Features and Benefits of the Cooper Split Roller Bearingcooperbearings.com/downloads/USA/US...

Features and Benefits of the Cooper Split Roller Bearing

Pillow Block Cap

Cartridge

Outer Race

Inner Race

Clamping Rings

Cage and Rollers

Aluminum Triple Labyrinth Seal

Pillow Block Base

Cooper Benefits

Reduce Down Time,(planned or unplanned).

Increase MaintenanceMan Hour Productivity.

Keeps Contaminants Out.

Can Increase Application Life.

Promotes Workplace Safety.

Cooper FeaturesSplit to the Shaft Bearing.

Superior Sealing.

Delivering result in...

Trapped Positions.

Hostile Environments.

V i s i t u s a t w w w . C o o p e r B e a r i n g s . c o m

DEMON S T R A B L E COST SAV I N G S

Solid Cooper Operating ProfitBearing Bearing Costs Levels

Re-installing Adjacent MachineryDowntime CostMaintenance CostInstallation CostAdaptor Sleeve CostBearing Cost

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ApplicationIdentificationGuide 11/29/06 10:35 AM Page 3


Contents

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While the utmost care has been used in compiling thiscatalog, Cooper assumes no responsibility for errors oromissions. Specifications are subject to change withoutnotice. This edition cancels all other previous issues.Copyright 2001 by the Cooper Split Roller Bearing Corp.Allrights reserved.

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Industry Application Potential

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Centrifugal Fans Page 6

Conveyors Page 8

Debarkers Page 9

Drag Chain Conveyors Page 11

Fin Tube Cooling Fans Page 13

Flocculators Page 15

Gear Drives Page 17

Lineshafts and Marine Propulsion Shafts Page 18

Lumber Dry Kilns Page 20

Motors and Generators Page 21

Pilger Mills Page 22

Roll Tables Page 24

Screw Conveyors Page 26

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INApplication Data Sheets

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Line Shaft and Marine Propulsion Data Sheet 6 & 37

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The Data Sheets may be photocopied in order to retain the originals in this publication.



Agitators and Mixers

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Where To Find Agitators...

What To Look For...

Most agitators can be found in paper mills.They can also be found in other plants where mixing is required. Geographically,they may be located anywhere in the country.

An OEM’s horizontal shaft agitator.

This situation requires the inner race to befixed to the shaft in such a way that theshaft cannot slip through.The inner race canbe mounted in a recess, or betweenretaining rings.

Vertical ShaftWith a vertical shaft, the weight of theshafting, blade, and pulley or coupling weightmust be considered in addition to thethrust load from the agitator blade.Thedead weight of these components must beadded to the calculated thrust, if theimpeller is pulling upward, or subtracted ifthe impeller pushes downward. Since theshaft comes out of the tank verticallyupward, the bearings will not usually besprayed with liquid.While horizontal shaftstypically use pillow block mounts, verticalshafts trend toward flange mounts.

Application DescriptionAgitators are commonly used in the paperindustry to mix pulp (stock) and water, oradditives to the pulp, such as bleach.Theprimary concern is the axial (thrust) loadproduced by the blades.The shaft can beoriented vertically or horizontally, and aretypically 2 - 6" in diameter.The speed isnormally slow, usually 60 to 250 rpm,depending on the shaft size.

Advantages of CooperThe main advantage of a Cooper bearing isthe aluminum triple labyrinth (ATL) seal.Due to the bearing position on the stocktank, it is possible that the inboard bearingwill get sprayed.

With the slow shaft speeds involved, thecartridge can be fully packed with waterresistant grease and with the labyrinthdesign, prevents water from entering thecartridge housing.This is essential to the lifeof the inboard bearing.

Another advantage is the split design.Thisdesign allows for easy inspection andchange out in trapped locations betweenthe drive unit (usually a belt or gearbox)and the impeller.

Bearing Selection DataAgitators are typically high thrustapplications. In order to calculate the thrustload the motor horsepower and output rpmare required. If the agitator is belt driven, thediameter of the drive sheave and thediameter of the driven sheave are necessary.

The blade diameter and the number ofblades must be known.The distancesbetween the bearings and the blades arenecessary. For a vertical shaft, the weight ofthe blade and shaft must be provided.

Additional InformationClamping force (applies to fixed bearingonly). In most agitator applications, thrustloads of 4,000 to 5,000 lbs and higher areoften encountered.The slow speedmaximizes Cooper’s axial capacity, however;02 Series are still required in most cases.

The thrust capacity at low speed is higherthan the clamping force of the clamp rings.When the thrust capacity of the bearing issufficient, but the clamping force is notsufficient to hold the axial force, the shaftwill slip through the bore of the inner race.



Ball and Hammer Mills

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Where To Find Ball Mills...

What To Look For...

Ball and hammer mills can be found in many industries.They include cement,iron ore and limestone industries.

Belt and Gear Driven Ball Mills.

Application DescriptionA ball or hammer mill is a machine used tobreak up or pulverize large chunks ofmaterial for processing. A ball mill usesunconfined steel balls, tumbling in a largecylinder, to break up the raw material.Hammer mills replace the steel balls withrotating hammers, to break up the rawmaterial.The initial chunks of material areplaced in the cylinder at one end and exitout the other end through a screen.Thescreen determines the final size of thematerial suitable for processing.

During rotation, the material travels fromone end of the cylinder to the other bymeans of spiral vanes or ribs called flights,located on the inside walls of the cylinder.The cylinder can also be slightly inclined tohelp transfer the material. When thematerial reaches the screen, it exits forprocessing. If the material is too large, itremains in the cylinder until the correct sizeis achieved.

Typical shaft speeds range anywhere from20-60 rpm depending on the size and typeof material being processed.

Advantages of CooperThere are several advantages to choosing aCooper bearing. One advantage is the splitdesign.The split design allows for installationand inspection without removing sheaves,couplings, and other machine components.This can cut a machines down time from aday to only a few hours.

Another advantage is the design of theinternal components of the bearing. ACooper bearing has fewer, larger diameterrollers than most comparable bearings.This gives them a far greater tolerance toshock and vibration loads.

Bearing Selection DataThe motor horsepower and output rpm arerequired. If the mill is belt driven, thediameter of the drive sheave and the

diameter of the driven sheave arenecessary. In order to calculate the radialload, the weight of the cylinder, balls orhammers, and material must be known. Inaddition to these, the diameter of thehammers is also required for radial loadcalculations on a hammer mill.The axial(thrust) load can be determined by theangle of tilt and the total weight. It is alsoimportant to note the environment(temperature, contamination, etc.).

Additional Information - Shock LoadsThere are heavy shock loads involved in thisapplication. For this reason, a grease withextreme pressure (EP) additives is usuallyused.

Thermal Expansion/ContractionSince the mills can be quite long, thermalexpansion/contraction should be evaluatedfor the expansion bearing, even if there isonly a moderate temperature rise duringoperation.



Bucket Elevators

P a g e 4

Where To Find Bucket Elevators...

What To Look For...

Bucket elevators can be found in any industry where material handling of bulk solids is required. This can include agriculture (grain, fertilizer, etc.), power industry (coal, ash, etc.), rock quarries (rocks, minerals, etc.), and the marine industry (barge unloaders) are just a few areas where bucket elevators can be found.

A schematic of a typical bucket elevator is shown below.

Application DescriptionAs the name implies, a bucket elevator liftsloose or granular material in buckets. Theelevator or “leg” is usually vertical but canbe inclined. The buckets are rectangularand typically made of cast iron, weldedsteel, or plastic (fiberglass). The buckets areattached to a chain similar to a bicycle chainor bolted to a flat belt. The chain is a loopsupported by sprockets at the top (head)and bottom (tail) of the leg. The drive isusually on top and consists of a motor andgearbox. Sprocket speed is slow, usually inthe range 40 to 80 rpm.

From a drive standpoint, very little power isrequired. When empty the weight of thechain and buckets climbing the elevator arebalanced by the chain and bucketsdescending. Net power consumption islimited to mechanical losses in the system.When loaded, the power consumption isstill small since the weight of material beinglifted is the only net load and speed is slow.

The head shaft bearings can carrysubstantial load regardless of the motorhorsepower. The entire weight of chainsand buckets must be supported as well asthe shaft, sprocket, and coupling. If the gearreducer is a shaft mount type, the weight ofthe gearbox is added to the drive sidebearing load. It is not unusual to use 02 Series bearings on an elevator with onlya 20 Hp motor. The tail shaft is lightlyloaded, serving primarily as a guide. Thesebearings are typically 01 Series.

Where To Find ThemBucket elevators can be found in anyindustry where material handling of bulksolids is required.

This can include agriculture (grain, fertilizer,etc.), power industry (coal, ash, etc.), rockquarries (rocks, minerals, etc.), and themarine industry (barge unloaders). Theseare just a few areas where bucket elevatorscan be found.

Advantages of CooperOne of the main advantages of usingCooper bearings on bucket elevators is thesplit design. The head shaft bearings can belocated over 100 feet in the air. If solidbearings were used, a crane would benecessary to remove the motor and othercomponents in order to install the drive sidebearing. The split feature of Cooper allowsthese bearings to be replaced withoutremoving any of the components on thebucket elevator. A crane would not benecessary and down time would beminimal. The split feature also allows easyvisual inspection of the bearings withoutdisturbing the bucket elevator.

Another advantage of using Cooperbearings is our standard Aluminum TripleLabyrinth or ATL seal. The bearings on abucket elevator are subject to a lot of dirt,dust, and the elements (rain).The bore of the seals contains two rows of“O” ring material, which compress onto theshaft when mounted. This creates a 100%sealing capability between the shaft and theseal.

The only other entrance into the bearing isthrough the labyrinth of the seal, which isfilled with grease during installation.This sealing arrangement is excellent inkeeping out contamination and moistureproviding a longer bearing life.

Motor MountHeadShaftBearings

TailShaftBearings

Buckets


LubricationThe head shaft of a bucket elevator isaccessible by a long climb up a steep ladder.The same difficulty of access that makessplit bearings desirable makes maintenancesporadic. The slow speed and self purgingnature of the ATL seal allow the bearings torun fully packed with grease. This also helpskeep contaminants out. The best benefit,however, is low frequency of re-lubrication.At 60 rpm it will take 6 months for thebearing to turn 16 million revolutions. Thisshould be stressed in any presentation foran elevator application.


Bucket Elevators

P a g e 5

Bearing Selection DataThe primary concern on a bucket elevatoris the amount of radial load supported bythe bearings. This radial load is composedof the weight of the rotating componentsand shaft mount reducer (if present). Tocalculate the total radial load and make abearing selection, the following informationis required:

1. Shaft diameter

2. Shaft speed at bearings

3. Weight of each bucket

4. Number of buckets

5. Volume of buckets

6. Density of material in buckets

7. Weight of shaft mount reducer (if present)

8. Weight of chain and sprockets

9. Motor horsepower

Additional Information -Sample Bearing SelectionAn elevator leg is described by its height; forexample, a 60 foot leg has a height of 60feet. The length of chain would thereforebe double that or 120 feet. If the chainwere known to be 18 lbs/ft, chain weightwould be 120 x 18 or 2,160 lbs. If the pitchof the buckets was 12 inches, there wouldbe 120 /1 or 120 buckets. A .75 cubic footcapacity steel bucket can weigh 60 lbs, 120x 60 = 7,200 lbs. Half of those buckets canbe full of a material weighing 85 lbs/ft3. Theweight of material would be 1/2 x 120 x .75x 85 = 3,825 lbs. Four feet of 3-7/16”shafting and two 50 lb sprockets would add265 lbs to the total. The weight suspendedon the head pulley bearings would be13,450 lbs.

Half the total would be supported by eachof the two bearings on the head shaft. Loadper bearing would be 13/450¸ 2 or 6,725lbs. Using a 1.5 service factor and 60 rpm,the required C rating for a 50,000 hour L10

life would be 47,903 lbs. The 01 BCP 307would not be adequate with a rating of40,300 lbs. The selection would go to the02 Series.

Use of fiberglass buckets would change theloading significantly. The largest singlecomponent of the load is the weight of thebuckets, usually more than half the total. Inthe previous example, a fiberglass bucket ofsimilar capacity would weigh about 5 lbs.The weight savings would be 55 lbs perbucket or 6,600 lbs.

The load per bearing would drop by 3,300lbs and the required C rating would fall to24,397 lbs. This is well within the capacityof the 01 series. In general, if plastic bucketsare employed, 01 Series will be adequate.


Centrifugal Fans

P a g e 6 V i s i t u s a t w w w . C o o p e r B e a r i n g s . c o m

Where To Find Centrifugal Fans...

What To Look For...

Centrifugal fans can be found in almost any type of manufacturing facility, office building,or plant across the entire country.Some applications for centrifugal fans include: cement, marine, paper, power,quarrying, steel, sugar, and water and sewage industries.

Industries that require constant forced air ventiation. A typical Cooper fan application in

a power plant is shown below.

Application DescriptionCentrifugal fans discharge air or gasesradially from a fan wheel.They are generallyclassified as single or double inlet.This isusually abbreviated as SWSI (single width,single inlet) or DWDI (double width,double inlet).

In general, fans can be categorized as centerhung or overhung. Center hung fans have abearing on either side of the fan wheel andcan be classified as an arrangement 3 or 7.While arrangement 3 or 7 can be single ordouble inlet, typically these arrangementsare used for double inlet fans. Overhungfans have both bearings on one side of thefan wheel.They are usually considered anarrangement 1 or 8, and are generally singleinlet types.There are other arrangements(see Appendix 1), but these are the mostcommon.

Single inlet fans usually have an overhungfan wheel.The majority of the wheel weightis carried by the bearing closest to thewheel.The bearing closest to the drive maybe cap loaded, which holds the shaft down.To prevent excess shaft whip from theoverhung load, the shaft must be larger indiameter than on a center hung fan withthe same load.

Double inlet fans usually have a center hungfan wheel.When the wheel is centered onthe bearings, the weight is shared by bothbearings. Because the load is supportedfrom both sides, the shaft can be relativelysmaller in diameter than one that supportsan overhung load.

Advantages of CooperThe flange guided cylindrical roller bearing,used in Cooper bearings, has the lowestcoefficient of friction of any rolling elementbearing. Reduction of friction means lessheat generation by the bearing. The low

friction makes Cooper a very high speedbearing even though it is split.The use of alabyrinth seal rather than a contact sealfurther reduces the amount of heatgeneration. Consequently, Cooper bearingswill run cooler than double row sphericalroller bearings, double row tapered rollers,and even most ball bearings on a givenapplication.

Coopers perform well in light loadsituations that frequently occur on fans.Single inlet fans with a direct drive motoroften create situations where the bearingsmay be too lightly loaded. A too lightlyloaded bearing may skid rather than roll,generating heat and leading to prematurefailure.

The split design also allows installationwithout removing sheaves, couplings, andother bearings.This can cut a machine’sdowntime from a day to only a couple ofhours.

Bearing Selection DataIn order to make the proper selections, itmust be determined if the fan is an SWSI orDWDI, and what type of arrangement it is.For both a SWSI and DWDI the motorhorsepower and output rpm is required. Ifthe fan is belt driven, the diameter of themotor sheave and the diameter of the fansheave are necessary. For eitherarrangement the weight of the wheel isneeded, and for an overhung fan wheel thedistance between the bearings must beknown.

For a SWSI fan the biggest concern is theaxial load. In order to calculate the axial loadit is important to know if thrust vanes arepresent or not.

In some applications manufacturers installthrust vanes on the back of the fan wheel.These vanes will generally reduce the axialthrust by half.The area of the inlet cone atits smallest diameter must also be known.The static pressure of the fan, in inches ofwater, is also needed. If the static pressure isnot available, it can be determined using thedrive power and gas flow rate (usually givenin cubic feet per minute or cfm).

This method gives a -10 % to + 35% errorfor the static pressure. So to make anaccurate selection we would prefer toknow the static pressure of the fan.


Centrifugal Fans

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For a DWDI fan the primary concernfor making a selection is the radial loadproduced by the weight of the fanwheel and belt pull, if any.The fanwheels are essentially two single wheelspositioned back to back. Nearly all thethrust load is eliminated because theaxial load produced by one wheel isbalanced by the other.The exceptionto this is when there are dampers onthe inlets that are operatedindependently.Then the thrust wouldhave to be calculated the same as asingle inlet fan.

Additional Information -ClearanceTo select the proper clearance in thebearing the shaft temperature and theambient temperature is needed. If theshaft temperature is 70°F hotter thanthe ambient temperature, the shaft willcause the inner race to heat up andexpand, while the outer race will becooled by the air.This expansion willdecrease the clearance, and if there isinsufficient clearance the bearing willbind and seize up. In temperaturedifferences between the shaft andbearing housing surface greater than70°F, C3 clearance must be specified. Ifthe temperature difference is greaterthan 130°F, C5 clearance must bespecified.

Spherical FitIn high speed applications such as fanswe recommend using an S1 sphericalfit.The S1 fit is obtained by selectiveassembly.

By taking cartridges at the high end oftolerance and pedestals at the low end oftolerance, a minimum clearance in the balland socket joint is obtained.The S1 fit willdampen vibration and reduce any resultingdamage to the bearing, cartridge, andpedestal.

Larger and multiple fans pose noproblems for Cooper bearings

Belt drive center hung fan

Basic Fan Arrangements

Belt drive overhung fan

Direct drive center hung fan Direct drive overhung fan


Conveyors

P a g e 8 V i s i t u s a t w w w . C o o p e r B e a r i n g s . c o m

Where To Find Conveyors...

What To Look For...

Small conveyor systems can be found in cement ready-mix plants, load out facilities for trucks, railcars, and barges, or anywhere dry bulk materials must be handled. Large systems are commonly found in mines and coal fired power plants.

A typical belt conveyor is shown left and below.

Application DescriptionBelt conveyors are used to transport dry materials up inclines or across relatively flatdistances. A small conveyor system, generally driven by motors under 100 HP, may be assimple as a head pulley, tail pulley, and idlers. Large conveyor systems, up to 1000 HP, havehead and tail pulleys, idlers, as well as bend, snub, and take-up pulleys.These large systemsmay also have a secondary drive.

Advantages of CooperThere are several advantages to choosing aCooper Split Roller Bearing for any beltconveyor system.The primary advantage isthe Aluminum Triple Labyrinth or ATL seal.The ATL seal clamps to and spins with theshaft.Two “O” rings in the bore of each ATLgrip the shaft to form a complete seal.TheATL seal is the best standard seal in theindustry, and is good for even “Taconite” likeapplications when used under certainconditions.These applications involve veryfine dust particles being conveyed anddeposited near bearing locations.

The split design of Cooper bearings allowsfor installation and visual inspection intrapped locations between the drive andpulley.The design of Cooper’s single rowcylindrical roller can withstand the shockload placed on the bearings much betterthan other rolling element geometries.Thebearings must withstand a considerableamount of shock load in conveyorapplications, especially, if the belt is fullduring start up.

Bearing Selection DataThe drive horsepower or belt HP must beknown.The belt speed in feet per minute(FPM), or the RPM, as well as the pulleydiameter is needed. It is important to notethe arc of contact, also known as the degreeof wrap, between the pulley and the belt.The pulley surface, plain (smooth), or lagged(ridged) is also required.The belt tension onboth sides of the drive pulley(s) would beextremely helpful if known.

In addition to the load due to the drive, thedead weight of the components areimportant in determining the bearing load.The weight of the pulleys, coupling(s), andalso of the shaft mount speed reducer, ifthere is one, is needed. Also note if the beltis level or inclined.The length of theconveyor and the belt’s weight in poundsper foot, along with the width of the beltand the tons per hour capacity of the beltare also helpful in the load calculations.

Additional Information - Lubrication and MaintenanceMost slow moving applications generallyrequire a heavier lubrication than standardbearing grease. Generally, conveyor bearingsdemand a lubricant with EP additives and aVG grade 460 base oil. Examples of theseinclude Mobil Mobiltemp 78,TexacoStarplex Premium, and LubricatingEngineers 1250 Almasol.Timely andfrequent lubrication is a must to fulfil theexpected life of a bearing.Generally for conveyors, relubricationshould occur every two to four weeks.Relubrication coats the contacting surfaceswith fresh grease, and purges any fineparticles out of the bearing that wereattempting to move past the triple labyrinth.

Cooper bearing used in steel mill in trappedposition between the drive and head shaft.


Debarkers

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Where To Find Debarkers...

What To Look For...

Debarkers, as their name would imply, arefound in the lumber industry. Debarking isusually the first process raw timber goes through upon arrival at the sawmill.Logging trucks are off-loaded and the logs are conveyed directly to the debarker.Most debarkers see heavy abuse from shock loads as product is dumped into the machine, rotated or tumbled, and kicked out of the system.

Lumber Mills and forestry operations.

Application DescriptionDebarkers are used to strip the bark fromrough cut timber. There are two main typesof debarkers. One of them is the headdebarker which employs a floating cutterhead that traverses over a rotating log andstrips off the bark. Head debarkers canaccommodate logs up to 54” in diameterand up to 24’ in length. The second type isa drum debarker. A drum debarker consistsof a large drum that accepts a number oflogs from a conveyor and tumbles the logsagainst each other as it rotates to removethe bark.

The drum is supported and rotated onrubber tire drives similar to a rotary kiln.Drum debarkers rotate very slowly (as lowas 9 rpm) and can accommodate muchlonger logs than a head debarker.

Head debarkers support one log at a timebetween two rows of steel-toothed bullwheels. The bull wheel shafts can be drivenby 15 hp to 100 hp electric, hydraulic, ordiesel motors. Shaft speed is generally lessthan 30 rpm but shock loads from logsbeing dumped onto and kicked off of thedebarker are very high. Radial load dependson the size of the logs and the workingpressure of the debarker head hold-down.

Drum debarkers are driven by multipleunderrollers. Drive motors range from 75hp to about 125 hp, and there can bemultiple drives depending on the size of thedrum and number of underrollers. Manymanufacturers use rubber tired drives to aidin shock absorption, improve speed control,and to “soft start” the equipment whenramping up. Radial loads come from theweight of the drum coupled with the sizeand number of logs. There are substantialforces during start-up and shock loads fromthe logs tumbling that need to beconsidered.

In addition, the friction forces generatedbetween the rubber tires and drum addload to the system.

Advantages of CooperDebarkers provide classic trappedapplications for Cooper bearings. The splitdesign of Cooper bearings allows forinstallation and visual inspection in trappedlocations between the bull wheels on ahead debarker. In addition to the bull wheelshafts, most head debarkers have belt drivenfloating cutter heads.

If the bearing is trapped between the beltsheave and the drive, Cooper provides theadvantage of being fully split for ease ofreplacement. This fully split-to-the-shaftdesign reduces downtime due to changeout or maintenance to the time requireddisassembling and reassembling the pillowblock. Motors, wheels, sheaves, and shaftsall stay in place during replacement.

There are several other advantages tochoosing a Cooper Split Roller Bearing fordebarkers. The design of the Cooper singlerow cylindrical roller can withstand theshock load placed on the bearings muchbetter than other rolling element bearinggeometries.The bearings must withstand aconsiderable amount of shock load indebarker applications, especially duringloading and start-up.

Continued on next page.

Head Debarker


Debarkers - Continued

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One of the most significant features of theCooper bearing is the Aluminum TripleLabyrinth (ATL) seal.The ATL seal clampsto and spins with the shaft.Two “O” rings inthe bore of each ATL grip the shaft to forma complete seal.The ATL seal is the beststandard seal in the industry, and isespecially good at keeping out fine sawdustand dirt particles found in the debarkingprocess.

Bearing Selection DataThe load due to log weight and pressureexerted by the cutting head are the majorfactors to be considered in calculating radialload for a head debarker. To calculate totalresultant load drive horsepower, drive type,shaft size and RPM, number of bull wheels,and distance between the bearings isneeded.The weight of the floating headcutter and its designed working pressure isalso needed.

If bearings are being selected for the drivehead, other factors need to be considered.The drive horsepower, drive type, shaft sizeand RPM, and sheave diameters are neededto calculate tension from belt pull. Theworking pressure, weight of the floatinghead cutter, and the distance between

bearings is needed to calculate resultantload from contact with the log.

Drum debarkers handle much heavier totalloads, but are more basic machines than ahead cutter.The most important factor inbearing selection for a drum debarker isdetermining the total weight of the drumvessel, the weight of its normal operatingload of timber, and number of supportwheels. The drive horsepower, drive type,drive wheel (rubber tire) diameter, shaft sizeand RPM are also needed. One veryimportant factor to consider is whether thedrum is on an incline. Most debarkers arenot inclined, but if one is, we need to knowthe degree of the angle or its rise over run.Inclined rotating drums can exert very highaxial loads and these need to be examinedbefore selecting the bearing.

Additional Information - Common FeaturesBecause shock loads are troublesome toquantify, it is not uncommon to recommendthat steel or ductile iron pedestals be usedon debarker applications. The combinationof heavy loads and slow speed make itdifficult to achieve adequate lubrication flowto contact areas.

The addition of thin-dense chrome to theraces improves lubrication and surfacehardness, making it an attractive option ondebarker bearings.

Lubrication and MaintenanceMost slow moving applications generallyrequire a heavier lubrication than standardbearing grease. Generally, debarker bearingsdemand a lubricant with extreme pressure(EP) additives and a VG grade 460 base oil.Examples of these include ChevronUltraDuty #2,Texaco Starplex Premium,and Lubricating Engineers 1250 Almasol.The use of dry film additives (such asmolybdeneum compounds) may aid inestablishing and maintaining an adequatelubrication film on the running surfaces ofthe bearing.

Timely and frequent maintenance isnecessary to maintain a fully packed bearingand fulfil the expected life of the bearing.Generally, regreasing should occur everytwo to four weeks. Relubrication coats thecontacting surfaces with fresh grease, andpurges any fine particles out of the bearingthat were attempting to move past thetriple labyrinth seal.

Large Drum Debarker Detail of Drum Under-roller Drive


Drag Chain Conveyors

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Where To Find Drag Chain Conveyors...

What To Look For...

Drag chain conveyors are found in lumber,paper, scrap metal, and waste handling industries. In the movement of scrap metal, the metal is dropped onto the drag conveyors from an input chute and typically moves the scrap up a 10 to 12 ft.incline.

Some of the longer drag chain conveyors are found in the pulp mills.These conveyors tend to be level and move pulp over 80 to 100 ft. distances.Flights or hooks can be found on lumber mill drag conveyor chains. The wood is dropped onto the conveyor and “grabbed”by the chain flights as the conveyor rotates.Most drag chain conveyors see heavy abuse from shock loads as product is dumped onto the chains!

Application DescriptionDrag chain conveyors are generally used totransport materials, up inclines or acrossrelatively flat surfaces, many times dumpingproduct into hoppers or onto otherconveyors. They drag material through atrough on chains instead of on a beltcupped by idlers.

Drag conveyors turn at relatively slowspeeds, typically around 5 to 10 rpm, andare subject to heavy shock loads. Incomparison to overland or belt conveyors,drag chain conveyors tend to be relativelyshort, most times less than 100 feet inlength.

It is not uncommon for the headshaft to befitted with steel hubs and a pipe sleeve onwhich the chain sprockets are mounted.Drive is usually through a gearbox reducermounted to the motor and coupled to theheadshaft.

Advantages of CooperConveyors provide classic trappedapplications for Cooper bearings. The splitdesign of Cooper bearings allows forinstallation and visual inspection in trappedlocations between the drive and chainsprocket drum. This fully split-to-the-shaftdesign reduces downtime due to changeout or maintenance to the time required todisassemble and reassemble the pillowblock. Motors, gearboxes, and shafts all stayin place during replacement.

There are several other advantages tochoosing a Cooper Split Roller Bearing for adrag chain conveyor system. The design ofthe Cooper single row cylindrical roller canwithstand the shock load placed on thebearings much better than other rollingelement bearing geometries.The bearingsmust withstand a considerable amount ofshock load in conveyor applications,especially if the trough is full during start up.

One of the most significant features of theCooper bearing is the Aluminum TripleLabyrinth (ATL) seal.The ATL seal clamps toand spins with the shaft.Two “O” rings inthe bore of each ATL grip the shaft to forma complete seal.The ATL seal is the beststandard seal in the industry, and isespecially good at keeping dust and dirtparticles being conveyed and depositednear bearing locations.

Bearing Selection DataThe load due to chain pull, material weight,and component weight are the majorfactors to be considered in calculating radialload.

Continued on next page...

Cooper bearings aretypically found in thislocation either as a

pillow block or flange housing.


Drag Chain Conveyors


To calculate total resultant load drivehorsepower, chain speed in feet per minute(FPM), or the shaft RPM, as well as thesprocket diameter is needed. The numberof chain strands and distance betweenbearings is also needed.The length of theconveyor and the tons-per-hour capacity ofthe belt are also helpful in the loadcalculations.

The tons-per-hour capacity is divided bychain speed to calculate the average weightof the material.This figure is multiplied timesthe length of the conveyor to approximatetotal material load. If the tons-per-hourcapacity cannot be provided, the chartbelow gives the average weight ofcommonly conveyed material for yourreference.

Material Average Weight(per ft3)

Cement 75 – 80 lbCoal 50 – 55 lb.Grains 38 – 45 lb.Gravel 90 – 100 lb.Sand (damp) 110 – 130 lb.Sawdust 10 – 13 lb.Stone 58 – 90 lb.Wood Chips 12 – 20 lb.

In addition to the load due to chain pull, thedead weight of the components isimportant in determining the bearing load.The weight of the sprockets, coupling(s),shaft mounted drum (usually heavy pipe),and also the speed reducer if it is shaftmounted are all factored into the loadcalculations. Note if the conveyor is levelor inclined.

Additional Information - Common FeaturesBecause shock loads are troublesome toquantify, it is not uncommon torecommend that steel or ductile ironpedestals be used on drag chainapplications. The combination of heavyloads and slow speed make it difficult toachieve adequate lubrication flow tocontact areas. The addition of thin-densechrome to the races improves lubricationand surface hardness, making it anattractive option on drag chain bearings.

Lubrication and Maintenance Most slow moving applications generallyrequire a heavier lubrication thanstandard bearing grease. Generally,conveyor bearings demand a lubricantwith extreme pressure (EP) additives anda VG grade 460 base oil. Examples ofthese include Chevron UltraDuty #2,Texaco Starplex Premium, and LubricatingEngineers 1250 Almasol.Timely andfrequent lubrication is a must to fulfil theexpected life of a bearing. Generally, forconveyors regreasing should occur everytwo to four weeks. Relubrication coatsthe contacting surfaces with fresh grease,and purges any fine particles out of thebearing that were attempting to movepast the triple labyrinth seal.


Fin Tube Cooling fnas


Where To Find Fin Fans...

What To Look For...

Fin fans are commonly found in refineries and chemical plants. They lose far less water to evaporation than conventional cooling towers and are used where water availability is less.

The greatest concentrations are in southern California,Texas, and in therefineries around Philadelphia.

Fin fans are found in groups, usually 12 ormore. In a large refinery or chemical plantit is not unusual to find hundreds.

Application DescriptionFin tube cooling fans are also known asfin fans. They have vertical shafts andlarge diameter blades, 8 to 12 feettypically. Fin tube cooling fans pull orpush air through groups of tubes thatare wrapped with fins. Fin fans areusually found in groups of 12 or more,positioned inside of a large box that isheld around twenty feet in the air onstilts.

The shaft diameter usually ranges from1-11/16" to 2-15/16". The standardshaft diameter utilized on new fans is2-15/16". In most cases the vertical finfan shaft is belt driven from the bottomof the shaft at speeds ranging from200-500 RPM.The original equipmentbearing is a ball or tapered rollerbearing with a set screw attachment tothe shaft. These bearings are mountedinto a square flange which in turn isattached to an angle or channel frame.Cooper Bearing Company hasdesigned a split square flange (DF line)to suit such applications.

Advantages of CooperThere are several advantages to usingCooper Split Roller Bearings in fin fanapplications. The solid bearingscurrently used on most fin fans areheld in place with set screws. Whenthat bearing fails, the set screws tear upthe shaft requiring the whole fan to beremoved and the shaft to beremachined. A Cooper bearing clampsto the shaft and the inner race protectsthe shaft when the bearing eventuallyfails. Without shaft damage, the fandoes not have to be pulled. A crane isno longer needed to switch out thebearings.

This not only reduces downtime but itremoves the risk of damaging the fin tubesupon extraction of the shaft.

Lubricant leakage is a problem on a verticalshaft. Most other bearings have contactseals where the shaft turns inside the seal.Eventually the seal wears and lubricationseeps through along the shaft. CooperBearing’s Aluminum Triple Labyrinth Seal(ATL) is clamped to and spins with theshaft.Two “O” rings in the bore of each ATLgrip the shaft and form a complete seal.This eliminates wear and does a muchbetter job of keeping the lubrication in thebearing over long periods of time.

With the use of retaining rings and aCooper Split Roller Bearing, a fin fan can beset up and properly aligned one time. Fromthen on, all of the fin fan components canbe referenced from the fixed bearing inposition. There is no need to realign orreposition the fan after each bearing changeout.

Bearing Selection DataTo calculate fan speed, the output rpm ofthe motor and both motor and fan sheavediameters are needed. The two sheaves areusually connected by V-belts under tension.Under running conditions the belt tension,causes a radial load on the bearing at thebase of the shaft. This radial load is alsoknown as belt pull. Belt pull can becalculated from motor hp, motor speed, andsheave diameters.

The axial load can be calculated from theweight of the blades and the shaft, plus thestatic pressure and blade diameter. Giventhe length and diameter of the shaft theweight can be calculated.

Usually the static pressure is only one totwo inches of water gauge, so only theblade diameter is needed.

Additional Information - Vertical Shaft ApplicationsBearing selection is based on holding up theshaft. For fin fan applications Cooper canhandle up to 1380 lbs. of axial force at 500RPM.



Fin Tube Cooling Fans- Continued


At slow speeds, a bearing has more thrustcapacity than clamping capacity. It is generalgood practice for vertical shafts to add 20%to the normal clamp ring screw torque.This is 50 inch lbs. for 01 series bearings inthe size range 1-11/16" to 3". A torquewrench is needed for consistent accuracy.Inaccurate torque may lead to shaft slippageand early failure. Retaining rings may alsobe used to prevent the shaft from slippingthrough the bore of the fixed bearing.

Lubrication and Shaft ToleranceA high temperature grease should be used forapplications above 180°F, typical for the topbearing on a fin fan. In general, a hightemperature grease with a VG 460 base oil andan EP additive is recommended. Examplesinclude Chevron Ultra Duty #2, Exxon RonexExtra Duty Moly, Lubricating Engineers 1250Almasol, Mobil Mobiltemp 78, and TexacoStarplex Premium.

The tolerance for most fin fans is +.000, -.003".Roundness and taper should be held to .001".

Most chemical plants and refineriesprovide huge opportunities for Cooperbearings on fin fan applications.


Flocculators


Where To Find Flocculators...

What To Look For...

Flocculators can be found at water filtration plants in medium to larger size towns and cities where dirty water may be a problem.The smaller cities generally buy their water from adjacent larger cities, and do not require their own filtration plants.

Note: flocculators are not found in thewaste water industry.

Typical horizontal paddle wheel flocculator.

Application DescriptionMost drinking water is stored in surfacereservoirs where the water picks upmaterials such as dirt and plant matter.To remove these materials a method calledflocculation is used.

Water is pumped from the reservoir into abasin about 8' deep, 15' wide, and 80 to100' long. Chemicals called flocculants areadded that cause the dirt and plant matterto bind together into larger particles sothey can be more easily filtered out.Tothoroughly mix the flocculants with thewater, a lineshaft in the bottom of the basinhas a number of paddle wheels turning at aslow speed (usually 10-12 rpm)

The 2 to 5" diameter lineshaft runs thelength of the basin and is supported by upto a dozen bearings.Typically there is achain drive at one end, or in the middle ofthe shaft, supported by one fixed bearing,and the remaining bearings are allexpansion bearings.

The three common arrangements arehorizontal paddle wheels, walking beams,and vertical mixers.The horizontal paddlewheel is the most common arrangement.

Advantages of CooperThere are several advantages to choosing aCooper bearing for use on flocculators.Thesplit design of the bearing allows for ease ofinspection and the ability to change abearing without removing othercomponents from the shaft.

The aluminum triple labyrinth seal, alongwith a full pack of grease, will prevent anychemicals, sediment, crustacean from Zebramuscles, or other foreign materials fromentering the bearing, while submerged inthe flocculator basin.

Due to inadequate sealing, other bearingsfail from these contaminants and destroythe shaft as they fail.This not only requires alengthy down time to fix the problem but acostly maintenance item to replace theworn shafts.With a Cooper, the bearingsand shaft can be inspected when the basinis drained once a year for routinemaintenance.

Bearing Selection DataIn most flocculators the radial load isminimal, so the 01 series bearing is used. Itis still important to note the shaft speedand shaft size.The length of the lineshaft isnecessary.

The drive arrangement, direct or chaindriven, along with its location (at the end ofthe shaft or in the middle of the shaft) isrequired.


A water filtration plant where flocculators are found


Flocculators - Continued


The type of couplings used, rigid or flexible,must also be known.The maximum watertemperature in the summer and theminimum water temperature in the winterwould also be helpful.

A rough sketch of the arrangement (seelineshaft data sheet) is also needed.

Additional Information - Bearing LifeThe biggest factors in bearing life are thecondition and alignment of the shaft. Anundersized or rusted shaft reduces the“grip” of the seal to the shaft. A poorlyaligned shaft “cranks” at the bearing,opening and closing seal contacts.

In one city, where all the shafts were withintolerance and laser alignment wasperformed, they have experienced noCooper failures in 15 years with 140Cooper bearings in service.

LubricationFor flocculator applications we recommendusing an aluminum complex food gradegrease.While aluminum complex resistswash out, it is not compatible with manyother types of grease. Prior to addingaluminum complex grease, the bearingshould be solvent cleaned of other greases.

A typical horizontal paddle wheel flocculator

Due to the slow speeds andsubmerged location, a full pack ofgrease should be used.

For routine greasing, grease lines shouldbe run from the surface down to thebearing.


Gear Drives


Where To Find Gear Drives...

What To Look For...

Gear drives can be located in plants where several machines next to each other are to be powered from the same drive unit.Typically, the shaft is perpendicular to the machinery, with bevel gears used to redirect the power. Gear drives are also used to reduce shaft speed from one shaft to another by varying the gear diameters..

A large spur gear can be seen behind the two herringbone gears.

Application DescriptionGear drives are used to transmit motionfrom one shaft to another.They can beclassified into three categories; spur gears,helical gears, and bevel gears.

Spur gears are used on machinery on lowspeed applications to transmit motion fromone shaft to another parallel shaft.

Helical gears are used when high speeds areinvolved with large power transmission, orwhere noise dampening is important. Bevelgears are used to transmit power betweenintersecting shafts.

Advantages of CooperThe primary advantage of a Cooper bearingis the split design. In some cases there maybe several gears on a common shaft.The splitdesign allows for installation and visualinspection of the bearing in trappedpositions, without removing any othercomponents from the shaft.This reducesdown time from several days to hours.

Bearing Selection DataIn order to calculate the loads placed on thebearing, for any type of gear the motorhorsepower and speed must be known.

Spur GearsSpur gears can be identified from their teeththat are parallel to the axis of rotation.Thesmaller of the two mating gears is called thepinion.The larger is often called the gear, orbull gear.When in operation they do notexert an axial load on the shaft.For this reason, the main concern for a spurgear is the radial load produced by the gearreaction. For each gear, the pitch diameterand number of teeth is required.Thepressure angle of the mating gears shouldalso be known.There are two commonpressure angles for spur gears, 14° and 20°.

Helical GearsHelical gear teeth are cut in the form ofhelices, making a constant angle with respectto the gear axis.When using helical gears,the helix angle results in a thrust load inaddition to the resultant radial load.Tocalculate both loads, the pitch diameter andnumber of teeth are required.The pressureangle and helix angle must also be provided.

Bevel GearsThere are four types of bevel gears; straight,zerol, spiral, and hypoid. Straight bevel gearsare used for slow speed (below 1000ft/min).The other three types are used forhigher speeds where vibration and noisereduction are important.

It is important to note if the bevel geardrive is a reversing type. If so, the shockloads typically exceed the thrust capacity ofa Cooper bearing. Please consult theengineering team for further information.


Lineshafts and Marine Propulsion Shafts


Where To Find Lineshafts...

What To Look For...

Lineshafts are typically found in pre - World War II paper mills, flour mills, textile mills, etc.They are also widely used in marine vessels.

A typical wall mounted mill lineshaft with belt driven power take-off shown in the bottom left.

Application DescriptionA lineshaft is a method of carrying powerfrom a single source to one or moremachines.This is done by joining sections ofshaft together with couplings to achieve thedesired length of shaft.

In order to power other pieces ofequipment a power take off (sheave, pulley,sprocket, gear, etc.) is attached to the shaft.A belt or chain is then connected to thepower take off and to the shaft of themachine.

Originally, a water wheel was used toprovide the power to a shaft that ran thelength of the mills. As steam turbinesbecame available they replaced the waterwheel, and with the advent of electricity,large motors took over. It wasn’t untilaround 1950 that lineshafts were replacedwith individual drives for each piece ofmachinery.

However, many old mills still use a lineshaftto transmit power to their machines. Milllineshafts can have the power source at oneend or somewhere near the center.Theymay be a few feet long or several hundred.A single shaft diameter may be maintainedthrough the full length or several stepdowns may occur.

Marine lineshafts will probably be in use forquite some time. In order to balance a shipthe heaviest components, such as theengine and reduction gear, must be near thecenter of the vessel (amidship).

The main propulsion is usually located atthe back of the ship (stern) andmaneuvering power (bow thruster) at thefront.To transfer power from the engine tothe propulsion units a line shaft is required.Since all marine shaft bearings are supportbearings (no sheaves or sprockets to

support), they are usually 01 series. A fewhigh powered vessels use 02 series bearings,but the majority only require 01series.Because the thrust loads are greater thanwhat a Cooper or almost any other fixedtype bearing can handle, a special flat thrustbearing is required. It is usually located inthe reduction gear box between the engineand intermediate shafting.To calculate theradial and thrust loads applied by the bevelgears, the pitch radius of the gear and thepressure angle of the gear teeth must beprovided.The cone angle made between theaxis of the shaft and the gear teeth is alsorequired.

Advantages of CooperThe primary advantage of using Cooperbearings is the split design. In lineshaftapplications it may be very difficult to installa solid replacement bearing due to theposition of the power take offs, and anycouplings.

Cooper also offers an SAF compatible lineof pedestals, which are drop inreplacements for many SAF style pillowblocks.

Bearing Selection DataOn a typical lineshaft the power take offmay be a sheave, pulley, sprocket, or gear.Depending on what type there is, differentinformation is required to make the properbearing selection. For all arrangements, thedrive horsepower, as well as thehorsepower of the machine(s) being drivenshould be known. Also, the shaft speed andshaft diameter(s) is needed.

Belt or Chain DriveThe type of drive (belt, rope,V-belt, orchain) must be noted.The drivensheave/sprocket diameter and the drivesheave/sprocket diameter is required.

Gear DriveThe pitch diameter of each gear isneeded. Also, the number of teeth (orpitch) and pressure angle is necessary.

A rough sketch of the arrangement(see lineshaft data sheet) is alsoneeded.

Additional Information - Intermediate SupportThe distances between power take offscan be large. A shaft will sag under itsown weight and will create a slope inthe shaft. A slope greater than 1/2500will cause a cylindrical roller bearing toedge load, and fail. A rule of thumb isto support the shaft at intervals of 20times the shaft diameter.


A Schottel system, or Z drive uses a centralengine to power remote gearboxes.Theconnecting shafts are joined by flexiblecouplings and universal joints. Each sectioncan be treated as independent and isusually supported by two bearings, onefixed (GR) and one expansion (EX) bearing.

Lineshafts and Marine Propulsion Shafts


The actual length at which the shaft sag willexceed the bearing’s ability to align itself,can be computed based on the diameter ofthe shaft.

Non Essential Bearing PositionsIn cases where independently poweredequipment has replaced equipment drivenby the line shaft, bearing positions may havebeen kept on the lineshaft that no longerserve any purpose. If there are bearings in alocation that no longer has additional radialload on them from a power take off, thereis a good possibility that the bearings aretoo lightly loaded and will fail due toskidding.

Bearing LocationThe location of fixed (GR) bearingsdepends on the location of the powersource and number and type of couplings.Exactly one fixed bearing is required foreach solid section of shafting. A solid sectioncan be created by joining separate sectionsof shafting with rigid couplings.

Separate sections can be achieved by joiningpieces of shaft with flexible couplings or byseparating them with the drive unit (locatingthe power source near the middle of thelineshaft). If the power source is located atone end and all couplings are rigid, a singlefixed (GR) bearing would be usedregardless of the shaft length.

In marine applications where the thrustloads are significant on ordinary propellershafts, a special flat thrust bearing is used inthe fixed position.This arrangement requiresthat all intermediate positions use expansion(EX) bearings.

A typical propulsion shaft arrangement utilizingCooper split bearings of various sizes.

The use of Cooper bearings in limited accesspositions is a distinct advantage.


Lumber Drying Kiln


Where To Find Drying Kilns...

What To Look For...

Dry kilns can be found wherever there arelarge lumber mills.This is typically in theNortheast, Northwest, and South, wherethe lumber industry is prevalent.

A typical lumber mill drying kiln.

Application DescriptionLumber dry kilns are used to dry lumberbefore it is processed.The kilns reduce thetime it takes for the raw lumber to properlydry before it can be cut into dimensionallumber. Generally, they are large metalbuildings with access doors on the two longsides.They vary in size, but are commonly60 - 100 feet wide by several hundred feetlong.

In order to dry the lumber, steam iscirculated through coils near the roof of thebuilding.The hot air is circulated throughthe coils and building by use of a fan.Theshaft runs the width of the building, andconnects to a motor outside.Thetemperatures inside the kiln are generallybetween 250°F and 300°F.

Each shaft is driven by a separate motor,typically 5 or 10 hp, running at a speed of600 to 1000 rpm.The shaft diameter inthese applications is usually less than 3" indiameter.

Advantages of CooperThe primary advantage of using Cooperbearings is the split design.The bearings aremounted near the roof, onto an I-beamthat spans the width of the building.Thismounting arrangement places them in atrapped position.The split design allows forinstallation and visual inspection in trappedlocations on top of the I-beam.

Another advantage of Cooper is theAluminum Triple Labyrinth or ATL seal.TheATL seal clamps to and spins with the shaft.In a high temperature application such asthis, it is necessary to replace the standardBuna/Neoprene “O” rings in the seal, withViton “O” rings.The Viton “O” rings arecapable of operating at temperatures up to350°F.

Bearing Selection DataTo calculate the fan speed, the output rpmof the motor is needed. Also, the fan sheaveand motor sheave diameters are required.The two sheaves are usually connected byV-belts running under tension. Underrunning conditions the belt tension causes aradial load on the bearing.This radial load isknown as the belt pull.The belt pull can becalculated from the motor horsepower,motor speed, and sheave diameters.

The axial load can be calculated from thediameter of the blades , and the staticpressure. Given the length and diameter ofthe shaft, the weight of the shaft can becalculated. Usually the static pressure is onlyone inch of water gage, so only the bladediameter is needed.

To determine the proper lubrication andbearing selection, the temperatureinside the kiln and the ambienttemperature is necessary.

Additional Information -Bearing LocationIn these applications, the fixed bearing canbe mounted in two possible locations. Onemounting arrangement can have the fixedbearing outside, next to the motor. Anadvantage of this placement is that thebearing will run cooler.The other bearinglocation is next to the fan.This is thepreferred position if the fan is a reversingtype. In other dry kiln applications, bothmounting arrangements have beensuccessful.

LubricationDue to the relatively slow speed and hightemperature (above 180°F), a hightemperature grease should be used.

In general, a high temperature grease witha VG 460 base oil and an extreme pressure(EP) additive is recommended. Examplesinclude Chevron Ultra Duty #2, LubricatingEngineers 1250 Almasol, and TexacoStarplex Premium.

Viton ‘O’ RingsIn a lumber dry kiln application, C3clearance between the rollers and the outerrace, is not necessary. Since the bearings aremounted inside the kiln, they are at thesame temperature as the shaft, and willexpand at the same rate. However, due tothe high temperatures, it is necessary tospecify that Viton “O” rings be used in theATL seal to replace the standardBuna/Neoprene “O” rings.


Motors and Generators


Where To Find Motors and Generators...

What To Look For...

Motors can be found in any plant or manufacturing facility where large machinery is operated, such as steel mills.Generators are widely used in the power industry, such as hydro electric power plants.

The most common arrangement has a center hung rotor supported at each endby a bearing.There are also single bearing arrangements as well. Pillow block and flange mounts are used.

Application DescriptionMotors are used to power equipmentdirectly; while generators are used toproduce electricity to power otherequipment.The output of a motor orgenerator is measured in Watts (W) orthousands of Watts (kW), or horsepower(Hp). Cooper has provided bearings forunits where the power output is a fewhundred kW to several thousand kW. Shaftsizes can range from 3 –1/2" to 36".

Advantages of CooperThe split design of the Cooper bearingallows for installation and inspection intrapped locations.The cylindrical rollersused in a Cooper bearing are excellent forhigh speed, high load applications. A Cooperbearing can operate at high speeds usinggrease lubrication, where a tapered orspherical roller can’t operate at that high ofspeed or would require oil lubrication.

One of the more common bearings beingreplaced with a Cooper bearing is a RENKsleeve bearing.This bearing requires apressurized oil lubrication system.With aCooper running on grease lubrication, theexpensive cost of an oil system iseliminated.

Bearing Selection DataWhen making a bearing selection formotors or generators, the weight of therotor and shaft is required.The operatingspeed is also necessary. It is also importantto note if a variable speed motor is used.The type of coupling should also beidentified. A sketch would also be helpful todetermine the bearing location and therequired mounting arrangement.

Mill Motors using Cooper split roller bearingswith high rise pedestals.

Additional Information - Mounting ArrangementsThe most common mount is a flange.Whenusing a pillow block, if a platform is notprovided for mounting the pillow block, ourspecial high rise pedestal can be used. Pleaseconsult the engineering department foradditional details, if necessary.

Electrical Specification (EL)The electrical specification is a companyprocedure involving re-inspection andselective assembly to ensure that thetolerances of the locating spigot, the bearingcomponents, and the spherical seat betweenthe cartridge and pedestal or flange, are inthe mid to low range of their respectivetolerances.

The units will then be marked indicating theEL specification has been met.

LubricationExtensive research was done in cooperationwith a motor/generator OEM to find onegrease that would meet a wide range ofoperating conditions (speed, loads, and shaftsize). It was determined that a hightemperature grease with a lithium complexthickener and extreme pressure additivesshould be used.

This grease should have a viscosity grade(VG) of 460. Some greases that meet thiscriteria are Lubricating Engineers 1250Almasol and Texaco Starplex Premium.


Pilger Mills


Where To Find Pilger Mills...

What To Look For...

Seamless tubing is used in the chemical industry, some high pressure natural gas transmission lines and nuclear power plants. It is not surprising then that the builders of nuclear power plants,Westinghouse, General Electric and Combustion Engineering operate seamless tube mills. Tubing for the chemical industrytends to be exotic alloys made by specialty metal companies such as Sandvik Special Metals, Altech Specialty Metals and INCO Alloys.

A removed crank shaft from a pilger mill.

Application DescriptionPilger mills convert a round billet intoseamless tubing. The billet may start out12" (300mm) in diameter with a small holethrough the center and end up 3/4"(19mm) in diameter. The billet is runthrough a die that reduces diameter whileincreasing length. The billet may start thepilgering process 20' (6 meters) long or lessand end as several hundred feet (100 ormore meters) of seamless tubing. Thetubing can be copper or copper alloy,stainless steel or more exotic alloys.

The driving force is a large weight known asthe mass compensator that moves verticallyupward slowly under power and is thendropped suddenly to draw the billetthrough the die. The heart of the machineis a crankshaft with five split and two solidring bearings on it. The solid ring bearingsare conventional double row sphericalsmounted in the machine box on either endof the crankshaft. They support half theload on the shaft.

Two bearings inboard of the pillow blocksare mounted in special connecting rods(con rods) that support the vertically

moving large weight. Two bearingsinboard of the weight bearings are alsomounted in con rods that runhorizontally to the die saddle. These areusually called the saddle bearings. Thelast bearing is mounted in a rigid housing,supports the center of the crankshaft andis called the center main.

The crankshaft rotates driving the weightup and moving the die back onto thebillet. When the weight falls the diedraws the billet forward squeezing it intoa thinner and longer shape. While thecrankshaft is rotating the con rodssupporting the weight are moving up anddown and the con rods pushing the diesaddle are moving back and forth. Thisaction is called reciprocating and causessignificantly different loads on thebearings than simple rotation.

Pilger mill bearings are special in anumber of ways. To reduce the shockload as the weight is dropped and the diemoves forward the internal clearance iskept to a minimum. The minimumbearing clearance is called C2. The innerrace of the bearing has a special chamfer

on the inside diameter and grooves on thesides. These modifications enable it to fittightly against the sides of the crank andallow lubrication to flow to the bearing.The cage has an extra strong joint that usesa steel ring with two screws securing eachhalf. The sides of the cage have flangesprojecting outward to contact the lips ofthe GR outer race. The outer race is aspecial “set out” design that enables it togrip the rod end more tightly thanconventional bearings.


Pilger Mills


The clamp rings have a specially groundoutside diameter so seal rings can ridethere and have gaskets at the joints.

Advantages of CooperThe nature of the crankshaft makes asplit bearing the only alternative for thebearings in these locations.

Bearing Selection DataNormally we want to know five thingsfor a proper bearing selection. In thecase of pilger mill bearings we need toconcentrate on three.

Shaft size, as always, is a must. Speed,in this case expressed as cycles perminute, must also be known. The radialload is our primary concern and canbe calculated from the amount ofweight being dropped and how far itdrops. Pilger mills have certaincharacteristics in common.Because they are indoors and we knowthe life expectancy of the bearings, wedo not need to know the environmentor expected life.

Additional InformationThe assembly of Cooper bearings on apilger mill crankshaft is critical tobearing life. Because the load isreciprocating, the peak load of eachcycle hits the inner race in the sameplace each revolution. It is essential tothe life of the bearing to place theinner race joints 90 degrees away fromthe point of peak load. There shouldbe a drawing showing where the innerrace joints should be placed relative totop center on the crankshaft.

The seals are also critical to bearing life. Ina survey done in 1997 indicated that thetwo biggest causes of bearing failure werethe condition of aging machines and thewash out of bearing lubricant by the dielubricant. Careful assembly and greasing ofthe seals is required to hold bearing greasein the bearing while excluding die lubricant.

Lubrication is critical to the life of anybearing. The tremendous loads andrelatively low speeds make lubricationdifficult. In general an NLGI #2 grease witha minimum VG 460 base oil viscosity and anEP additive are required. Resistance towash out is another important property.These properties are commonly found inhigh temperature greases. An alternative isto use synthetic grease with a minimum VG460 base fluid viscosity.

NEVER MIX SYNTHETICAND NON-SYNTHETICGREASES IN A BEARING


Roll Tables


Where To Find Roll Tables...

What To Look For...

Roll tables are found wherever metals are processed. This includes galvanizing lines, sheet metal coating facilities, rolling mills and casters. Both steel and aluminumare handled using roll tables. There are large numbers of bearings involved, two per roll on dozens or even hundreds of rolls. The best market for Cooper is wherethe environment is harsh, either from water spray or metal particles.

Overhead view of roll table at the exit of a reheat furnace is shown on the left.

Application DescriptionRoll tables are used to transport sheet,plate or slabs of metal through a variety ofprocesses that include rolling, coating andcooling. They consist of a number of rollsplaced side by side to form a table betweentwo process steps. There are usually guidesof some type on either side of the rolls tokeep the flat strip metal on the rollers. Thesteps can be between a reheat furnace androll stand, unwinder and coating process(paint or galvanizing) or slab caster andcooling bed. The environment frequentlyincludes heat, metal particles, water spray ora combination of the three.

A roll table consists of sections, typically offour rolls each, mounted on a steel frame.One or more of the rolls in each sectionare driven and the remainder are idlers.When a problem develops the entire “four-pack” can be removed for maintenance in ashop area.

Advantages of CooperMost of the original equipment solid ringbearings are either tapered bore with anadapter mount or straight bore thatrequire a complex three step shaftarrangement with a threaded section.Installing adapter mount bearings requiresproper tightening of the lock nut on theadapter. Too loose and the bearing slips,too tight and the clearance is removedfrom the bearing. Both problems lead topremature and frequent bearing failures.The clearance in a Cooper bearing ispreset, just clamp it to the shaft with therecommended torque on the clamp ringscrews.

When the straight bore bearingseventually fail, the shaft is damaged. Thecomplex shaft arrangement with threesteps and a threaded area make shaftrepair a major job. Cooper bearingsclamp to the shaft. When the bearingeventually fails it can be removed bycutting or burning the clamp ring screws.

In a hostile environment there is no betterseal on the market than Cooper’s aluminumtriple labyrinth (ATL) seal. Depending onspeed and temperature a full pack of greasemay be used to further enhance the ATLseal capability. If conditions are notfavorable for a full grease pack, grease portscan be added to the cartridge enablinggrease to be pumped directly to the seallabyrinth.

Standard Cooper bearings are often not adirect match for the bearings already inplace. Due to the large number of bearingsinvolved in a roll table we have been willingto make special pedestals, seals and othercomponents to fit the end user’s needs.When shaft modifications have beennecessary, as with three step shafts, Cooperhas provided detailed drawings to the enduser for their shaft modifications at nocharge.

Bearing Selection DataLike all other applications, we must knowthe shaft size. On rolls where there is a


Roll Tables


solid ring straight bore bearing and a threestep shaft, we must also know the existingbearing and housing numbers and how longthey are lasting.

Average life of the existing bearings can bedetermined most quickly from the totalnumber of rolls (times two bearings per roll)divided by the number of bearings replacedin the past year.

Radial load will depend on the roll designand thickness, width and type of materialbeing carried.

The best way to determine the roll weightand shaft arrangement at the bearings is toget a drawing of the roll.

The environment is a big factor. The twomain components of the environment from abearing standpoint are temperature andcontaminants (water spray or metalparticles).

Last but not least we will need the speed ofthe rolls in rpm.

Additional Information -Lubrication and MaintenanceMost relatively slow moving applications,especially with elevated temperatures,require a heavier lubrication than standardbearing grease.

Generally roll table bearings demand alubricant with EP additives and a VG grade460 base oil. Examples of these includeMobil Mobiltemp 78,Texaco StarplexPremium, and Lubricating Engineers 1250Almasol.

Timely and frequent lubrication is a must tofulfil the expected life of a bearing.Generally, for roll tables, relubrication shouldoccur every two to four weeks.

Side view of a steel mill roll table

Relubrication coats the contacting surfaceswith fresh grease, and purges any fineparticles out of the bearing that wereattempting to move past the triple labyrinth.


Screw Conveyors


Where To Find Screw Conveyors...

What To Look For...

Screw conveyors can be found wherever there is a need to convey granular or powder like materials or where bulk materials must be conveyed.They can be found in the following industries, food processing, paper, sugar, and feed mills.

Image of a typical horizontal screwconveyor shown on the left.

Application DescriptionScrew (or scroll) conveyors are used toconvey many types of material, such as flour,lime phosphate, sugar beet pulp, cement,gypsum dust, and feathers.

The material is fed into a trough where it isthen moved axially by the rotating screw, orflights until it reaches the discharge.Thetrough can be horizontal or inclined.Theshaft diameter usually ranges from 3" to 6".

Typically the screw conveyor is direct driventhrough a gear reducer.The operatingspeeds range from 10 rpm to 120 rpm,usually with a 5 Hp to 100 Hp motor.

Advantages of CooperThere are several advantages to choosing aCooper bearing for use on screwconveyors.The split design of the bearingallows for ease of inspection and the abilityto change a bearing without removingother components from the shaft.

If intermediate supports are used, the screwor flights usually can not be disassembledand a split bearing must be used.

Provided the operating speed is slow

enough, less than 2000" dn (dn = shaftsize x rpm), a full pack of grease could bemaintained.The combination of ouraluminum triple labyrinth (ATL) seal anda full pack of grease has proven to be avery effective method in keepingcontamination from entering the bearing.Due to inadequate sealing, other bearingsroutinely fail from the contamination.

Bearing Selection DataScrew conveyors are typically high thrustapplications.The amount of thrustdepends on many variables, such as thefriction of the material being handled, itsmoisture content, the volume of materialin the trough, the smoothness of theflights and the trough sides, etc.

Since there are so many factors indetermining the thrust, it is nearlyimpossible to calculate. If the followinginformation could be obtained, anapproximation of the thrust load can bemade.

The shaft size and shaft speed must beknown.The horsepower must also be

provided.The screw or flight diameter isnecessary.The weight of the screw shouldalso be known.

Also note if the trough is level or the angleof incline and the type of material beingconveyed.

Additional Information - Clamping ForceThe thrust capacity of the fixed bearing atlow speed is higher than the clamping forceof the clamp rings.When the thrust capacityof the bearing is sufficient, but the clampingforce is not sufficient to hold the axial force,the shaft will slip through the bore of theinner race.

This situation requires the inner race to befixed to the shaft in such a way that theshaft cannot slip through.The inner race canbe mounted in a recess, or betweenretaining rings. If stainless steel shafting isused, the use of retaining rings or a recess isrequired.

Bearing LocationIn these applications, the fixed bearing isusually located at the discharge end.This


Screw Conveyors


will help keep the screw in tension andprevent it from buckling.

Mounting ArrangementsThe screw is typically supported at eachend of the trough.These bearing locationscan be pillow block or flange mounts.The intermediate supports, if necessary, caneither be hanger mounts (see picturebelow) or inverted pillow blocks.Wheninverted pillow blocks are used, thecartridge is usually rotated approximately120° inside the pedestal.

This will keep the lube boss near top deadcenter so that the bearing can be lubricatedmanually or remotely without interferingwith the operation of the screw.

As well as the standard hanger bearing, Cooperoffer a triple mount hanger (shown below) and a stainless steel housing for use in the food industry (shown above).


Waste Water Treatment


Where To Find Water Treatment...

What To Look For...

In the late 1980’s the United States government cracked down on municipalities that were not treating their waste water. This led to a change in the size and nature of treatment plants.

They are no longer confined only to largecities or even just to municipalities alone.Many smaller towns now require certain industries to pre-treat waste water beforedumping it into the municipal system.

These industries include chemical, paper and meat packing.

Rotating Biological Contactors.

Application DescriptionOur two biggest applications in sewagetreatment have been Rotating BiologicalContactors (RBC) and brush type aerators.Aerators and RBC’s are used for a methodcalled biological treatment. Bacteria,sometimes called “bugs”, are introduced towaste stream to consume the sewage.

The bugs require a substantial amount ofoxygen to grow and the BOD (biologicaloxygen demand) is supplied by pushing airinto the water through aeration orexposing the biomass (bugs) to the air withan RBC.

A brush type aerator consists of a shaftspanning the waste stream or ditch.Attached to the shaft are galvanized steelor wooden paddles with something lessthan half their diameter submerged in thewaste water. Air is pushed into the waterby the paddles and some water is pushedinto the air. Both functions serve toincrease the level of dissolved oxygen in thewater.

Shaft sizes vary with width of the ditchand diameter of the paddle wheel. Thedrive is usually a motor and gearbox of25 to 50 hp (18 to 35 kW) with theaerator shaft speed under 60 rpm.Bearings will be 01 or 02 series accordingto load and L-10 life requirements. Pillowblock mounts on either side of the ditchare the common support.

RBC’s also consist of a shaft spanning thewaste stream ditch. A large number oftextured disks resembling oversizedplastic waffles are placed on the shaftuntil it looks like a solid roll of the samediameter of the disks. The roll issubmerged to varying extents in thewaste stream. The biomass is introducedonto the large surface area created bythe disks. As the shaft rotates thebiomass on the disks is alternatelyexposed to the air and waste stream.

RBC’s began to suffer shaft failures as thebugs grew and the weight of biomassclinging to the disks increased.

The solution was to increase the portion ofthe disks that was submerged. This solutionhad the dual benefit of making the biomass“lighter” when submerged and increasingthe contact time of the bacteria with thewaste water. The unhealthy side effect wasthat the shaft and bearings becamesubmerged. With the speeds low enoughto allow for a full pack of water resistantgrease, Cooper had a solution to offer.

Advantages of CooperThere are several advantages to choosing aCooper bearing for use on aerators andRBC’s.The split design of the bearing allowsfor ease of inspection and the ability tochange a bearing without removing othercomponents from the shaft.


Waste Water Treatment


The aluminum triple labyrinth seal, alongwith a full pack of grease, will prevent anychemicals, sediment, or other foreignmaterials from entering the bearing, whilesubmerged in operation. Due toinadequate sealing, other bearings failfrom these contaminants and destroy theshaft as they fail.This not only requires alengthy down time to fix the problem buta costly maintenance item to replace theworn shafts.With Cooper, the bearingsand shaft can be inspected during routinemaintenance.

Bearing Selection DataFor bearing selection purposes theweight of the rotor assembly can beassumed to be equally divided betweenthe two bearings. The load resulting fromthe drive torque will be applied to thedrive side bearing only. The followinginformation will be required:

1. Shaft diameter

2. Motor power and speed

3. Gearbox reduction ratio

4. Weight of the rotor

5. Diameter of paddles

Additional InformationThe bearing must be packed full of awater-resistant grease during assembly.The best way to keep a full pack in thebearing is with regular re-greasing. Forsubmerged bearings, the best way toprovide regular re-greasing is by runninga length of tubing from each bearing toan accessible area. Remember to fill thetube with grease before connecting tothe bearings.

A T y p i c a l D i s k T y p e A e r a t o r

A Ty p i c a l R o t a t i n g B i o l o g i c a l C o n t a c t o r

A series a waffle textured disks placed side by side on a center shaft to create an apparentlysolid roll. This method creates a very large surface area for water to contact the biomass.

A series of radially oriented paddles along a common shaft create a “brush” type aerator. The rotating paddles push air into the water and kick up water into the air. Oxygen becomesdissolved in the water so the bacteria can breathe and grow.


Bearing Selection Data Sheet - General Applications


END USERName: Company:Address:Telephone: Fax: Email:

DISTRIBUTORName: Company:Branch Address:Telephone: Fax: Email:

EQUIPMENTEquipment Name or Number:Equipment Manufacturer :

SHAFT LIFEShaft Diameter: Current Bearing Life:Current Bearing: Expected Bearing Life:

SPEEDBearing RPM:or Motor Speed: and Sheave Diameter:or Motor Speed: and Gearbox Ratio:or Feet/Minutes: and Head Pulley Diameter:

OPERATING ENVIRONMENTWet Environment, Please Check:

Yes: No: Splashed or Sprayed: Submerged: Exposed to Elements:

TemperatureShaft Temperature: Ambient Temperature: Other Heat Sources:

ContaminationMaterial:Extent of Contamination, Please Check: Light: Medium: Heavy:Do Bearings Fail Due to Contamination? Yes: No:

LOADType of Drive, Please Check:Direct Drive: Coupling Type: Flex Coupling: Rigid Coupling:Reduction Gear: with a Ratio of:Belt Drive: with a Sheave Diameter of:

SKETCH OF APPLICATION AND COMMENTS SAMPLE SKETCH






SPEEDBearing RPM:or Motor Speed: and Gear and Sprocket Ratio:or Trunnion Diameter: and Trunnion Speed:





LOADType of Drive, Please Check:Pinion Drive: Chain Drive: Trunnion Drive:Drive Horsepower: Vessel Diameter: Angle of Incline:Weight of Vessel, Balls or Hammer: Material:

Bearing Selection Data Sheet - Ball and Hammer Mills


SAMPLE SKETCHSKETCH OF APPLICATION AND COMMENTS


Bearing Selection Data Sheet - Conveyor Applications






SPEEDBearing RPM:or Motor Speed: and Gearbox Ratio:or Motor Speed: and Head Pulley Diameter:





LOADType of Drive, Please Check:Direct Drive: Drive Horsepower:

Shaft Mounted Speed Reducer:Yes No If Yes,Weight of Speed Reducer:

Flat BeltBelt Drive V-Belt

Chain


Bearing Selection Data Sheet - Conveyor Applications


LOAD - Continued PULLEYNumber of Motors: Lagged or Plain Please CheckAngle of Incline: Pulley DiameterTotal Drive HP: Belt Weight: (lbs/ft).FPM: Degree of Wrap:Belt Width:Overall Length:

SKETCH OF APPLICATION AND COMMENTS





SHAFT LIFEShaft Diameter: Current Bearing Life:Current Bearing: Expected Bearing Life:Vertical: or Horizontal:

SPEEDBearing RPM:or Motor Speed: and Motor Sheave Diameter:or Motor Speed: and Fan Sheave Diameter:





Bearing Selection Data Sheet - Fan and Blower Applications



LOADType of Drive, Please Check:Direct Drive: Belt Drive:

Drive Horsepower: Weight of Fan Wheel:

TELNI ELBUODTELNI ELGNIShtdiW elbuoD - WD htdiW elgniS - WS:PH rotoM

telnI elbuoD - ID telnI elgniS - IS:MFCTotal Drive HP:FPM:Inlet Diameter:Static Pressure:

SKETCH OF APPLICATION AND COMMENTS Please fill in dimensions ESPECIALLY for Overhung Arrangements

Bearing Selection Data Sheet - Fan and Blower Applications



Chain

Belt drive center hung fan Belt drive overhung fan

Direct drive center hung fan Direct drive overhung fan


Bearing Selection Data Sheet - Line Shaft / Marine Propulsion Applications






SPEEDBearing RPM:or Motor Speed: Gear and Sprocket Ratio:or Motor Speed: and Speed Up: or Slow Down:






M T P C

Bearing Selection Data Sheet - Line Shaft / Marine Propulsion Applications


LOADType of Drive, Please Check:Direct Drive: Through Gearbox: Belt Drive: Drive Horsepower:

Are Power Take Offs (Sheaves/Pulleys) Drawing Equal Horsepower? Yes: No: Please Check

ORIf No,Which Draws the Majority Load?

PART LEGEND

MOTOR(Include HP)

TURBINE(Include HP)

RRIGID

COUPLING(Inside Diameter) F

FLEXIBLECOUPLING

(Inside Diameter)

HHELD

BEARING

EEXPANSION

BEARING

PULLEYOR

SHEAVE

CONE PULLEY(Arrow indicates

direction of slope)

ARRANGEMENT

DistanceInches

A

B

B

A


Bearing Selection Data Sheet - Mixers and Agitators






SPEEDBearing RPM:or Motor Speed:or Motor Speed: and Motor Sheave Diameter: and Mixer Sheave Diameter:



TemperatureShaft Temperature: Surrounding Temperature: Other Heat Sources:



LOADType of Drive, Please Check:Direct Drive: or Belt Drive:

Drive Horsepower: Blade Diameter: Number of Blades:For Vertical Shaft:Weight of Blade and Shaft:

DIMENSIONS OF EXISTING BEARING

Bearing Selection Data Sheet - Mixers and Agitators



Chain

ARRANGEMENT

Ø of Bolt

Length on Shaft

DRIVE


Appplication Notes



L o c a t e Y o u r N e a r e s t D i s t r i b u t o r b y V i s i t i n g C o o p e r B e a r i n g s . c o m

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I s s u e A u g u s t 2 0 1 1

Customer Service Centers

USA, Canada, Mexico and Central AmericaCustomer Service CentresCooper Bearings GroupUSA, Canada, Mexico and Central AmericaThe Cooper Split Roller Bearing Corp.5365 Robin Hood RoadSuite BNorfolkVA 23513USA.Tel: +1 (1) 757 460 0925Fax: +1 (1) 757 464 3067Email: [email protected]

UK, Europe, South America, Asia, Australia and the Middle EastCooper Roller Bearings Company Ltd.Wisbech RoadKings LynnNorfolk PE30 5JXUnited KingdomTel: +44 (0) 1553 763447Fax: +44 (0) 1553 761113Email: [email protected]

GermanyCooper Geteilte Rollenlager GmbH.Postfach 100 423Oberbenrader Str. 40747704 KrefeldGERMANY Tel: +49 (0) 2151 713 016Fax: +49 (0) 2151 713 010Email: [email protected]

People’s Republic of ChinaCooper Bearings Group Beijing.Room 909, Canway Building Tower 1No 66, Nanlishi RoadXicheng DistrictBeijingPRC 100045Tel: +86 (0) 10 68080803 +86 (0) 10 68080805 +86 (0) 10 68080806 Fax: +86 (0) 10 68080801Email: [email protected]

BrazilCooper do Brasil Ltda.Caixa Postal 66.105CEP 05.314-970BrasilTel: +55 (0) 11 3022 3706Tel: +55 (0) 11 9156 2500Email: [email protected]

IndiaCooper Roller Bearings Company Ltd.Wisbech RoadKings LynnNorfolk PE30 5JXUnited KingdomTel: +91 (0) 9820180089Email: [email protected]

AustraliaCooper Bearings GroupPO BOX 241KelmscottWestern Australia 6991 Tel: +61(0) 8 93979990Fax: +61(0) 8 93979990Email: [email protected]

Features and Benefits of the Cooper Split Roller Bearingcooperbearings.com/downloads/USA/US...

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