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Schaeffler unveilsCompact 48Velectric drive

IN THIS ISSUE...

ISSUE 12 - Oct 2014

Custom bearings help maximise gas recovery

Large size, highperformance taperedroller bearings

Condition monitoringbrings big savings for Spanish wind farm

10 13 21

Schaeffler and the ABT Sportsline team win the inaugural Formula E ePrix in Beijing

COVER STORYFORMULA E VICTORY IN BEIJINGSEE PAGES 16 AND 17

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We welcome your comments on this or any of our articles, and would be very pleased to receive your feedback on “In Motion” Editor: Karen Preston Marketing Manager – Schaeffler (UK) Ltd Forge Lane, Minworth, Sutton Coldfield West Midlands B76 1AP Email: karen.preston@schaeffler.com

atthew received the Award at The Big Bang UK YoungScientists & Engineers Fair at the NEC, Birmingham in

March. Matthew’s winning device, theCygen is designed to charge a mobilephone while cycling, without the cyclisthaving to worry about the phone battery going flat, resulting in loss ofsatnav capability and the risk of thengetting lost.

The core of Matthew’s product is an axial gap brushless generator with a ringof magnets attached to the spokes. The device is designed to be totally non-contact, which means that there isno residual drag when the phone is notcharging. Matthew first came up with the idea while studying for his A Levels.During his work placement at Renishaw,Matthew was able to part-develop theCygen device. This device became the

core of Matthew’s A-Level Engineering and Technology (ET) Project. Renishaw also helped to manufacture a product prototype.

“I completed the ET Project at school and then decided to enter the project in

the regional [West Midlands] Big BangFair awards, which I ended up winning.This meant I could progress to theNational Big Bang finals at the NEC and benefit from the Young Engineers’mentoring scheme,” says Matthew.

Rod Edwards, Chief Executive of theYoung Engineers charity, says: “I wasdelighted to see Matthew Hunter win thisprestigious award. It was very rewarding tosee Matthew show his work to the Dukeof York and then go on to be presentedwith the Rose Bowl. Young Engineersreceives no direct Government fundingand only exists through the generosity ofdonors and sponsors like Renishaw andSchaeffler. Last year over 20,000 youngpeople received hands-on practicalengineering experience from YoungEngineers in schools and clubs aroundthe country, and none of this would bepossible without this financial support.”

MATTHEW HUNTER, FORMERLY A STUDENT AT CHIPPING SODBURYSPECIALIST TECHNOLOGY SCHOOL IN BRISTOL HAS WON THEYOUNG ENGINEERS’ DUKE OF YORK AWARD (ROSE BOWL) AND£1,000 PRIZE MONEY FOR ‘CREATIVE USE OF TECHNOLOGY’.

YOUNG ENGINEER WINS NATIONAL PRIZEWITH PHONE CHARGERFOR CYCLISTS

SCHAEFFLER UK WAS ANNOUNCED AS ‘BEST COMPANY’ IN THE PATHWAY TOAPPRENTICESHIP (PTA) AWARDS 2013, IN RECOGNITION OF THE COMPANY’SONGOING SUPPORT AND COMMITMENT TO THE PROGRAMME.

SUPPORTING THE NEXT GENERATIONOF UK ENGINEERING TALENT

orking in partnership with SEMTAand Further Education Colleges, theWelsh Government introduced thePtA programme in 2009. The scheme

is a chance for young people to learn skills andgain vital work experience, while givingemployers an in-depth look at potential entrantsto their industry.

The PtA Awards, which are organised by SEMTA,are part of the annual Engineering EmployersFederation (EEF) Future Manufacturing Awards.Neil Walters, Production Support Manager atSchaeffler UK, received the Best CompanyAward on behalf of the company. Hecommented: “Pathway to Apprenticeships is afantastic scheme and we are therefore delightedto have won the Best Company Award this year.As a manufacturer of automotive enginecomponents, Schaeffler UK has alwaysrecognised the importance of investing in itspeople. It is essential that we have a highlyskilled workforce, and apprentice programmes

play a major part in meeting this need.”Established in 1955, the Schaeffler plant inLlanelli manufactures high precision enginecomponents for the automotive market. Theplant currently employs 260 people and is anautonomous subsidiary of Schaeffler.

Adrian Roberts, Director of Human Resources atSchaeffler UK added: “As a company, we havealways recognised that a continuous flow of newengineering apprentices into the business is criticalto the ongoing success of our manufacturingplant in Llanelli. Taking on apprentices each yearenables us to continually develop the pool oftalent and skills that we have here. Developingstrong links with our local college, Coleg Sir Gar,has played a significant part in this successfulprogramme, giving selected youngsters a realtaste of manufacturing.”

Bill Peaper, National Manager - Wales at SEMTAcommented: “The Pathway to Apprenticeshipprogramme has been running since 2009.

The awards recognise the hard work of theapprentices, companies and colleges indelivering this quality programme.

All engineering colleges across Wales areinvolved in nominations for the Best Companyand Best Learner awards categories. Thesenominations include supporting evidence of whythe companies and learners [apprentices] havebeen nominated. The nominations are thenjudged and shortlisted to three finalists percategory, who are then invited to the awardsceremony. Schaeffler UK’s production plant inLlanelli is now recognised as one of the leadinglights in Wales in terms of the models andtechniques it uses to train apprentices.”

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SMatthew receives theaward from engineerand TV presenter KateBellingham (left) andKaren Preston fromsponsor Schaeffler UK.

Matthew and HRH the Duke of York

Left to right: Bill Peaper, National Manager Wales,SEMTA; Neil Walters, Production Support Manager,Schaeffler UK; Paul Byard, National Director, EEF Wales.

ichard effectively takes overKate Hartigan’s PresidentIndustrial responsibilitiesfollowing her retirement in

2013. Richard, who held the position of Vice President Automotive atSchaeffler UK from 2007 to 2013, is now also promoted to DeputyManaging Director, Schaeffler (UK) Ltd.

Richard joined Schaeffler in 1995 andhas managed sales, marketing,engineering, customer services and logistics functions in both the Industrial

and Automotive Sales divisions. He hasa BEng (Hons) Degree in ManufacturingEngineering and Business Studies fromCoventry University and an MBA fromWarwick Business School. In his newrole as President Industrial UK & Ireland,Richard will report to Mr. Uwe Hartmann,Senior Vice President Industrial SalesEurope, Middle East and Africa.

Richard Hall commented: “I am really excited to be taking on theresponsibility for Schaeffler’s Industrialbusiness for the UK and Ireland region.

We have an industry leading productportfolio of rolling bearings, plainbearings and linear systems, backed upwith a wide range of conditionmonitoring and maintenance solutions.Based on a solid foundation oftechnological leadership and strongcustomer relationships, we have a realopportunity to take the Industrial Divisionfurther in both our growing IndustrialAftermarket business and also a numberof key OEM sectors.”

In the last 10 years, Alena has held various sales and businessdevelopment roles for a world-leading automotive Tier Onesupplier. Based in both Germany and the UK, Alena gainedvaluable experience by working closely with customers such as Ford, BMW, GM and Mercedes. Alena has a Degree inInternational Business Management from Cardiff University.

Alena commented: “Moving toSchaeffler is a very exciting careermove for me. The company has astrong pedigree and excellentreputation in the automotive market,as well as being a prolific developer of innovative products. Schaeffler is continuously developing newlightweight, lower friction, moreenergy-efficient components andsystems for vehicle transmissions. This is helping to reduce the weight of the vehicle, improve fuelconsumption and minimise CO2emissions in order to help OEMs meet ever-tighter European vehicle emissions targets.

“Innovation and collaborative working with vehiclemanufacturers is critical and with the UK automotive sectorshowing very positive signs of growth, I look forward to helpingSchaeffler UK further develop its automotive business with bothexisting and new customers,” she added.

Richard Hall commented: “I am really proud of the UKAutomotive team and the business that we have developed overthe past six years. I am confident that Alena’s appointment willhelp Schaeffler UK further strengthen its relationships with ourOEM and Tier One customers.”

ALENA USEINOVIC HAS BEEN APPOINTED ASVICE PRESIDENT AUTOMOTIVE AT SCHAEFFLERUK, TAKING OVER DUTIES AND RESPONSIBILITIESFROM RICHARD HALL.

RICHARD HALL PROMOTED TO PRESIDENTINDUSTRIAL AND DEPUTY MANAGINGDIRECTOR AT SCHAEFFLER UK

ALENA USEINOVICAPPOINTED VICEPRESIDENT AUTOMOTIVE

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Richard Hall - President Industrialand Deputy Managing DirectorSchaeffler UK

Alena Useinovic

SCHAEFFLER (UK) LTD HAS RECEIVED THE 2013 ‘SUPPLIEROF THE YEAR AWARD’ FROM IADA, THE INDEPENDENTAUTHORISED DISTRIBUTOR ALLIANCE. THE ANNUAL AWARD ISVOTED FOR BY IADA MEMBERS AND IS BASED ON CUSTOMERSERVICE, RELIABILITY, QUALITY AND RANGE OF PRODUCTS,DELIVERY AND OVERALL BUSINESS PERFORMANCE.

Richard Hall, President Industrial forthe UK & Ireland and DeputyManaging Director at Schaeffler UK,received the award on behalf of histeam. He commented: “To receive theBest Supplier award from IADA for the second consecutive year is atremendous achievement. The awardrecognises the commitment andenthusiasm of all our staff insupporting the successful growth ofthe IADA members. We will continue to work hard and build on our excellent relationship with IADA.”

James Gibson, IADA MarketingDirector, who presented the award toRichard Hall stated: “All the staff atSchaeffler UK thoroughly deserve thisaward, as they have once again shownextremely high levels of commitment toIADA and its members by providing thevery best levels of service and supportin all areas.”

IADA was formed in 1998 by a selectgroup of independent distributors, withthe aim of becoming a nationallynetworked supplier of MRO supplysolutions. The organisation looks forways to improve the level of serviceand coverage for their customers andtoday has 20 members and operates

across 50 branches throughout theUK. Key to the success of IADA isproviding locally available stocks andexpert technical support. In addition,IADA is working hard to gain newnational supply contracts for MROproducts and has appointed adedicated team working on behalf of the members.

SCHAEFFLER UK RECEIVES2013 SUPPLIER OF THE YEARAWARD FROM IADA

James Gibson, IADA Marketing Director, (left)and Richard Hall - President Industrial andDeputy Managing Director Schaeffler UK

TCs are local centres oftechnical expertise indifferent regions of theworld. With highly qualified

engineers and a defined range ofservices, this means Schaeffler ispursuing its target of offering thesame high standards of customersupport all over the world.

Awarding the “Schaeffler TechnologyCentre” status is confirmation that,following a comprehensive audit,these high demands are being met.For more information about theSchaeffler Global Technology Networkplease visit: www.global-technology-network.com

Schaeffler sales staff and engineers inlocal Schaeffler Technology Centresform a strong team. In the regions,they bring Schaeffler’s engineeringand service knowledge even closer tothe customer and enable technicalissues to be addressed in the mosteffective way possible and within anoptimum timescale.

Expert advice and support is availablefor all aspects of rolling bearingtechnology including applicationengineering, calculations,manufacturing processes, lubrication,mounting services, conditionmonitoring and installation consultingto deliver customised rolling bearing solutions to uniformly high qualitystandards throughout the world.

Internal audits, regular trainingcourses, workshops and follow-upaudits ensure that SchaefflerTechnology Centres achieve andmaintain these high standards.

Furthermore, STCs constantly share information and ideas across aworldwide network of experts withinthe Global Technology Network.

If more in-depth specialist knowledgeis required, these networks ensurehighly qualified support is providedquickly – irrespective of where it isneeded in the world.

This technical collaboration betweenmembers of the Global TechnologyNetwork results in tangible benefitsfor Schaeffler customers. Customerprojects that demonstrate definitivecost savings are clearly documentedas Global Technology Solutions.

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SCHAEFFLER UK AWARDEDTECHNOLOGY CENTRE STATUS FOR LOCALENGINEERING EXPERTISE

AS PART OF THE SCHAEFFLER GLOBAL TECHNOLOGY NETWORK, SCHAEFFLER (UK) LTDHAS BEEN CERTIFIED AS A SCHAEFFLER TECHNOLOGY CENTRE (STC).

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NEW TECHNICALPOCKET GUIDE ANDSMARTPHONE APPFROM SCHAEFFLER

chaeffler’s TechnicalPocket Guide is a usefultechnical reference bookfor mechanical engineers,

technicians, apprentices and studentsacross numerous technical and scientific disciplines.

Practical and easy-to-use, the Guide is intended as an educational tool that becomes a trusted companion formany people in their day-to-day work.

The Guide covers a variety of technical subjects including units of measurement, mathematics, statistics, physics and chemistry, aswell as specialist subjects such asmechanics, acoustics, hydraulics and

pneumatics, mechatronics, tolerances and fits, constructionmaterials and components.

The user-friendly Guide bridges the gap between a comprehensivetextbook and purely tabular data. The Contents section is displayed in a logical manner and even complexinformation is explained clearly andconcisely.

The book comprises 14 colour-codedchapters for easy navigation. There are numerous diagrams anddrawings, well-structured texts, tables and formulae, allowing thereader to quickly find what he or she is looking for.

Dr Steve Lacey, Engineering Managerat Schaeffler UK commented: “The Technical Pocket Guide is theperfect desktop companion and aidememoire for anyone involved inengineering, from students andapprentices at the beginning of theircareers, right through to experiencedmechanical engineers, chiefdesigners and technical directors.”

The Guide had specialist support from Prof. Dr.-Ing. Harald Meerkamm,former head of the Chair forEngineering Design at the Friedrich-Alexander University of Erlangen-Nuremberg.

His technical and teaching experience enabled the entire content of the Guide to be carefullyrevised and updated.

Schaeffler also offers the TechnicalPocket Guide as a software App,providing a mobile reference guide.

In addition to the content of theprinted version, the mobile App also includes useful ‘search’ and‘bookmark’ functions, as well asinformation about Schaeffler.

A sharing function enables specific text passages to be shared via e-mail, Facebook, Twitter and Google+.

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For your copy of the Technical Pocket Guide, please call Schaeffler UK’s Marketing Department on 0121 313 5870 or email info.uk@schaeffler.com

SCHAEFFLER HAS PUBLISHED A NEW 700-PAGE TECHNICAL POCKET GUIDE FOR THE UK MARKET. THE PUBLICATION IS FREE-OF-CHARGE AND IS AVAILABLE IN EITHER PRINTED HARD COPY FORMAT OR AS AN APPLE/ANDROID APP.

Available on the

THE POCKET GUIDE ISAVAILABLE FREE OF CHARGE

Left to right: Karl-Heinz Lindner - Vice President Technical Office,Uwe Hartmann - Senior VicePresident Sales Industrial, RichardHall - President Industrial and

Deputy Managing DirectorSchaeffler UK and Robert

Schullan - PresidentSales Industrial.

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his is the eighth year thatGwyr has won an EESWaward working withSchaeffler UK. One of the

EESW judges this year described theschool’s project as “the best project I’ve seen in four years of judging.”

Schaeffler’s manufacturing plant acts asan EESW ‘link’ company and so eachyear devotes time and resources to advising students on their projects.

The EESW scheme operates throughlocal companies such as Schaeffler, who set teams of A-Level studentsprojects relating to actual industrialproblems. Over a period of six months,the students work to solve thesechallenges by cooperating withengineers from the link company.

“This year we did things a littledifferently,” explains Derrick Lewis,Technical Manager at Schaeffler UK and contact for EESW projects. “We decided to give the students a one-day on-site training course thatincluded project management tools andtechniques, a problem-solving exercise,followed by a ‘MOVE’ [a continuousimprovement programme] challenge,where the students helped to streamlineworkflows and eliminate waste inproduction areas at the plant.”

The students were invited back thefollowing week, when they werepresented with a selection of fivepossible projects to choose from. The team was asked to discuss which of these projects appealed to them andwhy. “Allowing students to choose theproblem they wanted to solve gave themownership of the project,” explains Lewis.

The team chose to tackle a probleminvolving detection and treatment ofbacteria in cooling towers at the plant.Current detection methods involve atechnician using agar-coated dip slidesand immersing these in water from thecooling towers. These slides are thenincubated for 48 hours, after which thebacteria levels are checked. This methodis time consuming and costly. “Thanks to the time spent at the plant learningabout the specific tools and techniques,we knew how to develop our ideas intoour working prototype,” states teamcaptain Nerys Griffith.

“Derrick ensured that we spent timewriting an accurate and concisestatement of requirements usingSMART [Specific, Measurable,Achievable, Realistic, Timely] objectives,which made it easier for me as teamcaptain to monitor our progressthroughout the project.”

The team’s solution involves using asensor system that measures the turbidityand attenuation of a water sample. Thesensors are connected to a Raspberry Pi computer, which compares light levelsto known calibrated results. From theanalysis completed, a determination ismade regarding the bacteria level in thesample. If this indicates that bacteria arepresent at a higher level than theplanned threshold, the water is thentreated with biocide. A status panelshows if the water is being treated, or if biocide levels become low. Failsafealarms are also written into the system.

A working model was demonstrated tosenior staff at Schaeffler UK beforebeing presented at the EESW’s annualSouth Wales awards ceremony held atThe Celtic Manor Resort, Newport.

“We are extremely happy to win thisaward,” says Rhys Browning, Head ofPhysics at Ysgol Gyfun Gwyr School.“We’d like to thank Derrick Lewis and his team for their continued support. The valuable experience and skills learntduring the competition will aid the pupilsin their chosen career pathways.”

THE TEAM FROM YSGOL GYFUN GWYR SCHOOL IN GOWERTON, SWANSEA WON THE ‘AIRBUSAWARD FOR BEST INNOVATIVE OR ADAPTIVE DESIGN’ FROM THE ENGINEERING EDUCATIONSCHEME WALES (EESW).

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GWYR SCHOOL WINS ITS EIGHTH EESW AWARD FOR COOLING TOWER PROJECT AT SCHAEFFLER UK

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HOUSING INCREASESBEARING OPERATINGLIFE BY UP TO 50%

he new FAG SNS plummerblock housing has beencompletely redesigned,providing numerous

technical advantages to users, including more even load distribution onthe bearings, resulting in an extendedoperating life. Schaeffler has alsooptimised the design further, resulting in a housing that is not only more costeffective to manufacture, but also easierto mount and dismount. Manufacturedfrom high quality, spheroidal graphitecast iron, the housing ensures a highlevel of robustness and operationalreliability. Other benefits includeimproved lubrication and conditionmonitoring of the bearings, as well asincreased application flexibility and asignificant reduction in overall cost ofownership. Due to the introduction of new, industry-standard mountingarrangements and dimensions, thehousing can also be installed as adirect replacement for a wide varietyof conventional plummer blockhousings.

Housing design minimises bearing loadThe unique, patented design of the FAGSNS plummer block housing distributesthe load on the bearings moreeffectively (uniformly) than previous andalternative housings.

Using its in-house developed bearingdesign, calculation and simulationsoftware, Bearinx®, Schaeffler is able to analyse different housing designswith various combinations of bearings,enabling the optimisation of thecomplete system (i.e. housing andbearings). By introducing some subtlegeometrical changes, including a smallarch-shaped cutaway at the bottomcentre of the housing, the load on thebottom roller (at the apex, 180 degrees)is now distributed more evenly acrosstwo or three rollers. By spreading theload from the shaft across a greaternumber of rolling elements, theoperating life of the bearing isincreased by up to 50%.

In Fig 1, the blue curve represents therolling element load on a bearinginstalled in a housing with conventionalsupport. The red curve represents thesame load but in a bearing installed inthe SNS housing with a cutaway. Thered curve has a wider load zone andmore even load distribution than theblue curve. In addition, the load on theroller at the apex is significantly higherin the blue curve. However, the redcurve demonstrates that a cutaway inthe feet of the housing creates a widerload zone. The maximum load from theshaft is no longer supported by theroller at the apex, but by its twoneighbouring rollers.

Design improvements reducelifecycle costsOther design changes have resulted inimproved bearing lubrication, mountingand condition monitoring – whichtogether contribute to a significantreduction in the Total Cost ofOwnership (TCO). A lubricationbore with a longer groove hasnow been added to the inside ofthe upper section of the housing.This means that different bearingtypes installed in each bearingposition can now be supplied withsufficient lubricant at all times.

To enable improved conditionmonitoring of the bearings, connectionsare now provided on both sides of thehousing as standard for Schaeffler’sFAG SmartCheck condition monitoringdevice.

Schaeffler can also supply the housingwith connections for its new Concept 8automatic lubrication system.

Flexible and cost-effective Bevels, small surfaces and an upperhousing section that covers the lowerhousing section, eliminate potentialcollection points for fluid andcontaminants. A variety of seals areavailable, which enable the bearings tooperate in harsh environments such asmining, quarrying, mineral processing,food and beverage processing.

Rolling bearings of different diametersand widths can be installed in the newSNS plummer block housing.

The bearings are movable and sofunction as non-locating bearings.Suitable bearings include the 222, 223, 230, 231, 232, and 240 series.The FAG SNS housings can be used as direct replacements for a widerange of conventional housings.

SCHAEFFLER HAS DEVELOPED A NEW PLUMMER BLOCK HOUSING FOR SPHERICAL ROLLER BEARINGS, WHICH INCREASES THE OPERATING LIFE OF

THE BEARINGS BY UP TO 50% COMPARED TO CONVENTIONAL PLUMMER BLOCK HOUSINGS.

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Fig 1.

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FAG SNS Plummer Block

Schaeffler worked with a team of eight students: Nerys Griffith, Fynn Bishop-Guest, Iwan Cole, Tom Francis, Gareth Goss, Aled Rees, Katherine Rees and Christian Stobbs. Also pictured are Rhys Browning of Ysgol Gyfun Gwyre School (left) and Derrick Lewis of Schaeffler UK (right).

Schaeffler UK recently supported a ‘Making Knexions’challenge at Morriston Comprehensive School in Swansea.The event was supported by Nigel Moore of YoungEngineers, Liz James from BaseWales, and Paul Griffithsfrom the Technology Department at Schaeffler UK.

11-12 year old pupils were given the task of designing andtesting a wind turbine constructed from paper card and thepopular building system, K’NEX®. As Paul Griffiths recalls:“Confused faces quickly turned into enthusiastic ones as thepupils got to grips with the task and wanted their team toproduce the best result.”

Each team was judged on the output of their wind turbine, thecost of construction and how well they worked together as ateam. According to Griffiths, form tutor Paul McNeil found thesession “very worthwhile” and has asked for a repeat event inthe next year. The aim of the event was to create a stronger linkbetween real-world engineers and the local primary school,which says Griffiths “was certainly achieved, and hopefully we’veenthused some pupils into becoming engineers in years to come.”

‘MAKING KNEXIONS’

he core element of thisrange is a compact 48Velectric drive module thatincludes a clutch and

planetary transmission, which can beplaced either on the front or the rearaxle of the vehicle.

The drive module paves the way for theeconomical hybridisation of vehicles.The low-voltage design reduces costscompared to high-voltage solutionswith their associated requirements. This economical hybridisation allowssignificant advances to be made interms of increased drive efficiency, asthe use of a 48V electric system opensup operational possibilities that werepreviously the exclusive domain ofvehicles equipped with high-voltagehybrid components, including“crawling” in traffic jams – electricallypowered driving in dense inner-citytraffic, i.e. moving off, driving at lowspeeds, and parking using electricpower. In addition to electric ‘boosting’

during starting and electric ‘sailing’ – a driving mode in which the electricmotor ensures constant speed whilethe internal combustion engine isswitched off – the system also enablesrecovery and storage of energy duringdeceleration, which is key in terms ofreducing fuel consumption.

The electric drive, which has an outputof up to 12kW, acts as the hybridvehicle‘s sole source of power when“crawling” in stop-and-go traffic. The electrically generated propulsion of Schaeffler‘s 48V drive module is

also sufficient for drivingin residential

areas,

parking in garages and for other lowspeed driving situations, for example,when moving off from traffic lights.

The high performance of the 48Vsystem also means that the driveelement opens up new potential forenergy recovery. Due to the higherrecuperation capability, the kineticenergy released during deceleration isnow no longer converted into heat thatsubsequently dissipates – as waspreviously the norm – but is instead fedback into the onboard electric systemin the form of electrical energy.Therefore, a hybrid solution withcombustion engine and 48V systemproves to be advantageous whengenerating electricity from braking

energy.

“Using a 48-volt solution todaymakes it possible to achieveoutputs of up to twelve kilowatts,”summarises Prof. Peter Gutzmer,CTO at Schaeffler.

NEW SCHAEFFLER UNVEILS COMPACT 48V ELECTRIC DRIVE

MODULE FOR HYBRID ELECTRIC VEHICLES

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BEARINGS AND AUTOMOTIVE COMPONENTAND SYSTEMS SUPPLIER SCHAEFFLERHAS DEVELOPED A RANGE OFINNOVATIVE SYSTEMS FOR FUTURE

PASSENGER VEHICLES EQUIPPED WITHON BOARD HIGH-PERFORMANCE.

“This entry-level form of hybridisation thereforealready offers the essential advantages of ahybrid vehicle while simultaneously providing an economically attractive, low-cost option thatallows CO2 emissions to be reduced by up to 15 per cent.”

“The fact that the drive unit is connected directlyto the prop shaft in rear-wheel drive vehiclesprevents drag losses by the internal combustionengine. We can therefore achieve maximumefficiency and enable driving situations that werepreviously only offered by hybrid vehicles withsignificantly more complex designs,” explains Dr. Tomas Smetana, Vice President ProductGroup Electric Axle Systems at Schaeffler. “Our combination of an electric motor andtransmission also allows the flow of force to be distributed selectively, drive torques can besuperimposed, and even torque vectoring – the variable distribution of torque that

serves to increase drivingsafety – is possible.”

In its current configuration,the cylindrical component ofthe drive module is 235mm inlength with a diameter of 165mm. This compactdesign means that the module can easily beintegrated into the drive train and overall designof the vehicle without any space having to besacrificed by the boot space or fuel tank.

Vehicle manufacturers that decide to install asecond low-voltage on-board electric system(48V in addition to the standard 12V system)can also integrate other suitable high-performance innovations into the vehicle. These include high-performance, rapid-reactionactuators for the chassis. These allow the groundclearance to be regulated according to the driving conditions and terrain,

which has apositive effect on the vehicle’s

aerodynamics and therefore on its fuelconsumption. In addition to high performancedue to the higher voltage range, a second on-board electric system also offers the advantageof smaller cable cross-sections. This reducesweight and facilitates the integration andinstallation of the cable harnesses in the vehicle.

A range of other functions that push today’sstandard 12V systems to their performance limitcan now be practically integrated into thearchitecture of a 48V system. These range frommechanical tensioners for 48V belt-driven startergenerators, to a number of electromechanicaladjusters for clutch, steering, roll stabilisation,self-levelling suspension, hybrid modules, axledrive solutions and electromechanical torquevectoring units.

SchaefflerHybrid Module48 Volt

48V Drive train

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2014 marks the beginning of a new era insports car racing. Not only does this year seethe return of Porsche, but also, for the firsttime, new technical regulations come intoeffect for the global racing series. Theseregulations limit the useable amount ofenergy but allow considerable freedom in

the areas of hybrid and powertrain technology – and so pose new challenges to entrants.Unlike F1 various engine concepts arepermitted. This makes WEC the perfect stage for manufacturers and suppliers todemonstrate their expertise.

“In the new regulations of the FIA WorldEndurance Championship, energy efficiency

and forward-thinking technology play a crucial role.

These are also the areas that Schaeffler is focusing on for automotive technology. The parallels between motorsport andproduction make WEC and the cooperationwith Porsche an ideal platform for Schaeffler,”said Prof. Peter Gutzmer, Chief TechnologyOfficer at Schaeffler.

Porsche and Schaeffler have been workingtogether for decades. The legendary 917, with which Porsche clinched its first twooverall victories at Le Mans in 1970/71, was a development prototype for Schaeffler’shydraulic valve train components.

The electric drive model paves the way foreconomical hybridization.

SCHAEFFLER HAS ANNOUNCED THAT IT WILL WORK WITHPORSCHE ON ITS NEW HYBRID LMP1 SPORTS CAR, WHICH WILLCOMPETE AT THE FIA WORLD ENDURANCE CHAMPIONSHIP (WEC).

NEW SCHAEFFLER WORK WITH PORSCHE ON HYBRID SPORTS CAR FOR LE MANS

Handshake of the Chief Technology Officers: Wolfgang Hatz(Porsche) and Prof. Peter Gutzmer (Schaeffler)

he function of the bearingsis to provide a flexiblesupport between the monocolumn and main rig

allowing for movement of the columncaused by waves and tidal currentrelative to the main rig.

The bearings, which have a borediameter of one metre, are designedto transfer these loads from thecolumn to the main rig. Chris Head,Application Engineer at Schaeffler UKcommented: “After several meetingswith the customer and its maincontractor for the extension column, it was clear to us that the customerwould require a unique design ofbearing that offered both a very highlevel of reliability and zeromaintenance.

“We therefore proposed Schaeffler’srange of ELGES spherical plainbearings, but customised with extrasealing features and low frictionsliding layers. These would ensuremaximum reliability and zeromaintenance.”

Schaeffler’s standard ELGES sphericalplain bearing is fitted with only oneseal on each side of the bearing, so a special sealing arrangement was discussed with the customer. The custom bearings are thereforefitted with additional seals anddesigned with an extra sliding layer in the bore.

This ensures low friction when theextension column moves relative to the main rig due to the ocean waves.

As Chris Head states: “We offeredadditional sealing features in the form ofa grease layer, which would allow us tolubricate the outermost lip seal, addeda special seal, which acts as a barrierfor the grease, with another seal toprevent the grease from contaminatingthe bearing sliding layer.”

The bearings were manufacturedaccording to strict customerspecifications, with all bearingmaterials, components, manufacturingand quality processes all fullytraceable.

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SCHAEFFLER UK HAS CUSTOM DESIGNED A SET OF MAINTENANCE-FREE SPHERICAL

PLAIN BEARINGS TO SUPPORT A NEWLY CONSTRUCTED PROCESS MODULE EXTENSION

COLUMN, WHICH IS FIXED TO THE MAIN OFFSHORE PLATFORM LOCATED IN THE NORTH SEA.

The bearings were installed on theoffshore platform extension column inMay 2013, and in order to ensure thatthe installation of the bearings couldproceed without difficulty under thechallenging and constricted conditionspresent on an offshore platform, aninstallation trial was carried out. Thiswas performed by two experiencedfitters from Schaeffler and allowedimportant details and the special toolsrequired for offshore installation to beincluded in the work planning. Thanksto Schaeffler’s Global TechnologyNetwork, the service personnel wereextremely well prepared, having beenbrought into the project planning andimplementation process at an earlystage by the sales and applicationengineering functions.

The customer was so impressed bythe professional skills displayed duringthe installation trial that he requesteda Schaeffler fitter be present when thepreliminary work was carried out onthe platform, in order to support theother companies involved and tomonitor their work operations.

Alan Stewart, Regional Sales ManagerNorth at Schaeffler UK commented:“This is a first for the oil and gassector. This project is the first one inwhich a process module extensioncolumn of this type is supported bybearings. The customer deemed thebearings to be a high priority on this

project, as their function is absolutelycritical in supporting the extensioncolumn.”

He continues: “We were informed bythe customer that we won thisbusiness due to our technicalknowledge and expertise, and becausewe understood exactly what thecustomer required. As the bearingsupplier, we successfully met all of ourdeadlines, helped enormously byexcellent cooperation between thethree main parties involved – the endcustomer, the construction contractorand Schaeffler.”

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Chris HeadSTC Applications Engineer, Schaeffler UK

Elges Sphericalplain bearing

Preparing toinstall onesleeve ontothe column

Preparation for installation of sleeves and bearings

Installing sleeve onto column prior to grouting

Alan Stewart, Regional Sales ManagerNorth, Schaeffler UK

CUSTOM BEARINGS HELP MAXIMISE GASRECOVERY FOR A NORTHSEA OIL AND GAS MAJOR

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AG tapered roller bearings inX-life quality can achieve areduction in frictional torqueof up to 50% compared to

conventional tapered roller bearings. The dynamic load rating (load carryingcapacity) of the X-life bearing hasincreased by 20%, with a resultingminimum 70% improvement in the basicnominal operating life of the bearing.

As well as improving the performanceand energy efficiency of the bearing, X-life tapered roller bearings alsoprovide additional benefits in terms of areduced design envelope, weight andfriction. Design engineers can nowpotentially replace a standard taperedroller bearing with a smaller X-lifeversion, therefore downsizing the systemand related components. Alternatively, a standard tapered roller bearing can bereplaced with an equivalent sized X-lifetapered roller bearing, which will provideimproved performance and energyefficiencies.

X-life tapered roller bearings alsocontribute significantly towards reducingoperating, servicing and maintenancecosts, particularly with regard to the Total Cost of Ownership (TCO).

Wind turbines, tractors andconstruction machinery

During the development of the X-lifetapered roller bearings, particularattention was paid to achieving high

reliability and minimising friction,particularly in high load applications andthose that require rotational accuracy.

This means that manufacturers ofhydraulic units or gearboxes (pinionbearing supports) such as those found inwind turbines, agricultural vehicles andconstruction machinery can now surpassprevious performance limits, whilstsignificantly improving operational safety.In terms of downsizing, the improvedcharacteristics of the X-life bearingsmean that the performance of thegearbox is improved, whilst the designenvelope remains the same.

The 20% improvement in dynamic loadrating and minimum 70% improvement

in basic rating life wereachieved by improving the geometry,surface quality, materials, dimensionaland running accuracies of the bearings.

The premium bearing material used inthe manufacture of the X-life taperedroller bearings is specially adapted to meet the requirements of the rollingbearings and is an important factor inthe increased performance of thebearings. The fine grain structure of thismaterial provides high toughness andtherefore high resistance to solidcontaminants.

In addition, a logarithmic profile wasdeveloped for the bearing raceways andthe outside surface of the rollers, whichcompensates for high stress peaksunder high loads and any “skewing” that may occur during operation. These optimised surfaces assist in theformation of an elasto-hydrodynamiclubricant film, even at very low operatingspeeds, which enables the bearings towithstand high loads during start-up.Furthermore, significantly improveddimensional and geometrical tolerancesensure optimum load distribution.

Stress peaks are therefore avoided,which reduces material loading.The frictional torque of the new X-lifetapered roller bearings has beenreduced by up to 50% compared toconventional products. This is due tohigh dimensional and running accuracyin conjunction with improved surfacetopography. The revised contactgeometry of the inner ring rib and rollerend face also assists with the reductionof friction. As a result, bearing operatingtemperature has also been reduced byup to 20%.

The new X-life tapered roller bearingsare not only more economical, but alsoresult in lower bearing operatingtemperatures, which in turn, placessignificantly less strain on the lubricant.This enables maintenance intervals to beextended and results in the bearingoperating at reduced noise levels.

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THE NEW BEARINGS ARE NOW AVAILABLE IN SIZES UP TO 635MM OUTSIDEDIAMETER (OD). THIS MEANS THAT SCHAEFFLER NOW OFFER CUSTOMERSTHE WIDEST RANGE OF HIGH PERFORMANCE TAPERED ROLLER BEARINGSON THE MARKET TODAY.

UNIQUE MULTI-POINTLUBRICATOR CATERS FORUP TO EIGHT DIFFERENTBEARING POSITIONS

AG CONCEPT8 is aninnovative, cost effectivelubrication system forrolling bearings that

ensures a constant, optimum supply of grease to the bearings without theneed for manual intervention,particularly if machines are located indifficult-to-access areas or aredeemed as critical to the productionprocess.

FAG CONCEPT8 provides up to eight separate lubrication points fordispensing precisely meteredquantities of lubricant to rollingbearings. The system can dispenselubricant to rolling bearings in a widerange of industrial applications,including pumps, fans, compressors,gearboxes, electric motors, machinetools, wind turbines, as well asproduction lines in food and beverageprocessing plants.

FAG CONCEPT8 is fitted with fourpairs of lubrication points (eight intotal), which are controlled by fourindividual dispensing pumps. Unlikeother multi-point lubricators on themarket, FAG CONCEPT8 enablesusers to individually control eachpump in order to optimise cycle timesand volumes of dispensed lubricant(lubricant can also be dispensed in a‘pulsed operation’).

This means the system can beadjusted to meet up to four differentbearing sizes, each with varyinglubrication requirements – an industryfirst. Rather than having to purchasemultiple single point lubricators tocope with different bearing lubricationrequirements, users can now buy oneFAG CONCEPT8.

FAG CONCEPT8 is also equippedwith heated outlets, which ensurereliable dispensing intervals, even atlow temperatures when the grease ismore viscous. In addition, as thelubricant is stored in a transparentreplaceable cartridge, users can easilycheck the lubricant level, enablingeasier fill-level control.

The system is easy-to-use with anintegrated LCD user display thatprovides clear navigation menus andtwo keypad control buttons for set upand adjustment.

FAG CONCEPT8 operates onSchaeffler’s ARCANOL range oflubricants. This range includes 17different greases, each one developedby Schaeffler application engineersand produced by leading internationallubricant manufacturers. Thesegreases therefore provide specificlubrication properties for almost everytype of industrial application.

AT MAINTEC 2014, SCHAEFFLER UNVEILED ITS UNIQUE MULTI-POINT LUBRICATORFOR ROLLING BEARINGS. THE SYSTEM CAN BE ADJUSTED TO PROVIDE FOURDIFFERENT LUBRICATION VOLUMES TO CATER FOR BEARINGS WITH VARYINGLUBRICATION REQUIREMENTS – AN INDUSTRY FIRST.

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LARGE SIZE, HIGH PERFORMANCEX-LIFE TAPERED ROLLER BEARINGS REDUCE FRICTIONALTORQUE BY UP TO 50%

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JWCI PROCESS ENGINEERING HAS SOLVED A CHEESESTORAGE CHALLENGE FOR ITS CUSTOMER WITH THE HELP OFTRACK ROLLER GUIDANCE SYSTEMS FROM SCHAEFFLER UK.

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crew drives are suitable for a variety of machine building,automation, handling andautomotive engineering

applications. Screw drives comprise athreaded spindle and threaded nut. Due to the rotation of the spindle, thenut moves in a linear manner along thespindle, converting the rotary motion ofthe drive into linear motion.

A screw drive is rigidly connected to the adjacent construction, providing axialdisplacement or positioning of thecomponent. Nuts are available in aflanged or cylindrical design and in theform of single or double nuts. Preloaded(double) nuts enable high positionalaccuracy and rigidity. The thread on theshaft is either rolled or ground.

Selection criteria for screw drives arebased on a number of requirementsincluding positional accuracy, rigidity,freedom from clearance/preload, loadcarrying capacity, speed, basic rating life, frictional torque, smoothness ofrunning, and pitch.

Ballscrew drivesIn ballscrew drives, the load istransmitted from the spindle by meansof precision, hardened steel balls to thenut. The nut (cylindrical or flanged) has areturn system for recirculating the rollingelements. Ballscrew drives are able tooffer high load carrying capacities andsmooth, uniform running with highefficiency and reliability.

Schaeffler’s KGT range of ballscrewdrives have a contact angle of 45°.External drive forces induce an axialforce, which causes axial deflection as a function of the preload. In the case ofpreloaded single nuts, the preload isachieved by the introduction of oversizeballs, resulting in four-point contact withthe raceways.

Double nuts are preloaded by the use of a spacer, which sets the nut in an ‘O’ arrangement. In this case, the rollingelements are in two-point contact withthe raceways.

The KGT series is available in accuracyclass T7 (52µm variation over a 300mm

axial travel) as standard, with a class T5 (23µm) option also available. Other tolerances can be supplied inaccordance with ISO 3408-3 (DIN 69051).

Temperature, sealing & lubricationThe KGT range of ballscrew drives canbe used at operating temperatures from-10°C to +80°C. Ball screw shafts(KGS) are available in diameters from6mm up to 80mm and in lengths from900mm up to 7600mm.

Bob Love, Business DevelopmentManager at Schaeffler UK commented:“The new rolled ballscrews are awelcome addition to Schaeffler’s rangeof screw drives. We expect considerableinterest from OEMs, machine buildersand designers of automation andproduction handling systems.”

In addition to the supply of ballscrews,Schaeffler is also able to offer a rangeof shaft support bearings, includingangular contact ball bearings and hybridangular contact thrust ball bearings forshort stroke ballscrew applications.

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THE NEW BALLSCREWS COMPLETE SCHAEFFLER’S SCREW DRIVES OFFERING, WHICHNOW INCLUDES BALLSCREW DRIVES (GROUND AND ROLLED), PLANETARY SCREW DRIVES,ROLLER SCREW DRIVES, AS WELL AS A RANGE OF BALLSCREW SUPPORT BEARINGS.

he tracked storage rackingsystems, which weredesigned, manufacturedand installed by JWCI, have

increased cheese storage capacity atthe customer’s cold storage facility bymore than 70% – without the customerhaving to expand its existing floor space.John Clarke, Managing Director at JWCIcomments: “We had to meet very stricttimescales and budgets on this projectand so it was important that oursuppliers delivered on time and within

budget – both of which I’m pleased tosay Schaeffler did. We would thereforehave no hesitation in specifyingSchaeffler products again in the future,” adds John Clarke.

He continues: “Over the last five yearsor so, JWCI has designed and installedstorage racking systems of variousdesigns for cheese producers. The firstproject involved the design andinstallation of a relatively small system,designed to fit the existing floor spacefor a customer. The second project, for adifferent customer, was installed as atrial racking system. The success of thisspawned a third project in 2012, whichinvolved the design and installation of amuch larger cheese racking system.”

In this third project, the customer – a small UK-based producer of Stiltoncheese – needed to increase itsproduction output significantly withouthaving to invest in new cold storagefacilities or expand its existing storagefloor space. “Unless a solution wasfound to the storage issue, this couldhave prevented further growth of thecustomer’s business. We thereforedesigned a stainless steel trackedracking system that utilised the existingstorage space much more effectively,which meant the customer couldincrease production output significantlywithout having to invest in new premisesor expand its existing cold storagefacility,” states Clarke.

“We designed, manufactured andinstalled a fully hygienic tracked rackingsystem that could be easily moved by asingle operator, eliminating trip hazardsand resulting in a safer workingenvironment,” he adds.

The slabs of cheese are stored intemperatures of 10 to 12°C. Thestorage racks are 3.5 metres high and18 metres in length and utilise almostall the existing space in the cold storage area – from floor to ceiling.

As and when required, the racks ofcheese products can be manuallypushed or pulled from storage by simply

sliding the racks back and forth alongthe low friction top guide rails – whichrequires minimal effort.

Essentially, the top guide rails preventthe storage racks from falling over bysupporting the loads and ensuring thatthe racks remain inline at all times.

JWCI designed and built the storageracking systems and assembled these onsite in April 2013. For the racking systemtop rails, JWCI specified a total of 48 x3-metre long LFS series guidewaysfrom Schaeffler, as well as LFR serieslocating track rollers and bolts.

LFR series locating track rollers aredouble row angular contact ball bearingsthat comprise an outer ring with aGothic arch profile, an inner ring andtwo ball and cage assemblies. The inner ring and outer ring are madefrom 100Cr6 rolling bearing steel. The special outer ring provides two-point contact in the contact zone withthe raceway. The bearings can supportaxial forces from both directions, as wellas radial forces.

Chris Lait, Regional Sales Engineer atSchaeffler UK commented: “For thecheese storage racks, we customengineered the track rollers in stainlesssteel in order to provide maximumcorrosion resistance and to protect theguides from frequent washdowns, aswell as to withstand the low ambienttemperatures in the cool storage facility.

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Trends in machine tool developmentindicate faster cutting speeds arerequired, as well as increasedmachining accuracies. Designers ofmachine tools and other high precisionproduction machinery thereforerequire components, assemblies andsystems that provide suitable levels of stability, precision and dynamics.

At the same time, high precisionmotion control of machine toolsincreasingly requires ready-to-fit,complete linear motion systems withintegrated features such as sealingand lubrication, specifically matched to the application. In response to theseneeds, Schaeffler has extended itsRUE-E range of linear recirculating

roller bearings and guidewayassemblies to include a new size, the RUE25-E, which also offers a range of new integrated features and technical benefits.

For the main axis of machine tools,monorail guidance systems based onrecirculating balls and rollers are wellproven alongside flat cage units andlinear recirculating roller bearings.These systems are ready-to-fit,preloaded and can support loads andforces from all directions. Linearrecirculating roller bearing andguideway assemblies of series RUEare primarily used in these applicationsdue to increasingly heavy workpieces,new machining materials and high

cutting forces. These units offer veryhigh load carrying capacities, greaterflexibility and integrated functions.

Schaeffler's RUE25-E maintainsnumerous proven features from itspredecessor, the RUE-D series, but also provides more integratedfunctions. These include a lubricatorthat distributes the minimum volumeof lubricant. This enables lubricationwith oil (rather than grease),regardless of the mounting positionand without additional precautionsneeding to be taken such as extralubricant connectors on both sides ofthe carriage.

By optimising the design, materialsand manufacturing process for the

RUE25-E, Schaeffler has also reduced friction and displacement resistance byapproximately 40%. This results inimprovedperformance interms of the runningcharacteristics anddynamics of the guides,as well as an increasedmaximum travel speed ofup to 3 m/s.

The power density of the unit istherefore higher, while the size anddimensions remain similar. The newoptimised sealing concept for theRUE-E series is also fully maintained.

The RUE25-E can be retrofitted as a one-for-one replacement of itspredecessor, the RUE D series.

The guideways remain unchanged, but the carriages and guideways cannow be combined in any way desired.The units can be specified in accuracyclasses G2 or G3. The RUE25-E isavailable as a standard flangemounted unit, with either a long flangecarriage or a high, long carriage.

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SCHAEFFLER EXTENDS BALLSCREWDRIVES TO INCLUDENEW ROLLED VERSION

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RUE-E linearrecirculating rollerbearing

Trackedstorageracking

Guideway, trackroller and bolt

MONORAIL GUIDE FOR MACHINE TOOLS REDUCESFRICTION BY 40% AND INCLUDES LUBRICATOR

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topic of electric mobility with emotions in afascinating way,” he continued.

The collaboration with ABT Sportsline has along-term focus and far exceeds a puresponsoring arrangement. “We’re supporting thefurther development of the racing car and itscomponents in the future, supported by theknowledge and experience of our engineers atSchaeffler,” added Gutzmer.

Hans-Jürgen Abt, Managing Director of ABTSportsline commented: “We’re delighted that inSchaeffler we have on board the perfectpartner for the challenges we face in FormulaE. From the company’s presence in DTM we’vecome to know the passion with which all theemployees support motorsport.” “The collaboration in the field of technology is

a very important aspect. Starting in the secondseason, the teams will be allowed to subjectsome of the vehicle’s components to furtherdevelopment – so a partner with such a wealthof engineering expertise and experience inelectric mobility is obviously worth a mint,” he added.

Schaeffler is a renowned supplier to theautomotive industry, as well as a leadingmanufacturer of rolling bearings worldwide. A development partner to the automotiveindustry with system expertise for the entiredrive train, Schaeffler is continuouslydeveloping new lightweight, lower friction, moreenergy-efficient components and systems forvehicle engines, transmissions and chassis. Thisis helping to reduce vehicle weight, improvefuel consumption and minimise CO2 emissions.

Schaeffler is working with a number of majorautomotive manufacturers, both within andoutside of the UK, to co-develop more energy-efficient solutions for internalcombustion engine-powered vehicles. Theseinclude UniAir, the world’s first fully variablehydraulic valve control system; a thermalmanagement module for internal combustionengines that reduces CO2 emissions by up to4%; a lightweight spur gear differential that is30% lighter than its predecessor and createsup to 70% free axial space in the gearbox; and low friction angular contact ball bearingsfor turbochargers, which are helping to set new performance benchmarks in high-endpassenger cars, light duty and heavy dutytrucks.

Schaeffler is also involved in the developmentof concepts and components for the next-generation of hybrid and all-electric vehicles.One of these, the eDifferential, is an activeelectric differential installed on the front andrear axles, which combines the electric drivewith the option of wheel-selectable drive powercontrol. This enables torque distributionbetween the right and left wheel, whichenhances driving dynamics, safety and comfort.

Schaeffler also develops bearings, bottombrackets and other components for electricbicycles (e-bikes). These maintenance-freecomponents offer longer operating life andsmooth, lower friction operation, resulting inhigh efficiency and dynamics, as well asimproved comfort.

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The FIA Formula E series takes placein major cities around the globe usingfully electric vehicles. ABT Sportslineis the only German team in aninternational field that includes teamsfrom the USA, India, China andEurope. The former Formula One stars Alain Prost and Jarno Trulli haveentered their own teams, as well asadventurer Richard Branson and actorLeonardo DiCaprio. More than tendrivers have Formula One experience,including Brazilian Lucas di Grassi(30), who also competes in the FIAWorld Endurance Championship(WEC). Team ABT Sportsline’s secondcockpit is occupied by Germanyoungster Daniel Abt (21), who is also competing in GP2 as part of the

Formula One supporting programme.Schaeffler logos are featured on thecars of both Daniel Abt and Lucas di Grassi.

Formula E events are not held onpermanent race tracks but on streetcircuits in the heart of major cities.After Beijing, Formula E will visitPutrajaya (Malaysia), followed byPunta del Este (Uruguay), BuenosAires (Argentina), Miami (USA), Long Beach (USA), Monaco, Berlin(Germany), culminating in London(UK) where the final will take place on 27th June 2015.

At the events, practice, qualifyingsessions and the race itself all takeplace over a single day.

“Helping to shape the electrification of the automobile is one of our keystrategic topics of the future.Schaeffler is an innovation leader inthis field, frequently pioneering newideas. Formula E is bold and visionary,which makes it a perfect fit for us andan ideal complement to ourcommitments in DTM, WEC andFormula Student,” commented Prof.Peter Gutzmer, Member of theManagement Board for Technology at Schaeffler. “Motorsport is not onlyideally suited to accelerating thefurther development of newtechnologies, but also energises the

AS THE EXCLUSIVE TECHNOLOGY PARTNER OF TEAM ABTSPORTSLINE, SCHAEFFLER IS CELEBRATING THE TEAM’SFIRST WIN IN FIA FORMULA E, AFTER LUCAS DI GRASSISTOLE VICTORY IN THE INAUGURAL FORMULA EEVERGRANDE SPRING BEIJING EPRIX, WHICH TOOK PLACEIN BEIJING, CHINA ON 13TH SEPTEMBER 2014.

ABT SPORTSLINE ANDSCHAEFFLER CELEBRATE FIRST WIN IN FIA FORMULA E IN BEIJING

THE FORMULA E CAR IN DETAIL

Vehicle: Formula car, carbon/aluminummonocoque chassis

Power unit: Rear-wheel drive from two motor generator units (MGUs)

Transmission: Sequential 5-speed, with paddle shifters

Output (practice 200 kW (270 hp)& qualifying):Output (race): 150 kW (202.5 hp),

additional power output of30 kW (40.5 hp) by #FanBoost for three drivers

Acceleration: 0–100 km/h in 2.9 sec

Top speed: 225 km/h

Minimum 888 kg (incl. driver)weight:Dimensions: Length: 5,000 mm,

Width: 1,800mm, Height: 1,250 mm

Tires: Low profile tires A strong team behind the champion: Prof. Dr. Peter Gutzmer (the fourth from left), Schaeffler Group

deputy CEO and CTO, Joerg Walz (third from right), Vice President Communications and MarketingSchaeffler Automotive, Dr. Zhang Yilin (the first from left), Schaeffler Greater China CEO.

The all electric racing car in Formula E can reach from zero to 100km/h within three seconds.

Formula E drivers(Left) Lucas di Grassiand Daniel Abt.

Schaeffler chief technology officer Prof. Peter Gutzmerand team principal Hans-Jürgen Abt signing the contract

Lucas di Grassi celebrates the race win

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EXCEPTION-BASEDREMOTE CONDITIONMONITORING FOR UECCSHIPS’ GEARBOXES

SCHAEFFLER UK HAS INSTALLED CONDITION MONITORING SYSTEMS ON TWO SHIPS OPERATEDBY UNITED EUROPEAN CAR CARRIERS (UECC). THE MONITORING SYSTEMS, WHICH AREINSTALLED IN THE SHIPS’ ENGINE CONTROL ROOMS, ARE SET UP TO MONITOR THE VIBRATIONBEHAVIOUR OF THE ENGINE GEARBOXES.

s well as supplying andinstalling the conditionmonitoring hardware,Schaeffler is also providing

ongoing exception-based remotemonitoring services via V-SAT link.

This service not only provides an earlywarning system for any potentialgearbox failures, but also generatesuseful diagnostics and trend data thatUECC can give to class inspectors(e.g. Lloyds Register) during routineship audit inspections. These gearboxdiagnostics reports eliminate the needfor time consuming, inspections, whichcost tens of thousands of pounds pergearbox and cause costly delays while the ships remain in dry dock.

UECC is Europe’s leading provider of short sea RoRo transportation. The company transports around 1.5million units per year from a fleet of 23 vessels, two of which – theAutoStar and AutoSun – are fitted with Schaeffler’s FAG DTECT X1svibration monitoring systems.

On each ship, a single, 8-channel FAG DTECT X1s system is set up tomonitor four vibration points (two onthe gearbox input shaft and two on theoutput shaft) on each of the two mainengine gearboxes. The systems aremounted close to the gearboxes inprotective enclosures. A panel PCdisplays the vibration data from eachgearbox.

The systems are connected to theship’s V-SAT communications system.

The FAG DTECT X1s is a conditionmonitoring system that is suitable foruse in a wide range of industrial andmarine environments, including themonitoring of rotating components andmachines such as bearings, gearboxes,turbochargers, compressors, fans,pumps and drives.

All commonly used acceleration, speed and displacement sensors can be connected to the FAG DTECTX1s, enabling process parameterssuch as speed, temperature, torqueand pressure to be monitored.

UK-based company HargreavesMarine, Schaeffler UK’s partner for themarine industry, was responsible forthe specification and installation of theFAG DTECT X1s systems, as well asthe ongoing remote monitoring service.

The condition monitoring systems wereinstalled in 2013 and have alreadyproved their worth at UECC.Hargreaves MarineManaging Director, BobHargreaves says “If analarm is generated from theFAG DTECT X1s systems,we can immediately seethis regardless of wherethe ships are located in theworld. We can see whichbearing on which gearboxis responsible for triggeringthe alarm, and then decidewhether action is required by the ship’s engineers.

“We’ve adopted an exception-basedmonitoring strategy, whereby every 12hours, vibration data from the gearboxmonitoring systems is sent ashore tous via satellite link and cloud server.We can look at the vibration frequencyof the bearings inside the gearbox inorder to detect any deviations from thenorm. We can therefore monitor thehealth of the gearboxes and notify theship’s engineers if any remedial actionis necessary.”

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The UECC vessel AutoSun

The UECC vessel AutoStar

FAG DTECT X1s

FAG DTECT X1s installation

NEW POWER UNIT AND ALARM INDICATOR SIMPLIFYCONNECTION OF UP TO FOURFAG SMARTCHECK DEVICES

he FAG SmartConnectBoxpower supply unit enableseasy distribution of powersupply inputs and outputs

to a maximum of four FAGSmartCheck devices. In addition, a standard speed sensor andSchaeffler’s new FAG SmartLamplocal alarm indicator unit can also be connected to the FAGSmartConnectBox.

Rather than running separate cablesfrom four FAG SmartCheck devices to a speed sensor, this new systemprovides a cleaner, more elegantsolution for customers, particularlywhen monitoring the condition of largerotating machines such as electricmotors, geared motors and variablespeed drives.

FAG SmartCheck is an extremelycompact, online condition monitoringdevice that monitors vibration andtemperature, as well as a range ofother machine and process-specificparameters such as pressure and flow rate.

By monitoring these parameters, usersare provided with a broad basis ofinformation in real time, which enablesthe accurate assessment of machinecondition. The device is typicallymounted direct to the machinehousing.

Small and lightweight, the device can fit into areas on a machine wherespace is restricted.

Due to its IP67 protection rating, the FAG SmartConnectBox can alsobe mounted direct to the machinebeing monitored. The user mustprovide the SmartConnectBox with apower supply, but configuration of theFAG SmartCheck device is not alwaysnecessary – the user simply plugs inthe devices with the standard cablesprovided and the system is ready touse in the default setting.

FAG SmartConnectBox also providestwo analogue inputs (0-10V, 4-20mA),four analogue outputs (0-10V, 4-20mA) and a digital output, enablingthe system to output data to otherproduction control systems and PLCs.FAG SmartLamp enables localvisualisation of the alarm status ofeach SmartCheck device. This isparticularly useful if the fourSmartCheck devices are installed in a location that is hidden from view.

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SCHAEFFLER HAS LAUNCHED TWO NEW PRODUCTS THAT SIMPLIFY THE DISTRIBUTIONOF POWER AND INPUT/OUTPUT (I/O) SIGNALS OF UP TO FOUR FAG SMARTCHECKONLINE CONDITION MONITORING DEVICES, RESULTING IN REDUCED CABLING COSTSAND FASTER, EASIER INSTALLATION.

FAG SmartLamp

Easy distribution of power supply and in and output tomaximum of four FAG SmartCheck.

FAG SmartConnectBox and FAG SmartLamp.

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REMOTE CONDITION MONITORING BRINGS BIG SAVINGS FOR SPANISH WIND FARM

he latest generation ofcondition monitoring systemsdo just this, enabling plantoperators to monitor both

the condition of lubricating oils and thevibration of critical components such asgears and rolling bearings, on a widerange of heavy duty rotating plant andmachinery.

Industrial gears and gearboxes, forexample, are critical to the smoothoperation of heavy plant, including windturbines. If excess wear or damage isallowed to develop within a gearbox, thiscould result in secondary damage toother drive train systems, leading to highrepair costs and costly downtime.

Fixed (online) condition monitoringsystems can be set up to monitor boththe condition of the lubricating oil andthe vibration of rotating parts, enablingthe early detection of damage to heavyduty, oil-lubricated industrial gears.Schaeffler’s FAG Wear Debris Check oilmonitoring system indicates damage orwear to bearings, cages and gears withina gearbox or other industrial gear unit.The system requires no calibration and issuitable for use in almost every industrysector, including wind turbine gearboxdrive trains, providing plant operatorswith a reliable system for preventingunplanned downtime and reducing MRO costs.

The system’s oil monitor works byutilising an inductive particle counter(sensor), which is able to distinguishbetween ferrous and non-ferrous metalparticles that are present in thelubricating oil.

On a typical gearbox application, theparticle counter or sensor is installed inthe oil flow, directly before the oil filter, or as a separate circuit. The sensoroperates on the principle that any wearto a component such as a bearing orgear tooth will result in small metalparticles being rubbed off into the oil,often several months prior to an actualfailure.

The sensor provides information on thenumber of particles present in the oil,and then classifies these according totheir physical size. Analysing the oil inthis way enables damage and wear tothe gears to be detected much earlier,even in planetary gearboxes used onwind turbines.

In addition to oil analysis, the FAG Wear Debris Check can be set up tooperate in conjunction with onlinecondition monitoring systems, includingSchaeffler’s FAG WiPro s, a systemdedicated to the condition monitoring of wind turbines. This means thatcompanies can also monitor the vibrationbehaviour of the machine and itscomponents, including rolling bearingsand gear wheels. By using specialinterfaces, these systems can be easilyintegrated with online vibrationmonitoring systems, which can beadapted or retrofitted to suit customerrequirements. By installing vibrationsensors on the machine or gearbox that needs to be monitored, changes inthe operating behaviour are detected,indicating early signs of damage. This enables the plant to start suitablerepair work or plan some scheduledmaintenance in order to prevent failureof the machine, resulting in costlyproduction downtime.

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BY INSTALLING CONDITION MONITORING SYSTEMS FROM SCHAEFFLER ON 56 WINDTURBINES, SPANISH RENEWABLE ENERGY PROVIDER GEOLICA IS MAKING SIGNIFICANTANNUAL COST SAVINGS.

OIL ANALYSIS AND VIBRATION MONITORING PROVIDE EARLY WARNING TO PLANT OPERATORS

FAG WiPro sOnline ConditionMonitoring System

or wind farms, anyunplanned downtimecaused by damaged windturbine drive train

components can have significanteconomic consequences in terms oflost production and costly repairs. To avoid this, Geolica required acondition monitoring system for itswind turbines, which would detect anysigns of damage to drive traincomponents at an early stage, avoidingany unplanned downtime and givingthe company an opportunity to planany necessary maintenance work.

As Geolica had little experience ofcondition monitoring systems andanalysing vibration data, the companyalso required a remote monitoringservice and technical support from thecondition monitoring system supplier.

Geolica operates two wind farms inSpain with a total installed power base of 84.8MW. The wind farms, San Juan de Bargas and Santo Cristode Magallon, are located in Aragon.

At the San Juan de Bargas wind farm,Schaeffler has a total of 56 condition

monitoring systems installed– one on each 800kW

rated wind turbine.The 8-channel FAGWiPro s systemcontinuously monitors

the condition of themain rotor bearings (one

sensor), gearbox bearings(three sensors) and generator

bearings (two sensors).

Schaeffler also provides remotemonitoring services on a 24/7 basis.This includes a monthly conditionmonitoring report, as well as an alarmreport if measured values moveoutside of their normal range.

FAG WiPro s

Schaeffler’s FAG WiPro s is an onlinecondition monitoring system that issuitable for the permanent monitoringof wind turbines. The system isextremely compact, offering a highdegree of flexibility for end users. Thesystem combines all control modulesinto a single compact housing,enabling easy installation in controlcabinets. The integrated multiplexerenables the recording of signals fromup to eight different sensors.

FAG WiPro s monitors vibrationconditions which, if left undetected,can cause costly shutdowns of windturbines. These conditions includedamage to bearings and gears, as well as shaft misalignments. If a specified threshold value or alarmlimit is exceeded, the system triggersan alarm. The vibration monitoring data can be analysed directly on siteor can be retrieved via a TCP/IPcommunications link and analysed byeither the end user or by Schaeffler.

Significant savings

Since installing the FAG WiPro ssystems at the wind farm, vibrationmeasurement data is continuouslymonitored by Schaeffler’s OnlineMonitoring Centre. Schaeffler providesGeolica with detailed informationabout the wind turbines, which hasenabled the company to adopt acondition-based maintenance strategy.Thanks to the FAG WiPro s systemsand Schaeffler’s online remotemonitoring support, costly damage todrive train components has alreadybeen prevented on several occasions.

For example, two years after installingthe condition monitoring systems, earlysigns of damage were detected to theraceway of the inner ring and rollingelements on an intermediate speedshaft bearing on a wind turbinegearbox. The total cost ofreplacing this bearing was€9,500. However, if thedamage had not beendetected, the cost of anew gearbox would havebeen around €100,000.Therefore, allowing for theannual cost of providing aremote monitoring servicefor Geolica (€9,000), thecost savings achievedwere €81,500.

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MODERN LUBRICANTS ARE REGARDED AS ‘HIGH END CONSTRUCTION PARTS’ THAT PLAY AN INTEGRAL ROLE WITHIN THE MACHINE ON WHICH THEY ARE USED. IT IS CRITICAL THAT ANY SYSTEMS SET UP TO MONITOR THE CONDITION OF AMACHINE ARE ALSO CAPABLE OF MONITORING THE CONDITION OF THE LUBRICANT.

FAG WearDebris Check C

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chaeffler recentlyhosted a customer GolfDay at Lindrick GolfClub and, to the delight

of many, Lee Westwood OBE – whohas represented Europe for the last eight Ryder Cups, made a surpriseappearance.

The Club had invited Lee Westwood to 'cut the ribbon' to officially opentheir brand new tunnel, which enables golfers to go under ratherthan across a busy road in-betweenthe 10th and 11th holes.

It made for a great opportunity forsome of our Schaeffler hosts andcustomers to get photos andautographs, and to even see him play the last hole!

Karen Preston, Communications & MarketingManager (left) and Rebecca Haynes, MarketingAssistant (right) with Lee Westwood OBE

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LEADERSHIP ANDPROFESSIONALDEVELOPMENT COURSE

ell done to Birgitta Liesching, SchaefflerTechnology Centre – Sutton, and PaulDavies, Resident Project Engineer atJaguar – Sutton, who have recently

received their certificates after completing theleadership and professional development course!

Paul Griffiths – Llanelli, is putting together a team ofpeople to take part in this years Gower MacMarathon.

Entrants can choose to do a 22 mile or 14 milewalk to raise funds forMacMillan Cancer Care.The walk is taking placeon Saturday 13thSeptember, and onceagain the Company isproviding transportationfrom the plant, to theevent and back. The walktakes you along the Southcoast of the Gower, along a strenuous route in places,however you are rewarded with some of the mostspectacular views in Wales. If you are interested inparticipating in this event, please contact Paul for moreinformation or visit the MacMillan website.

Siobhan Griffin, New Business Coordinator – Sutton,and her daughter Francesca had the opportunity toswim with whale sharks at Ningaloo Reef, Australia’slargest and most accessible fringing coral reef, ontheir recent trip to Australia.

The whale sharks were approximately 6m in length, andwere still children, but the adults grow to 12m and weigh 21.5 tons! Siobhan has commented “it was amazing andsomething I will never forget, the sea was so clear andthey were so serene just gliding alongside me”.

NEW BABY NEWS!LONG SERVICE AWARDS

VIP LEEMACMARATHON

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Kathy KnightSutton Coldfield

David ReesLlanelli

Huw JenkinsLlanelli

Paul JenkinsLlanelli

Robert DaviesLlanelli

Greison NethellLlanelli

Neil WaltersLlanelli

Debbie MillingtonSutton Coldfield

Andrew SheridanLlanelli

Leighton WilliamsLlanelli

John HutchingsLlanelli

Andrew ParkhouseLlanelli

John Bailey Llanelli

Dorian QuirkLlanelli

Jas Moore Sutton Coldfield

Richard HalletLlanelli

Nigel JenkinsLlanelli

Michael ThomasLlanelli

25 YEARS SERVICE

30 YEARS SERVICE

Wayne PowellLlanelli

Anna ReesLlanelli

Claire JonesLlanelli

20 YEARS SERVICE

During the successful Christmasmeal in Sutton at the end of lastyear, we had the chance tocelebrate the long service awardsfor those employees who couldn'tmake it to the Summer Ball.

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LONG SERVICE AWARDSPRESENTATIONS AT SUTTON

Colin Woodhoods 40 YearsRichard Maskew 40 YearsKaren Preston 25 YearsGary Mackintosh 10 Years

SWIMMING WITH SHARKS

Luke Stacey, final year Apprentice –Llanelli, has become the proud fatherof a baby girl. Eve Aurora Stacey wasborn on the 20th March 2014 at 4:24pmat Glangwilli Hospital. She was 3 weekspremature but was out of the hospitalafter one night. Congratulations to Lukeand his new family!

Nigel Howard, Met Lab Technician –Llanelli, has also become the fatherof a baby girl. On the 25th April 2014his daughter Mali Alys Hill-Howard wasborn and she weighed 6lb 14oz.Congratulations to Nigel and his familyon the birth of Mali!

15 YEARS SERVICE

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Andrew CarterLlanelli

Francesca withwhale shark

CONGRATULATIONS TO THOSE WHO HAVE RECENTLY REACHED A LONG SERVICE MILESTONE

Dr Steve Lacey, Birgitta Liesching and Richard Hall

Karen Preston and Richard Hall

Colin Woodhoods and Richard Hall

PaulDavies

...avoidunplanned downtime

By monitoring the vital signs, engineers are in control of their plant andmachinery and can prevent unforeseen problems turning into costly breakdowns.

Online fixed systems and handheld CM devices from Schaeffler have a proventrack record in a diverse range of industry sectors from steel, paper, quarrying and mining to pharmaceuticals, food processing, wind energy and marine.However, the objective is the same: to maximise production output by avoidingunplanned downtime.

Our experienced CM engineers work closely with production and plant personnelto understand and maintain efficiencies and achieve cost savings. Call us on 0121 313 5870 to arrange a no-obligation site visit by one of our engineers.

www.schaeffler.co.uk

Early diagnosis of machine condition is key to healthy engineering plant and equipment

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