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Introduction

A paving producer in Poland was experiencing frequent breakdowns due to bearing failures in a vibrating thickener machine. The bearings were mounted in an electric motor which supported unbalanced weights providing the vibration. In a period of 4 months the customer experienced 10 failures and each time it took 2 hours to replace the bearings. The bearings were experiencing grease loss due to high operating temperatures in excess of 110°C 230°F. NSK engineers performed an application review and recommended that the existing shielded bearings be replaced with NSK fluoride rubber contact seals.

Key Facts

  • Concrete (sett) thickener
  • Conditions: High temperature and vibration
  • Loss of grease and high operating temperature were identified as the cause of bearing failure
  • NSK solution: Deep Groove Ball Bearings with high temperature DDU seals and special material rings with  increased clearance
  • Extended life resulted in zero maintenance  after NSK bearings were used
  • Cost saving based on reduction in  failures and reduced maintenance required
  • Vibrating Thickener
Deep Groove Ball Bearing, 874x555
  • High Temperature Sealed Deep Groove Ball Bearings

Value Proposals

  • The customer experienced multiple failures on a vibrating motor application. NSK engineers performed analysis on a failed bearing which showed significant grease loss due to high operating temperatures.
  • After reviewing the application it was determined that the existing shielded deep groove ball bearing was inadequate for this application. NSK recommended a high temperature contact seal in combination with special material rings and C3 clearance.
  • A trial with the NSK DDU bearing was conducted and the results showed zero failures in a 4 month period.
  • This resulted in a significant reduction in maintenance costs, improved productivity and zero lost production.

Product Features

  • Steel Cage
  • Heat stabilized rings
  • C3 Internal bearing clearance
  • High temperature grease
  • High performance in contaminated environment
  • Temperature stability: up to 150°C 302°F
  • Longer bearing life through superior seal performance (Viton® Seals)

Cost Saving Breakdown

Before Cost p.a. NSK Solution Cost p.a.
Bearing failure - 20 in 8 months $213 No bearing failures during 4 months of testing $107
Maintenance: 20 electric motor $107 each $2,100 No maintenance required in 4 months $0
Lost annual production: 40 hours at $799/hr $31,960 No downtim in 4 months  $0
Total Costs $34,273 $107

Reference:SS-E-5002

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