® JUNE 2015 THE Path TO Smarter Bearings The True Cost of Bearing Lubrication A Deep Dive Into an Aerospace Gear Manufacturer Automotive Transmissions in Transition www.powertransmission.com Affordable Power Transmission high-quality components at low prices! Synchronous Drives AutomationDirect’s new line of synchronous drive components provide the same positive timing action of gears or chains but with the exibility and quiet running of belts. • Timing pulleys (sprockets) in both aluminum and steel are available in plain bore with setscrew or tapered bushing mounting styles. • Timing (toothed) belt options include several popular Drive Pulleys pitches and widths and are made of fi berglass starting at: reinforced neoprene. $5.25 • Tapered bushings in both QD®and Taper-lock® styles are available in most popular shaft sizes for mounting a variety of pulleys or sprockets to shafts. Get dependable power transmission at low, low prices with SureMotion® synchronous drives! Drive Belts starting at: $2.00 Precision Gearboxes The SureGear® PGCN series is an exceptional gearbox for servo, stepper, and Worm Gearboxes other motion control applications requiring a NEMA size input/output inter- IronHorse® worm gearboxes are manufactured face. Available in NEMA 17, NEMA 23 and NEMA 34 frames sizes with a wide in an ISO9001 certi ed plant by one of the range of ratios, a 20,000 hour service life, and a one year warranty. leading worm gear reducer manufacturers in the world today. They are available in both The SureGear® PGA and PGB series of high-precision servo gear reducers are aluminum and cast iron with a variety of frame excellent choices for applications that require accuracy and reliability at an sizes and ratios. Dual shaft, right hand shaft, exceptional value. The PGA series is an in-line con guration while the PGB and hollow shaft options are o ered and come series is a right-angled reducer. Both provide a level of precision and torque with a one year warranty. that is best in class and come with a ve year warranty. • Aluminum gearboxes start at $88.00 • SureGear small NEMA motor gearboxes start at $209.00 • Cast Iron gearboxes start at $147.00 • SureGear servomotor gearboxes start at $398.00 Research, price, buy at: www.automationdirect.com/power-transmission Order Today, Ships Today! * See our Web site for details and restrictions. © Copyright 2014 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405 the #1 value in automation 1506-PowerTransmissionEngineering-SynchronousDrives-MAG.indd 1 5/7/2015 12:02:39 PM CONTENTS ® JUNE 2015 [26] [34] FEATURE ARTICLES TECHNICAL ARTICLES [20] The True Cost of Bearing Lubrication [48] Ask the Expert Save money and maintenance with Comparing the efficiency of different types high-performance, dry-running of stepper motors. plastic bearings. [52] Calculation of the Efficiency of Worm [26] Don't Tap the Glass Gear Drives A deep-sea dive into Delta Gear. A physically grounded calculation method to determine the efficiency of worm [34] The Path to Smarter geardrives. Bearings Interview with Schaeffler's Stefan [58] Theoretical and Experimental Study Hantke. of the Frictional Losses of Radial Shaft Seals for Industrial Gearbox [38] Transmissions in Transition An engineering model for radial lip seal Report from the 9th CTI Symposium. friction based on a physical approach. [64] Bigger is Best Gearless mill drives may be the key to maintaining throughput despite ore grade quality decline of 40% in last decade. Vol. 9, No. 4. POWER TRANSMISSION ENGINEERING (ISSN 2331-2483) is published monthly except in January, May, July and November by Randall Publications LLC, 1840 Jarvis Ave., Elk Grove Village, IL 60007, (847) 437-6604. Cover price $7.00. U.S. Application to Mail at Periodicals Postage Prices is Pending at Palatine, IL and at additional mailing offices. Send address changes to POWER TRANSMISSION ENGINEERING, 1840 Jarvis Ave., Elk Grove Village, IL 60007. Randall Publications LLC makes every effort to ensure that the processes described in POWER TRANSMISSION ENGINEERING conform to sound engineering practice. Neither the authors nor the publisher can be held responsible for injuries sustained while following the procedures described. Postmaster: Send address changes to POWER TRANSMISSION ENGINEERING, 1840 Jarvis Avenue, Elk Grove Village, IL, 60007. ©2015 Contents copyrighted by RANDALL PUBLICATIONS, LLC. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission in writing from the publisher. Contents of ads are subject to Publisher’s approval. JUNE 2015 Power Transmission Engineering 1 CONTENTS VOL. 9, NO. 4 [04] PTExtras New suppliers, educational videos and upcoming events. [06] Editorial Intelligent Integration. [08] Product News The newest hardware and software. [44] Blog Bytes A series of bearings-related technical tidbits, courtesy of powertransmission. com. [70] Global Investment Outlook Slow Growth Ahead; Farm Belt No Help. [72] Industry News News you should know; comings, goings… [76] Calendar of Events July 14-16: SEMICON West 2015, San Francisco. August 6-8: Asia International ® Transmission Expo, Beijing. August 10-12: MPIF Basic PM Short Course, State College, PA. A Divisiona ofb A&E Incorporatedat [78] Advertiser Index Every Advertiser, page-by-page. Designed to [79] Subscriptions TM Free subscriptions, anywhere in the Protect world. Overload Release Clutches [80] Power Play Surviving the Robot Revolution. ® JUNE 2015 THE Path TO Smarter Bearings The True Cost of Bearing Lubrication A Deep Dive Into an Aerospace Gear Manufacturer Automotive Transmissions in Transition Phone: 262.554.7500 Cover photos courtesy of the Fax: 262.554.7503 Schaeffler Group www.powertransmission.com www.cabatinc.com 2 Power Transmission Engineering JUNE 2015 WWW.POWERTRANSMISSION.COM]———— Gear up for higher reliability with upgraded SKF Explorer bearings A robust solution for harsh and demanding gearbox environments, upgraded SKF Explorer bearings enable a gear unit to transmit more torque, sustain higher external loads, or even be downsized to improve cost effi ciency. In addition, these bearings provide substantially longer life than other bearings. In fact, they have up to twice the rating life of original SKF Explorer bearings, especially under contaminated and poor lubrication operating conditions. With expertise in bearings, sealing, and lubrication solutions, SKF engineers can add value to the complete gear unit by enhancing reliability and performance, while improving the cost-effectiveness of the complete solution. For more information, please visit skf.com or contact your Enhance gear unit reliability and improve performance local SKF representative. Upgraded SKF Explorer self-aligning bearings have enhanced wear and contamination resistance, and are better able to run under tough conditions – up to 100% longer bearing rating life. The Power of Knowledge Engineering PTExtras www.powertransmission.com More Suppliers, More Choices We’re constantly improving the online Buyers Guide at Randall Publications LLC 1840 Jarvis Avenue powertransmission.com by adding Elk Grove Village, IL 60007 new suppliers of gears, bearings, Phone: (847) 437-6604 belts, clutches, couplings, motors Fax: (847) 437-6618 and other mechanical power transmission components. Stop by EDITORIAL Publisher & Editor-in-Chief the site to see who’s been added Michael Goldstein recently: [email protected] Managing Editor & Associate Publisher MiHow2 Video Instruction Randy Stott [email protected] Senior Editor Jack McGuinn [email protected] Assistant Editor Erik Schmidt [email protected] News Editor Alex Cannella [email protected] Editorial Consultant Paul R. Goldstein ART Motion Industries produces a series of educational videos Art Director in conjunction with the major manufacturers of power David Ropinski [email protected] transmission equipment. These videos give tips on the proper maintenance, installation and use of various products. Here are ADVERTISING Advertising Sales Manager a sampling of recent topics: & Associate Publisher • Troubleshooting Elastomeric Couplings Dave Friedman [email protected] • How to Make Sure You Have the Correct Amount of Tension China Sales Agent in Your Chain Eric Wu Eastco Industry Co., Ltd. • Advantages of Hypoid Gearing Tel: (86)(21) 52305107 Fax: (86)(21) 52305106 Many of the videos are hosted by Tom Clark, and are part of the Cell: (86) 13817160576 Tom’s Toolbox series. To see the videos, visit www.mihow2.com. [email protected] Materials Coordinator Dorothy Fiandaca [email protected] DIGITAL Content Manager Kirk Sturgulewski [email protected] CIRCULATION Circulation Manager Carol Tratar Stay Connected [email protected] Upcoming Events Follow us on Twitter Circulation Coordinator twitter.com/#!/PowerTransMag Barbara Novak Powertransmission.com is your resource [email protected] for the latest information on upcoming RANDALL PUBLICATIONS STAFF events related to design engineering and President Michael Goldstein the use of mechanical power transmission Connect with us on LinkedIn products. Visit often and stay informed. www.linkedin.com/groups/ Accounting Power-Transmission-Engineering- Luann Harrold PTE-2950055 Subscribe Online www.powertransmission.com/ subscribe.htm 4 Power Transmission Engineering