for automotive, railway and industrial bearings. Great manufacturing and design experience allow HARP to develop new advanced bearing solutions for railways and reduce time on market. Products for railway transport • Axle box bearings for freight cars and locomotives • Bearings for traction motors of locomotives • Tapered bearing units • Cylindrical bearings units CONTENT Page 4 Application Page 5 Energy efficient HARP bearing units with extended lifetime Page 6 CRU Duplex (Cylindrical Roller Unit) for freight and passenger cars Page 7 TBU (Tapered Bearing Unit) for freight and passenger cars Page 8 Axle box cylindrical roller bearings for freight cars Page 9 Axle box cylindrical roller bearings for freight and passenger cars Page 10 Axle box cylindrical roller bearings for locomotives Page 11 Axle box cylindrical roller bearings for electric traction motors Page 12 Research and development Page 13 Testing certification center Page 14 Quality management Page 15 Sales geography Application Axle boxes of freight cars Axle boxes of locomotives Traction motors of locomotives Generators and reduction gears of locomotives Underground and tram cars 4 Application ENERGY EFFICIENT HARP BEARING UNITS WITH EXTENDED SERVICE LIFETIME Specially developed innovative bearings: • Cartridge units for axleboxes of freight and passenger railway cars – CRU 130x250 and TBU • Cartridge units for axleboxes of locomotives – CRU 160x270 (Cylindrical Roller Unit) • Sealed units for traction electric motors of locomotives – CRB (Cylindrical Roller Bearings) Main advantages in comparison with conventional cylindrical bearings (CRB): The principal integrated result of the optimized design and technology is maintenance intervals increase by more than 2.5 times (800 000 km and more). BY MEANS OF: ACHIEVED: • optimal roller profiling • reduction of maximum contact stresses on the raceway • high requirements for roller surface quality (up to 10%) and on the roller end face contact areas (by • special heat treatment of rings 3…4 times) • more precise realization of optimal geometry • increased operation durability of units and microgeometry of rings • reduction of wear rate on the raceway and on the roller • use of special Klüberplex BEM 41-132 HARP end face contact areas (by 2...4 times) grease • lower bearing unit operating temperature (by 10-20°C) • reduced mechanical losses and, as a consequence, lower energy consumption for traction The design of the CRU 130x250 with flange rings has eliminated one of the major drawbacks of axlebox unit — low reliability of the face mounting, caused by the presence of a spacer ring in the classical design. Dynamic axial force on the axlebox face is reduced by 4 times. Unique Klüberplex HARP grease, developed together with Klüber Lubrication (Freudenberg Group), Germany, is the only grease that, along with record high resistance to wear and to contact fatigue surface damage, low starting and running torques, provides high performance under low-temperature conditions down to -60°C. The results of the monitoring of the operation of cars equipped with CRU 130x230 bearings proved higher operation reliability of axlebox units — the average number of uncouplings due to failures of the axlebox units per year for one car was reduced by 4 times, compared to cars equipped with conventional cylindrical bearings. The result is reduction of the operating costs for the axlebox unit and costs for preventive maintenance and repair of the bearing units during the service life of a car. Significant reduction of labour consumption and costs when assembling wheelsets: the bearing is delivered pre-assembled, greased and adjusted for radial clearances and dimensions of a bore of inner rings, and does not require any additional operations prior to mounting on the axle. As a result, installation time is reduced, as are the production capacities, personnel and energy required. Can be mounted or dismounted on existing equipment: application of duplex bearings means that the purchase and installation of special new equipment is not required. AS A CONSEQUENCE: • • low life cycle cost for a railway car • improved traffic safety 5 CRU Duplex (Cylindrical Roller unit) for freight and passenger cars Double radial roller bearing with short cylindrical rollers and shields. CRU 130x250 is designed for installation in axleboxes of freight cars with axle load of 23.5 tonnes and pedestal opening of 320 mm, as well as in the axleboxes of passenger cars. Its design is completely interchangeable with existing units and can be installed to replace mass produced CRB bearings (36-42726E2M and 36-232726E2M). СRU 130 x 250 Maintenance intervals, km 800 000 Dimensions (d x D x B), mm 130 x 250 x 160/161.2 Weight, kg 34.9 Load capacity, kN dynamic 1001 static 1548 Maximum rotational speed, RPM 1800 Allowable temperature range -60…+120°C Axlebox unit with CRU 130X250 This is a sealed double bearing unit adjusted for radial clearances and dimensions of a bore of inner rings. Basic geometric parameters of the internal design are fully compatible with serially produced axlebox bearing units with long-term experience of reliable operation in the railways. The microgeometry of the rollers and bearing rings is distinguished by the optimized profiles, stricter requirements (letter «Y») for surface machining and special heat treatment of the material. The bearing is lubricated with Klüberplex BEM 41-132 HARP, specially developed together with Klüber Lubrication (Freudenberg Group). 6 TBU (Tapered Bearing Unit) for freight and passenger cars TBU 130 x 230 TBU 130 x 250 TBU 150 x 250 Maintenance intervals up to 800 000 km Dimensions (d x D x C), mm 130 x 230 x 150 130 x 250 x 160 150 x 250 x 160 Weight, kg 38.5 47.9 42.3 Load capacity, kN dynamic 990 990 1011 static 1720 1720 1930 Axlebox unit with CRU 130X250 Double-row tapered roller bearing unit The TBU is designed for installation in the axleboxes / with adapters of freight cars with axle load of 23.5, 25 tonnes and higher, and pedestal opening of 260 mm, as well as in the axleboxes of passenger cars. This is a double-row cartridge bearing with tapered rollers, adjusted for clearances and lubricated with Klüberplex BEM 41-141 HARP grease. The bearing has a built-in seal, preventing penetration of water, dust, dirt, etc. into the bearing. All surfaces of the bearing are protected by a layer of phosphate coating, preventing them from corrosion damage. The bearing is supplied ready for installation by pressing. 7 Axle box cylindrical roller bearings for freight CARS GOST 3042726EM and 3232726EM 42724EM1 and 232724EM1 Designation DIN (WJ/WJP 130x240) (WJ/WJP 120x240) Dimensions (d x D x B/C), mm 130 х 240 х 80 120 х 240 х 80 Weight, kg 14.8 15.7 Dynamic, kN 540 540 Load, kN Static, kN 780 780 Radial clearance, mm min 0.130 max 0.180 min 0.130 max 0.180 Application Axle boxes of freight and passengers Axle boxes of freight and passengers cars cars 80-0.25 80-0.25 Single-row radial roller bearing with short cylindrical rollers WJ/WJP 130x240 and WJ/WJP 120x240. Bearings are designed for axle boxes of freight and passengers cars for track gauge of 1435 mm 3 (standard gauge). Bearings are manufactured in -0.0 compliance with standards DIN EN 12080 and DIN EN 12082. 240 -0.025 130 WJ/WJP 130x240 8 Axle box cylindrical roller bearings FREIGHT AND PASSENGER CARS Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 TBU WJ/WJ NU NJ WJP (TBU 130x230 / (CRU 130x150) (32000) (42000) (232000) TBU 150x250) Overall dimensions, Load, Bearing designation mm kN Maximum Weight, rotational Fig. Application International kg speed, No. GOST d D B/С(S) dynamic static designations RPM 30-42724ЛМ WJ120x240x80-M 120 240 80 18.2 548 713 1800 4 Wheelset axle 30-232724ЛМ WJP120X240x81,2/80-M 120 240 81.2/80 18.2 548 713 1800 boxes of railway 5 42724EM1 WJ120x240x80 120 240 80 15.7 560 750 1800 cranes for wreck 4 trains 232724EM1 WJP120x240x80 120 240 80 15.7 560 750 1800 5 TBU 597826ХУКМУ 130 230 150 38.5 990 1720 1800 2 3042726EM WJ130x240x80 130 240 80 14.8 540 780 1800 4 3232726EM WJP130x240x80 130 240 80 14.8 540 780 1800 5 30-32726Л1М WJ 130x250x80-M/C4 130 250 80 18.5 554 722 1800 3 30-42726Е2М WJ130x250x81,2/80-C4 130 250 80 17.14 584 774 1800 4 Axle boxes of 30-232726E2M WJP130x250x81,2/80-M 130 250 81.2/80 17.14 584 774 1800 passenger and 5 30-42726Л4М WJ130x250x80M/C4 130 250 80 18.7 554 722 1800 freight cars, 4 electric trains 30-232726Л4М WJP130x250x81,2/80-M 130 250 81.2/80 18.9 554 722 1800 5 36-42726Е2М WJ130x250x80P/P6+C4 130 250 80 17.14 584 774 1800 4 WJP130x250x81,2/80P/ 36-232726Е2М 130 250 81.2/80 17.14 584 774 1800 5 P6+C4 H6- 130 250 160/161.2 34.9 1001 1548 1800 1 882726E2K1МУС44 30-42728ЕМ WJ140x260x80-C4 140 260 80 18.18 625 833 1800 4 WJP140x260x81,2/80 Axle boxes of 30-232728ЕМ 140 260 81.2/80 18.16 625 833 1800 5 -C4 special freight cars and electric 30-42728Л4М WJ140x260x80M/C4 140 260 80 19.9 625 833 1800 trains 4 30-232728Л4М WJP140x260x81,2M/C4 140 260 81.2/80 19.9 625 833 1800 5 Axle boxes of TBU 597830ХУКМУ 150 250 160 42.3 1011 1930 1800 2 freight cars 9 Axle box cylindrical roller bearings Locomotives Fig.