Schaeffler’s bearing solution for vibrating screens helps recyclers maximise productivity

In the complex recycling sector, operators need a robust and reliable vibrating screen to ensure they can separate their feedstock down to an appropriate size at a high frequency.

With long service life an important consideration, Original Equipment Manufacturers (OEMs) have aimed to continually improve their design to ensure operators get the most from their vibrating screens.

As a renowned Australia-wide distributor of bearings, power transmission and industrial products, CBC Australia offers a suite of products from a range of premium suppliers.

As part of its offering, CBC specialises in delivering quality, high precision and cost-effective spherical roller bearings. CBC are well recognised for offering a strong service provision in the management, supply and distribution of bearings throughout Australia.

Tony Tormey, CBC Australia Product Manager – Industrial Bearings, says the FAG T41D Spherical Roller Bearing series from Schaeffler is the latest iteration in the shaker screen bearing solution for vibrating screens.

Schaeffler stock a range of screen bearings, including the T41A, T41B and T41D series to suit the application.

“The T41D screen bearing is proving to be essential in the vibrating screen industry,” Tormey explains.

Tormey says that in order to allow thermal expansion of the shaft, loose fits are commonly used, which usually leads to fretting corrosion. This can restrict thermal expansion of the shaft, increasing bearing loads ultimately reducing bearing life.

The T41D – design however, has a premium hard chromium coating (Durotect CK) on the bore, avoiding fretting corrosion as well as elevated bearing load. This results in a longer service life.

Additional benefit of the coating is the prevention of shaft damage as fretting corrosion is avoided. This reduces repair costs.

“If you put a machine component under the microscope, you will see the peaks with a standard bearing. With the hard chromium coating on the bore, basically it alleviates a lot of those peaks and provides a more of a consistent surface,” Tony says.

With superior qualities of the T41D bearing series with Durotect CK coating on the bore, operators can work more efficiently with a low total cost of ownership, all while delivering a higher level of performance and machine reliability.

The vibrating screen is one of the toughest applications for a bearing due to the high oscillating loads impacting the bearing components, including the grease.

Tormey says the FAG shaker screen bearings from Schaeffler feature Bainite heat treatment giving improved productivity through temperature stability up to 200°C.

Additionally there is a surface hardened cage with high wear resistance and outer ring guidance to accommodate centrifugal forces. The internal design also allows for a relatively larger volume of grease, which is critical in such an application.

Tighter ID and OD dimensional tolerances also provide better control of fit in both housing and shaft.

CBC recommends Schaeffler’s FAG Spherical Roller bearings in X-life quality as they operate 70 per cent longer than regular bearings in the same installation position. Bearings from 22317-EL-XL-T41D right through to 222330-E1-XL-T41D are supplied standard with Durotect CK coated bores.

Tormey says Schaeffler also provide a range of bearing housings with four different sealing options available, depending on application and spherical rollers as a complete package. These include a double lip seal, V-ring seal, labyrinth and taconite seal option depending on the medium.

Additionally, Schaeffler offers tools for the mechanical, hydraulic and thermal mounting and dismounting of bearings.

Moreover, CBC branches across the country offer national sales and local support. This extends to engineering services that include condition monitoring and process improvement.

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Extending shredder service life

Shredding and removing deleterious materials can place extensive pressure on the machine itself, meaning the right componentry is needed to support the task. Fortunately, innovations in productivity have continued to offer the recycling sector higher throughputs at a lower operating cost.

For shredding applications, a high performance spherical roller bearing is no different, paving the way for precise, repeatable motions and reliable extended operations.

While the basic functionality of today’s spherical roller bearings is similar to that introduced in the 1950s, suppliers such as Timken have tirelessly worked towards continuous improvements and upgrades.

As an overarching principle, Timken has worked towards the core principles of greater load-carrying capacity, reduced operating temperature and extended service life.

Depending on the size of the shredder and application, Timken offer a range of spherical roller bearings to support an after-market solution or product replacement. It offers a range of solutions, including pulp and paper, power transmission, metals, cement/aggregates and other applications.

Hardened steel cages, for example, work to deliver greater fatigue strength and protection against shock and acceleration loads. The steel cage comprises a unique slotted design that allows increased contaminant purging and lube flow, supporting lower temperatures and longer operating life.

Rollers are guided by cage pockets, as opposed to a centre ring, which eliminates a friction point, resulting in four to 10 per cent less rotational torque and five degrees Celsius lower operating temperatures.

In designing high-performance bearings, Timken has expanded its offering to suit the challenging needs of various sectors.

One of its strengths as a supplier is offering both hardened steel cages and brass cages, while maintaining an acute awareness of the intricacies of each customer application. Its full line-up of spherical roller bearings includes coverage of all common sizes, from a small (25mm to 240mm), mid-size (240mm to 440mm) and large bore (>440mm).

“If you’re looking for a replacement shredder bearing, Timken has a number of advantages,” explains Tony Tormey, CBC Australia Product Manager – Industrial Bearings.

Timken spherical roller shredder bearings by design have lower operating temperatures to extend bearing life. By running 5°C cooler, on average, than the competition, the bearings can increase lubricant life which can mean nine per cent more bearing life.

Lower temperatures reduce the oxidation and deterioration of oils, greases and films and extend lubrication, thereby extending bearing service life. Additionally, this reduces friction and allows the bearing to turn and reduce torque.

Tormey says extra strength is important to reducing downtime, as some recycling plants could be running 24 hours a day, seven days a week. He says that Timken spherical roller bearings offer higher load ratings that create a significant advantage over standard bearings, giving rise to less fatigue and placing less stress on the bearings.

Heavier loads may not only help operators take on more materials, but offer a variety of benefits. High performance can mean an increase in bearing service life, which allows operators to downsize other component selections while maintaining current levels of systems performance. For example, this might allow a metal recycler to increase its power density, leading to greater throughputs and longer system life.

Longer rollers also result in four to eight per cent higher load ratings or 14 to 29 per cent longer predicted bearing life. With higher load ratings, operators can carry heavier loads, thus improving productivity.

In shredding applications for example, Timken recommends brass cages to handle the extreme operating environment. Brass cages offer extra strength and durability in the most unrelenting conditions allowing for high gravitational forces, shock loads and minimal lubrication.

New surface finishing techniques on the roller and raceway surfaces further enhance the benefits of greater durability and cooler operation. Importantly, the result reduces operating costs and extends the life of one’s shredder.

A practical example was observed when a Belgian Pellet Mill installed Timken spherical roller bearings at its site, reporting a fivefold increase in bearing life and operating temperatures 5 ̊C – 8 ̊C cooler than the competition. The end result led to fewer maintenance cycles and greater uptime – demonstrating the importance of choosing the right technology to fit the task.

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