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Introduction

A steel mill planned to mount NSK bearings inside a huge gearbox for the first time. Test rig trials detected higher noise during running compared to the original design. A vibration analysis was conducted, but no clear results were reached. The customer wanted to dismount the bearings as this was the only feature that had been changed. This would be costly and cause a significant delay in the production schedule of the gearboxes. After consultation with NSK, an AIP expert visited the site to perform a Condition Monitoring review before any action was taken.

Key Facts

  • Coiler Gearbox
  • Commissioning tests of new bearing set up
  • Unexplained noise during testing
  • NSK Solution: Condition Monitoring Service (CMS) with detailed analysis to identify bearings and associated components health. NSK performed a full vibration analysis of the running gearbox
  • The results showed that the bearings were in optimum condition and no issues were identified
  • This allowed the manufacturer to pass the commissioning trials
  • Significant costs were saved because further investigation and disassembly of the gearbox were not necessary
  • Cold Rolling Mill
  • Condition Monitoring Service (CMS)

Value Proposals

  • An NSK expert performed an AIP Survey on the gearbox
  • The NSK engineer conducted a Condition Monitoring review including all technical data, measurement conditions and explanations of spectrum analysis
  • At the fixed trial running speed, the resonance of the machine was reached and some noise appeared
  • No issue was detected on the bearings and there was no risk due to the noise on the final application resulting from the variable speed on the coiler gearbox

Product Features

  • Live assessment of a machine's condition and health while the machine is still in operation.

  • Predicted life of the critical components inside the machine allowing for more accurate maintenance planning.

  • On-site support from NSK Engineers. Not only are our engineering experts fully trained in the use of condition monitoring, they are also experienced bearing experts and can take diagnostics to the ultimate level of root cause. This allows them to also recommend improved bearing and linear motion solutions.

  • Assurance that NSK as a full range supplier can help with the provision of critical bearing and linear motion spares.

Cost Saving Breakdown

Before Cost p.a. NSK Solution Cost p.a.
NSK Solution compared to old design
Cost savings on bearing
$1,876
Remove the bearings from coiler gearbox and install new bearings $2,680
Late delivery
Cost savings on commissioning
$14,150
Total Costs Before NSK Solution

Reference:SS-E-3007

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