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Success Story

Industry: Quarrying, Mining and Construction

Application: Autoclave Bogie Wheel Assembly

Cost Savings: $148,297

Introduction

A customer was experiencing constant bearing failure within an Autoclave bogie wheel assembly utilizing Deep Groove Ball Bearings. The failures resulted in damage of surrounding hardware (housings and axles) creating high labor and replacement parts cost. NSK Engineers examined the application and determined that ingress of hard particulates and moisture, combined with excessive load was causing premature bearing failure. NSK recommended upgrading to NSKHPS Spherical Roller Bearings, which offered greater service life and reliability, as NSKHPS roller bearings carry greater loads and operate at higher temperatures. This solution resulted in eliminating continuous ongoing maintenance and substantially reduced colateral damage to surrounding components.

Key Facts

  • Autoclave Bogie wheel Assembly
  • High loads and temperature combined with contaminated environment caused standard deep groove ball bearings to fail prematurely
  • Constant bearing failure resulted in damage to surrounding hardware and high maintanence costs
  • Bearings within 10 axles replaced every 2 - 3 weeks
  • NSK Solution: NSKHPS Spherical Roller Bearings
  • Extended lifetime resulted in zero maintenance requirements and significant reduction in hardware colateral damage
  • Autoclave Bogie Wheel Assembly
Spherical Roller Bearing
  • NSKHPS Spherical Roller Bearing

Value Proposals

  • The customer experienced constant failures in a Autoclave Bogie wheel assembly
  • NSK engineers performed a Failed Bearing Analysis which showed ingress of contaminants from the production process, moisture and excessive load as the cause
  • An Application Review showed that the existing Deep Groove Ball Bearings were inadequate
  • NSK recommended NSKHPS Spherical Roller Bearings
  • Since introduction, the bearing life has significantly improved, which has resulted in significant reduction of Hardware damage and eliminating maintenance, providing a large cost saving for the customer.

Product Features

  • Highest load rating SRB's which enables downsizing
  • Optimum raceway design & surface finishing
  • Brass cage design (CAM) or strengthened steel cage (EA)
  • High cleanliness Z-steel
  • Temperature stability: up to 392° F
  • 40 mm to 260 mm bore size
  • Up to twice the operating life
  • Up to 20% higher limiting speed
  • Dynamic load rating: 25% higher
  • Lower maintenance cost and improved productivity

Product Sheet >>

Cost Saving Breakdown

Before Cost p.a. NSK Solution Cost p.a.
Bearing Costs:
Deep Groove Ball Bearings		 $16,226 Bearing Costs:
NSKHPS Spherical Roller Bearings		 $3,343
Annual Maintenance Costs:
2040 hours @ $28/hour		 $56,840 Annual Maintenance Costs: $0
Annual Hardware Costs:
Replacement of damaged bearing housings and axles		 $82,753 Annual Hardware Costs:
Bearing housings and axles		 $4,179
Total Costs $155,819 $7,522

Reference:SS-E-2036