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added
competence
A Schaeffler Group customer journal for the production machinery industry
CURRENT NEWS
Issue 1 · 2006
: Systematically direct
INA Drives & Mechatronics has system solutions for turntables and linear axes
EMO 2005 – Review
Advance in technology for the
customers – page 2
Rolling bearing forum for
machine tools
Record numbers attend the
“Technical Symposia” – page 4
Software-Innovation
Finely tuned, coordinated system: Directly driven turntable with INA YRTSM bearings with integrated measuring system
BEARINX®-online spindle
calculation – page 5
With 130 employees in Suhl, INA Drives
& Mechatronics GmbH & Co. oHG
(IDAM) is the specialist for direct drive
technology in the Schaeffler production
machinery division. IDAM‘s product
portfolio includes, in addition to linear
and rotary AC synchronous motors and
reluctance motors in a wide range of
sizes and performance capabilities, all
electronic modules required for their
operation, such as amplifiers, modulators, and compact control units.
Company debut
The machine manufacturer
Berthold Hermle AG – page 5
Clear view into the universe
YRTM-Supporting the largest
telescope SALT – page 6
Coordination and fine tuning ensure
development and success
For the clients of Schaeffler KG, the
advantages of a partnership with IDAM
are not limited to the latter‘s particularly
well-designed and mature range of
products. Rather, an enormous potential
for the development of production
machinery arises from the solid integration of IDAM within the eponymous INAFAG branch. The application expertise of
the leading rolling bearing manufacturer
coupled with the cutting-edge competence of IDAM results in synergies and
development trends which give machine
manufacturers in the market a considerable advantage.
External rotor (ER) is a hit
In mechanical engineering, slotted
high-torque synchronous motors in
FAG02-051470 Newsletter 1/2006-C1 1
internal rotor (IR) and external rotor (ER)
versions deliver an impressive performance with efficient use of energy, maximum power density, high acceleration,
and high end speeds. As they operate
without contact, friction and wear are
irrelevant. The external rotor direct drive
solutions produced by IDAM and the turntable bearings by INA make an excellent
combination.
The synchronous external rotors are
thus increasingly found as coordinated
comprehensive solutions in direct-drive
turntables or in pivotal axes of machine
tools. The optimized combination of turntable bearings, measuring system and
direct drive is a stand-alone feature of
INA-FAG branch management production
machinery and a good example of the
“added competence” philosophy.
Linear drives with the IDAM L2D motor
series
The L2D motors offer new solution
approaches in direct drive technology
for linear motion. The force of attraction
between the primary and secondary
part is reduced to a value approaching
zero. This is the result of a new design.
The iron-core linear AC synchronous
motor has two symmetrically opposed
secondary parts. A reduced proportion of iron in the moving primary part
additionally reduces the mass in this
three-phase motor. The L2D motor series
is predestined for dynamic applications
which require high performance.
The L1 series and the yogurt cup
In contrast, the motors of the L1 series
are excellently suited for small and
medium positioning units. These slotted
linear synchronous motors are eminently
suitable for handling systems and movements of smaller weight. They meet the
highest accuracy and dynamic standards.
With their compact design, they were
practically designed for Adolf Illig Maschinenbau GmbH & Co. KG in Heilbronn,
which implemented its new FSL 70 mold,
filling and seaming system. Four linear
axes on this machine are equipped with
IDAM L1-based direct drives. For the
thermoforming of yogurt packaging, there
are now five pages of decoration options
(including the addition of photo-realistic
images and writing on the underside of
the yogurt cup) which were previously not
available in this quality and price class.
Perhaps you‘ve acquired an appetite for
Schaeffler KG direct drive technology? It‘s
a wholesome diet for machine tools!
06.03.2006 16:35:17 Uhr
added
competence
editorial
Those who
can look
beyond the
quality of
individual
components
and sub-systems become
genuine solution partners.
INA, FAG
and IDAM think in terms of entire
systems when it comes to machine
tools. The turntable, main spindle,
linear axes and (direct) drive subsystems are always networked in
conceptual and concrete terms in
comprehensive, precisely coordinated, application-specific solutions.
Yet the bearing units themselves
are already small system solutions
with their numerous integrated
functions such as sealing, flange,
measuring system, coating, etc. This
approach to system solutions is the
core of our branch philosophy of
“added competence”. We demonstrated how our approach benefits
you at EMO 2005 in Hannover.
In this issue, we present several
highlights from our branch, but also discuss several broader themes
which continue to be relevant in the
world of machine tools.
I wish you the pleasure of enjoyable discovery in your reading!
Sincerely yours, Helmut Bode
Director of Branch Management
Production machinery Schaeffler KG
Issue 1 · 2006 – Page 2
EMO 2005 – Advance in technology for the customers
“Thermally stable rotary axis systems” development project
Directly
driven rotary
axes permit
significantly
greater dynamics with
simultaneously increased limit
speeds. A direct drive technology ready
for serial production, combined with
new bearing technologies, significantly
expands the range of uses for rotary
axes. Goals such as the combination of
milling and drilling with additional rotary
machining are increasingly within reach.
Still, the technological advance towards
combined machining has its price: high
thermal dissipation losses. Modeling of
thermal factors is required, particularly
for axis systems that rotate extremely
fast. Extensive system knowledge is the
key to success in such cases, as the system performance is not determined solely
by components such as the drive, bearings, cooling or peripherals (e.g. seals).
Just as important are the connecting parts
as well as knowledge of the complex
mechanical and thermal interaction of all
of the components in the assembly. An
internal pre-development project of the
Schaeffler Group Industry is currently working out the details of engineering highly
dynamic rotary axes.
Floating bearing solution
for the main spindle
Major system solution on a compact scale
Complete spring pre-loaded modular assemblies now provide a
convenient structural solution for secure control of the floating
bearing section of main spindles. They unite the bearing arrangement, sliding socket and springs in a compact system ready
for installation. This reduces the space required and eliminates
the need for surrounding components such as a restraining cover
and fastening screws. Risky, time-consuming processing and assembly procedures are eliminated. At the same time, the interface
reduction optimizes the heat transfer between the outer ring and
the housing, and increases the precision of the overall system.
The preloading and the rigidity at the operating point can be individually adjusted by omitting supplied springs and/or reduction
of the spring deflection area. The bore diameter and exterior diameter of the assemblies correspond to the dimensions and standard components of the spindle bearing series; only the outer ring
is double the standard width. The circumferential surface of the
outer ring is superfinely ground and coated with thin-film chrome
plating. In addition to the sealed standard version, FAG offers a
range of options which can be adapted to specific application
conditions, such as open versions, DLR versions for oil-air lubrication, as well as additional options such as distortion protection,
disassembly aids, and adaptation of the outer ring geometry.
INA – FAG Tradeshow booth at EMO 2005
Hydrostatic linear guidance in the standard installation space as per DIN 645
Roller and hydrostatic guides in the same machine design
A hydrostatic bearing arrangement has
the best shock-absorbing properties,
which requires a larger installation space,
more assembly work and thus higher
costs. In linear equipment, it is often
used as a separate structure in the form
of a wrap-around guide. It is precisely the
differing installation space requirements
for profile and hydrostatic guide systems
that confront mechanical engineers with
almost insurmountable hurdles when
trying to incorporate both types of
guide systems in the design solution.
But this would be especially practical for
FAG02-051470 Newsletter 1/2006-C2 2
production machines! It would then be
possible with the same machine design
to use monorail or
hydrostatic
guide
systems, depending on
the customer‘s requirements, without changing
the structure of the
machine. This motivated
INA linear technology experts and the Werkzeugmaschinenlabor der RWTH
Aachen (Machine Tool Laboratory
of RWTH Aachen University) to carry
out a joint study of a hydrostatic guide
system in a standard DIN 645 installation
space for a monorail guide system. The
prototypes have load-bearing capabilities
that correspond to the load applications
for a monorail guide system. In the study,
the pocket geometry and the hydraulic
controls were adapted so that even the
static rigidity of a monorail guide system
is achieved in the direction of pressure.
Further features include, for example,
complete sealing with oil recirculation as
well as integrated regulator and electricity
control valves. In the future, this solution
will enable engineers to used both roller
as well as hydrostatic guide elements in
the same machine design, taking into account the geometric connection dimensions.
06.03.2006 16:35:20 Uhr
added
competence
1
Issue 1 · 2006 – Page 3
2
3
4
5
High precision bearings for
combined loads
Double row axial contact ball bearings
for screw drives
Bearings for
screw drives
Axial Radial Bearing
Axial Angular Contact Ball Bearing
Series ZKLN..-DAC
Series BSB..-SU
integrated
7
8
6
Bearings for
screw drives
Application Specific Tandem Sets
for Main Spindles
:
9
Bearing Solutions for
Machine Tools
FAG SpiCoM
The Spindle Condition Monitoring System
Floating Bearing Solutions
for Machine Tool Spindles
Low Temperature
The New Spindle Bearing Generation
BEARINX®-online
Spindle Calculation
Please send me the following product information at no charge:
__x Bearing Solutions for Machine Tools 1
Item No. 005-172-039/PKW US-D 09052
__x High precision bearings for combined loads 2
Item No. 029-097-487/TPI 120 GB-D
__x Double row axial contact ball bearings for screw drives 3
Item No. 028-988-230/TPI 121 GB-D
__x Bearings for screw drives 4
Item No. 029-93-465/TPI 123GB-D
__x Bearings for screw drives (Fitting and maintenance manual) 5
Item No. 005-393-485/TPI 100GB-D
__x Application Specific Tandem Sets for Main Spindles 6
Item No. AC 41 164 EA
__x SpiCoM – The Spindle Condition Monitoring System 7
Item No. AC 41 159 EA
__x Floating Bearing Solutions for Machine Tool Spindles 8
Item No. AC 41 163 EA
__x Low Temperature – The New Spindle Bearing Generation 9
Item No. AC 41 162 EA
__x BEARINX®-online Spindle Calculation :
Item No. 029-087-104/PSB US-D 09051
__x Thermally Stable Rotary Axes
Item No. 029-128-528/TSR US-D 0905 5
__x Super Precision Bearings for Main Spindles
Item No. AC 41 130 / 6 EA
__x Bearing Solutions for Productronics
Item No. 005-510-740/PKP GB-D 11051
__x BEARINX®-online
Item No. 029-087-198/PSB US-D 09051
❏
INA-Customer ❏ FAG-Customer
Per Telefax to
/ 82 21 30
+49 (0) 9132
❏ INA/FAG-Customer ❏ Distributor
Company/Representative
Street
Zip Code
Telephone/Fax
❏ Please send me the
print version of the selected items instead of
sending the .pdf version
to my e-mail address.
E-Mail
Die Schaeffler KG on location in Bilbao and Paris
March 6–11, 2006
March 27–31, 2006
Hall 4, Stand B49–C50
Hall 5a, Stand C 021
Bilbao
Paris Nord Villepinte
FAG02-051470 Newsletter 1/2006-C3 3
You‘ll find us with our new
bearing solutions for production
machines at these upcoming
trade shows:
06.03.2006 16:35:22 Uhr
added
competence
Issue 1 · 2006 – Page 4
Record numbers attend the “Technical Symposia” in Schweinfurt
The rolling bearing forum for machine tools is a hot tip internationally as well
Within just a few days of the announcement by the Production Machinery
Division of Schaeffler Group Industrial
that three “Technical Symposia” were to
be held in Schweinfurt, the conferences
were completely booked. Under the
title “Added competence for machine
tools – Systematically finding the right
solutions,” sophisticated workshops,
high-caliber specialist presentations,
and lots of opportunities for personal
and professional exchanges awaited the
participants.
The leitmotif of the event was provided
by the system solution approach known
as “added competence”, which describes
how INA, FAG and IDAM have become a
strong high-performance network particularly for machine tools, whose system-oriented thinking has made these
technological leaders among component
suppliers for bearing systems into development partners for the sector. After an
introductory presentation by the branch
manager Helmut Bode on the latest developments in the branch and current
motor-driven spindles, Gabriele Laugisch
(spindle bearing application technology)
spoke about the realistic recording of process behavior. Gerald Nonnast (machine
tool application technology) presented
relevant methods of calculation for feed
axes and turntables.
The topic of linear axis bearing systems
was presented for the first time at a
technical conference. Peter Lutz (director
of roller monorail guidance systems technology) used examples of applications
to illustrate the future requirements for
monorail guidance systems. Dr. Martin
Voll, director of spindle bearing application technology, then spoke about “The
significance of load groups and collective
loads”. After that, Juergen Weyh, chairman of the board of the newly founded
INA Drives & Mechatronics GmbH & Co.
KG, (IDAM), took a look at high-speed and
high-torque applications of rotary direct
drives and the synchronization behavior
in the linear section of the machine tool.
Horst Masuch, director of spindle bearing
development, focused on the new pre-
machine tool and spindle manufacturers,
their customers, engineering firms and representatives from academia. In addition
to clients from Switzerland and Austria,
several German-speaking representatives
of leading eastern European companies
took part in the conferences for the first
time in 2005.
Laboratory Lecture from Wilhelm Conrad Röntgen
are continued on a biannual basis with
presentations on all aspects of high-precision bearing systems in machine tools.
Due to the enormous demand, each
conference is presented three times consecutively. In the course of their 10-year
history, the “Technical Symposia” have
developed into an important forum for
The “Technical Symposium” in Italy has
become a tradition. The fifth event of this
kind took place in Parma in May 2005.
This was also the first time that INA,
FAG and IDAM participated jointly. More
customers than ever before attended the
workshops and presentations on turntable bearing systems with integrated direct
drive technology, bearing arrangements
for feed axes, main spindle bearing solutions and linear axis bearing systems in
machine tools. Branch customers are also
supported on location with “Technical
Symposia” in England, France, Switzerland, the United States, and elsewhere.
High-Precision Bearings – Lexicon
I The running accuracy
Main Entrance to FAG in Schweinfurt
Technical Symposium in Italy
market data, Dr. Christian Brecher, the
chairman of the Department of Machine
Tools at the Werkzeugmaschinenlabor der
RWTH Aachen (Machine Tool Laboratory
of RWTH Aachen University), spoke about
the trends in machine tool engineering.
He focused on the importance and development of virtual prototypes, sensor and
diagnostic systems and active damping
systems. This was followed by the presentation on “Rolling bearing technology in
the design of highly dynamic turntables”
by Juergen Hilbinger, the branch segment
manager for machine tools and printing
machines. He spoke in depth about
the complex mechanical and thermal
interaction of all assembly components.
Two presentations were dedicated to the
simulation of bearing systems in machine
tools. With regard to bearing systems for
spring-loaded locating bearing units and
the low-temperature spindle bearings
with the TX cage design. The final presentation was made by Joerg-Oliver
Hestermann from machine tool application technology, who focused on the
benefits of bearings adapted specifically
to the individual applications in a speech
entitled “Optimized feed spindle bearing
systems”. Hallowed lecture halls: In the
evening the participants enjoyed an
exciting presentation in the lecture hall
and the original laboratory in which W. C.
Röntgen discovered the X-ray in 1895.
The „Technical Symposia“ were initiated
in 1996 by the former FAG Aircraft/Super
Precision Spindle Bearings GmbH, which
now forms the spindle bearing product
line as part of the Production Machinery
Division. There, the “Technical Symposia”
FAG02-051470 Newsletter 1/2006-C4 4
Der Radial runout is a significant
accuracy characteristic of a spindle,
to which a bearing makes a large
contribution. The bottom line value
of the bearing lies in the dynamic imbalance of the turning ring, defined
according to the DIN ISO 11321-1 collaboratively constructed bearing. Here
again several factors work together,
most notable the fluctuation in
Shoe guidance and
magnetic drive
Shoe guidance and
friction drive
(Mechanical contact
pressure system,
driven or revolving)
The shoe-grinding process minimizes
fluctuations in the wall thickness of the
bearing rings.
Here again the inner ring is led on
two sliding shoes by a reference surface. Raceway and inner diameter are
ground accordingly. The ideal point
will be put to a spindle assessment
of the suction.
The diameter equality of the rolling
elements has a significant influence.
The smaller the allowed discrepancy
tolerance, the truer the bearing will
run and the more stable the shaft
will be kept. With a spindle bearing
with 70mm bore nominal dimension
the DIN Value (Kia) of the runout
accuracy P2 lies, for example, with
2.5 µm. FAG main spindle bearings
have the accuracy class P4S, which
corresponds to the runout accuracy of the P2 class. In practice they
achieve the runout accuracy values
of even 1 µm, under which even the
Unreproducible Impact lies.
wall thickness between the inner ring
raceway and the inner diameter. The
smallest fluctuation tolerance will get
in the way of the suction.
06.03.2006 16:35:28 Uhr
added
competence
Issue 1 · 2006 – Page 5
Software innovation: BEARINX®-online spindle calculation
Computational Program Revamped and Expanded
With BEARINX®-online, Schaeffler KG has
created one of the leading programs for
performing rolling bearing calculations.
This facilitates the detailed analysis of
rolling bearing applications – from individual bearings to complex shaft systems.
While the FAG expertise in the calculation of rolling bearings has been successively integrated over the past several
years, the current version of the software
has been significantly upgraded with a
special module for spindle calculation.
The functionality of BEARINX® with regard
to the influences of centrifugal force on
load distribution and running behavior of
the rolling elements in ball bearings has
been expanded.
®
e
BEARINX -onlin
on
ti
Spindle calcula
on
Order Applicati
Form by Fax at
344
+49 9132 823
The program includes many other useful
components which enable users to select
the appropriate bearing solution quickly
and safely.
Flexural Mode of a Spindle
An overview of BEARINX®-online spindle calculation
• Recommendations for installation
fittings depending on the specified
speed
• Calculation of the design parameters
for contact pressure and kinematics
in the bearing
• Cinematic bearing frequencies for
vibration analyses
• Calculation of the bearing rigidity at
the operating point taking all relevant
influences into account
• Graphical representation of shaft
reactions (shaft deflection and shaft
inclination)
• Critical speeds and graphical representation of the features
• Rigid and elastic adjustment of the
bearing taking into account the fit,
temperature and speed
• Calculation of the fatigue life in
accordance with DIN ISO 281,
Supplement 4
Die BEARNIX®-online Spindle Calculation
Everything revolves around milling and outstanding results
Spotlight on the Machine-Tool Company Berthold Hermle AG
The machine manufacturer Berthold
Hermle AG is one of the leading international producers of milling machines and
machining centers. More than 17,000
Hermle universal milling machines and
machining centers are currently in use
worldwide. They facilitate efficient machining of tools, molds and serial parts.
A dense sales and service network
ensures that partners are available on
location in all major countries around
the globe.
Hermle machines are manufactured in
Gosheim in southwestern Germany – an
area that has been home to precision
engineering and mechanical engineering
for generations.
The expertise of the company results
from its dynamic contacts with research
institutes and laboratories as well as the
precisely balanced production depth,
which is applied only in those locations
where it makes sense. All components
that are essential to the accuracy and
durability of a machine are developed
and manufactured in our own plants.
With their high quality and extraordinary
precision, Hermle universal milling machines and machining centers are used in
innumerable production areas, especially
in demanding sectors such as medical
FAG02-051470 Newsletter 1/2006-C5 5
technology, the optical industry, aviation,
the automotive industry, racing, and their
suppliers. The renowned Hermle precision, combined with process consulting
and project management, has made the
company the most important partner
for machinery in nearly all key branches
– from large, complex assemblies to the
smallest high-tech components.
Hermle offers an impressive range of
products:
Universal milling machine tools
The U product line is found everywhere
where flexibility, accuracy and universality are required. This proven machine concept, which utilizes the latest technology,
is ideal for tool, mold and die design and
construction as well as the production
of individual parts and small production
runs. The models U 740 and U 1130 have
been technically adapted to today‘s
market requirements by integrating motor
spindle technology, automation technology, modular design and an extensive
range of options.
Vertical machining centers
The C series, which includes the C 600
and C 1200 models, is ideal for tool, mold
and die construction as well as for use
in production. The C 30 and C 40 models
represent a new, highly dynamic generation of machines. They have a modular
design in which all packages designed
for economic machining are integrated.
The performance data speaks for itself:
Cast mineral machine base body, pick-up
tool changer, spindle speeds between
10,000 and 40,000 rpms, iTNC 530 or S
840 D controls, automation packages,
tool storage units and extensive option
packages. All models in the C series are
available in 3, 4 or 5-axis versions.
Automation solutions and machines from
a single source
With its machines, Hermle offers individual customer solutions from a single
source, from simple special assemblies
to flexible production units. The whollyowned subsidiary Hermle-Leibinger
Systemtechnik develops and manufactures automation solutions and special
assemblies as well as a wide range of
handling systems, tool magazine extensions, pallet changing systems with the
Hermle pallet tensioning system, pallet
storage as well as turnkey projects especially for Hermle products.
CONTINUED ON PAGE 6
Renowned Hermle precision
06.03.2006 16:35:30 Uhr
added
competence
CONTINUED FROM PAGE 5
Fair cooperation among development
partners
INA and FAG have supported Maschinenfabrik Berthold Hermle AG as committed
system partners for many years, particularly in the integration of linear guidance
systems and rotating bearings for feed
axles (ZKLF) and cylindrical axles (YRT).
Issue 1 · 2006 – Page 6
Gaze into the universe with INA rotary table bearings
SALT – The largest optical telescope with INA rotary table bearings
The Southern African Large Telescope
(SALT) is located in the Karoo desert in
South Africa and will give a glimpse into
the history of the universe. It will collect
light that was emitted by stars and galaxies some 13.5 million years ago.
“The telescope is a billion times more
powerful than the human eye. It can in
principle detect the light of a burning
candle on the moon” explains Andreas
Pieper, INA‘s Head of Technical Market
Development for Asia, South Africa and
Australia.
The reflector unit measures 11 meters in
diameter and consists of 91 hexagonal,
aluminium coated mirrors that can be
individually aligned. The entire reflector
unit is supported by air bearings and guided by an INA rotary table bearing YRTM
395. With a restricted axial and radial
runout of 3 µm and an encoder measurement accuracy of +/- 3 angular seconds it
precisely fulfils the required accuracy.
The bundled signal is received by the
four and a half ton “tracker”, which is
supported by six INA telescopic struts
specially designed for SALT with the apThe INA Rotary Table Bearing with Integrated
Track Alignment System YRTM 395 supports the
SALT Reflection Unit allowing Ultimate Precision
propriate INA cardanic joints. The tracker
can be precisely positioned to 6 µm.
A support roller combination including
58 INA stud type track rollers of type
NUKR 40 guides the rotatable cupola.
(suggestion: dome)
Milling
The fair cooperation and technology
transfer for the Hermle products makes
Schaeffler KG an important development
partner for this leading machine tool
manufacturer.
The Lagoon Nebula as it was 13.5 Million Years ago
The SALT Telescope in South Africa
How new ideas develop from bringing together different elements
added competence – creativity techniques for engineers, part 13
Management personnel, teams or individual employees
of a company frequently ask themselves how intuition,
good ideas or sharp analytical thinking about problems
and solutions can best be developed. One way of
developing new idea generation processes is to crossassociate lots of individual thoughts, rather like crossbreeding roses. New types are created and further
developed, until the perfect solution or a new idea is
born. Synectics is a systematic brainstorming process
– collecting different, apparently irrelevant elements.
Synectics is one of the most important creative techniques used today. The method was developed in 1944
by the American W. J. Gordon, who questioned artists
and scientists about the secrets of their creativity. The
objective of synectics is to distance oneself from a
problem through analogies. The ideal number of participants for this creativity technique is eight to twelve
persons per group. It is important that the participants
come from different departments.
the top of their heads. Gordon noted that the first phase of
this process generally does not produce the anticipated
bright ideas. However, those who do not mention their
initial spontaneous ideas may possibly inhibit further
creativity. In practice, this round has often produced interesting approaches to solutions which can be used later.
3. Re-formulate the original problem
Provide a new definition of the problem.
4. Create direct analogies (e.g. drawn from nature)
Try to transform the problem completely. Ask the participants what parallels or direct analogies occur to them. As
a rule, analogies drawn from nature are very helpful for
technical problems.
5. Create personal analogies
Ask the participants to imagine themselves in one of the
selected analogies (for example, as a plant, an animal,
etc.), and to describe how they feel.
1. Describe the problem to the group
Then encourage your colleagues to ask questions in
order to look at the problem from all angles.
6. Create symbolic analogies
Ask the participants to describe an analogy as briefly
and clearly as possible. This step leads to abstraction.
2. Draw up spontaneous suggestions for solutions
Ask the participants which solutions occur to them off
7. Create direct analogies (e.g. drawn from technology)
Ask the participants for examples drawn from nature or
FAG02-051470 Newsletter 1/2006-C6 6
from technology which will match the statements from
the previous phase of the process. With the analogies generated at this point, the transformation of the problem
from its starting point will reach its culmination.
8. Describe selected analogies
Ask the participants to describe the selected analogies
as simply but in as much detail as possible.
9. Re-create the connection to the original problem
Ask the participants to what extent the descriptions
are useful for the problem. Can solution approaches be
generated from the selected analogies?
10. Write down the solution approaches developed and
evaluate them
The idea behind synectics is to create receptivity for
ideas from other areas by getting people to think outside
the box. How do others deal with analogous ideas? How
can I find a solution to a similar problem? Open your
mind to other viewpoints, and you‘ll be amazed at the
new ideas that are developed.
06.03.2006 16:35:32 Uhr
added
competence
Issue 1 · 2006 – Page 7
Time for a new coat?
INA special coatings for application optimization
Standard components frequently do not meet the requirements for long-term, maintenance-free use under extreme operating conditions. Malfunctions due to corrosion or wear
make life difficult for machine operators. Thus the leading linear technology manufacturer INA Schaeffler KG, Linear Technology Division, 66424 Homburg/Saar, Germany, has
developed an intelligent modular system designed to meet specific requirements for the use of its linear and profile guide systems under special operating conditions. Three
top performers from this system are introduced here:
Corrotect® Corrosion Protection
Corrotect® Corrosion Protection is a galvanically applied surface coating. The black
chrome-plated, cathodic rust-proofing
layer is extremely thin and is consolidated in the surface roughness profile and
partially removed under load. In the case
of parts coated with Corrotect®, there is
some shrinkage in the area of consolidation; a visually blank surface is created.
The cathodic protection prevents the
formation of rust on this surface.
The advantages of Corrotect® coating
include:
- no influence on load-bearing capability
or service life
- extremely high corrosion resistance
- all-round protection against rust
- rust is prevented in smaller blank spots
by cathodic protection
- no loss of load-bearing capability as
with the use of corrosion-resistant steel
- protection against EP additives
- thermal conductivity
Components coated with Corrotect® are
especially suited for applications which
require extreme corrosion resistance. This
coating is also being used very successfully to prevent splashes of welding
material from adhering.
The following linear products are available with Corrotect® coating:
RUE..E (..E KT), KUVE..B (..B KT), W, WH, LFS..R, LFR.., KB.., KS.., KH..
Protect A Corrosion and Wear Protection
Protect A is a pure chrome layer with a
pearly surface structure. The coating is
applied galvanically, whereby the parts
to be coated are heated to approximately
+50 °C. No structural changes occur in the
parts. They remain completely dimensionally stable. The guide can be used in
a temperature range between -10 °C and
+100 °C. The matte gray chrome layer
with its pearled structure retains a certain
amount of lubrication between the pearls.
This provides effective protection against
wear even in the case of mixed friction
and slippage. The rolling elements and the
seals smooth the surface during runningin. This results in lower friction coefficients.
The advantages of the Protect A coating
include:
- no influence on load-bearing capability
and service life
- significantly higher corrosion resistance
(see comparison on page 5)
- higher wear resistance due to the higher
hardness
- effective protection against wear in the
case of mixed friction
- protection against EP additives
- thermal conductivity
Protect A contains no chrome 6. Components with this coating are thus the first
choice for use in the food industry.
The following linear products are available with Protect A coating: RUE..E (..E KT), KUVE..B (..B KT)
Further products from the shaft and track roller division are available upon request.
Protect B Corrosion Protection and
High Wear Protection
cations used in aggressive environments
and at high temperatures.
Protect B consists of two layers. Thin-film
chromium plating (Protect A) is coated
with mixed chromium oxide. The guide
can be used in a temperature range
between -10 °C and +100 °C. Corrosion
resistance is achieved via the thin-film
chrome plating. The layer of mixed chromium oxide assists lubrication in appli-
The advantages of the Protect B coating
include
- no influence on load-bearing capability
or service life
- higher corrosion resistance
- improvement in running-in behavior
- effective protection against wear in the
case of insufficient lubrication
- in aggressive environments and at high
temperatures, the second coat assists
lubrication
- protection against EP additives
- thermal conductivity
Protect B is the coating best suited to
meet tough requirements for corrosion
protection and in cases when continuous
lubrication cannot be ensured.
The following linear products are available with Protect B coating: RUE..E (KT), KUVE..B (KT)
Further products from the shaft and track roller division are available upon request.
Clean grease – The right lubricant for everybody
Printed circuit board and semi-conductor manufacturing benefit from INA/FAG expertise in tribology
Aggressive media, electrical continuity,
friction, vacuum applications, particle
emission, wear, and corrosion are factors
that can be difficult to handle. Competent
control of these phenomena is one of the
most important requirements for bearings
in the productronics segment.
The reliability and service life of a bearing
depends to a large extent on how well
its lubrication meets the desired per-
FAG02-051470 Newsletter 1/2006-C7 7
formance requirements as well as the
challenges posed by concrete adverse
environmental influences. Together with
renowned lubricant manufacturers, the
Schaeffler Group has developed application-specific lubricants that are tested
for their suitability in the company‘s own
laboratories using the latest methods
before approval and then, batch for batch,
are tested once again before use. In
order to determine which lubricants were
particularly useful with regard to particle
emission, series of tests were carried out
in cooperation with neutral research institutes on particle emissions of lubricants
under defined application conditions. One
test setup with which particle emissions
for lubricated linear guides were determined is shown in Figure … Measurements
were taken at pre-defined points at which
especially high particle emission was
expected based on the application. For
other applications used under high vacuum conditions, special perfluoropolyether
oil-based (PFPE) lubricants with particularly favorable evaporation behavior are
tested for their suitability. However, not
only the right choice of lubricant but also
the addition of the right quantity of the
lubricant is important. Thorough testing
was conducted in this regard as well to determine the correct filling levels for sealed
and permanently lubricated bearings.
06.03.2006 16:35:34 Uhr
added
competence
WIN !!!
Win a “Blackberry Palm Organzier“!
Issue 1 · 2006 – Page 8
Yes, I would like to enter the drawing for the „Blackberry“!
Answer: _______________________________________________________________
Our question:
Lastname, first name: ___________________________________________________
What‘s the name of the direct drive
Company: _____________________________________________________________
specialist at Schaeffler KG?
Address: ______________________________________________________________
Just complete the client newsletter
City, ZIP: ______________________________________________________________
form (right), stating the correct answer and send it to:
Tel.: __________________________________________________________________
Schaeffler KG
Fax: __________________________________________________________________
Production Machinery
IEBSWE-LSA
E-mail: ________________________________________________________________
Georg-Schäfer-Straße 30
D-97421 Schweinfurt
Closing Date is Sep 15, 2006
We would appreciate it if you would answer the following questions:
Did we get your address right? Please let us know of any changes to be made
(please use capitals).
Legal recourse ruled out. The drawing is
closed to employees of the Schaeffler KG
and its trading partners.
Who else in your company should receive FAG “added competence”?
Fax: +49(0)9721/911435
What improvements would you like to see at Production Machinery
in the future?
Preview of issue 2/2006
The lucky winner of our competition 1/2005
1. Customer Specific Mirror
Image Tandem
Representing the EMAG Group, Volker Schmid, a staff
member in Strategic Purchasing (left), accepts the
mobile phone won in a contest. Mr. Schmid gave the
chic Nokia 6610i to the works council, who is organizing the raffle for this year‘s Christmas party. Thus all
EMAG staffers have a chance at winning the original
INA FAG gift.
2. Under Roller Diameter
Measurement Equipment
3. Second Edition BIEMH
+++ NEWSTICKER +++ NEWSTICKER +++ NEWSTICKER +++ NEWSTICKER +++ NEWSTICKER +++
Up to twice as fast – enhanced limiting
speed ZKLDF Bearings from the ZKLDF
line are finished, screw-on, double row
angular ball bearings.
Their operational field reaches from the
rapidly turning round tables to the abra-
sive tips. The efficiency of this bearing
series could be enormously increased.
Limiting speed can be increased up to
100 % through optimization with relatively matched optional features of the
connection construction. Further speed
enhancements can be achieved with
custom solutions, for example in the
grinding machine spindles.
TICKER +++ NEWSTICKER +++ NEWSTICKER +++ NEWSTICKER +++ NEWSTICKER +++ NEWSTICKER
HOTLINE
U.K.
Tel. +44 (0) 1752725506
Fax +44 (0) 1752733481
USA
Tel. +1203/7948232
Fax +1203/7948205
Far East Tel. +65 (0) 7348223
Fax +65 (0) 2352170
E-mail: [email protected]
www.schaeffler.com
FAG02-051470 Newsletter 1/2006-C8 8
Your local distributor:
GLOSS
The thoughtful moments of
Joe Bloggs
Recently, we received four invitations in a
single week: one from my friend Armin, who
is celebrating his God-knows-which birthday,
one from an old bowling pal of my better
half and two from relatives. My wife Barbara
is a willing social butterfly for all occasions,
but that was too much even for her. “Joe,”
she sighed at one point, her head buried
amidst wrapping paper and ribbon, “why
are we invited to so many parties?” “It‘s very simple,” I said, “probably because we‘re
a super team.” She laughed and wanted
to know if the pork roast wasn‘t agreeing
with me. Us – a super team? – “Yes,” I said,
“we‘re each one of a kind, and together
we‘re unbeatable.” “You‘re special, all
right!” she grinned, shaking her head. And
this is what I get when I try to compliment
her!
“Look,” I said, “we‘re like INA and FAG.
They combine their expertise and their
strengths; together they have the largest
product portfolio and offer perfectly coordinated programs from a single supplier. They
call the whole thing ‘added competence“.
I waited for her to blush properly upon
receiving so much praise from her spouse
at last, and how did she respond? She
doesn‘t understand anything about math,
but the bit about the super team is clear to
her now, as well as the reason for all the
invitations – because we each have our own
strengths and they complement each other
beautifully. Then she said my strength lies
in drinking beer and hers in preventing me
from drinking it. And so we always make
everybody laugh and provide first-class entertainment at any party.
One thing I‘m sure of: I‘m not giving her
any more compliments until Easter. At the
earliest.
See you at the next FAG added competence!
Best regards,
Joe Bloggs
Masthead
Published by:
Schaeffler KG
Production Machinery
Editor in chief:
Claudia Kaufhold
Address:
Schaeffler KG
IEBSWE-LSA
Georg-Schäfer-Straße 30
D-97421 Schweinfurt
Tel. +49 (0) 97 21-/-91 19 11
Fax +49 (0) 97 21-/-91 63 16
A Member of the Schaeffler Group
Editorial team:
Helmut Bode
Oswald Bayer
Claudia Kaufhold
Norfried Köhler
Produced by:
Buena la Vista AG, Würzburg
06.03.2006 16:35:35 Uhr