Displaying items by tag: SMB Bearings

Thursday, 07 September 2023 10:44

Bearings in space

~ AISI 304 and ceramic bearings will be vital to the next giant leaps for mankind ~

"Space is a risky business,” once said Aaron Cohen, the Acting Deputy Administrator of NASA. “I always considered every launch a barely controlled explosion." With several new space projects expected in the near future, these risks must be avoided at all costs. This puts a greater onus on engineers to create high-performing components that can withstand violent shuttle launches and inhospitable vacuums of space. Here, Chris Johnson, managing director at specialist bearing supplier SMB Bearings, explains the vital role of advanced bearings in man’s journeys beyond the stars.

The United Nations (UN) has identified space-based services and technologies as being key to its 17 Sustainable Development Goals for 2030. Space technology, says its website, will be “key in understanding climate change and during the full disaster management cycle; only two examples among countless applications to which space can contribute to.” Forbes magazine predicts several space technological developments over the coming years. They include green-oriented projects, like infra-red cameras on satellites to monitor thermal emissions produced by homes and businesses, and satellite imagery maps that will measure deforestation in relation to carbon usage.

Smaller payload trips to the Moon are also planned, adds Forbes, and the launch of more satellites. These projects will put more pressure on equipment manufacturers to source and use mission-critical machine components which can survive the vacuum of space. Vital components like sensors, solar cells, lenses and semiconductors will be subjected to extreme temperature fluctuations due to the sun's unfiltered radiation, causing failures and millions of dollars’ worth of damage, in some cases.

These challenges also apply to bearings. A major problem is that ultraclean vacuum environments, especially those characterised by high or low temperatures or highly corrosive elements, can affect bearing life by an astonishing 90 per cent. On the one hand, machine builders have been raising the performance requirements for bearing used in Earth-based applications like food processing and steel fabrication, specifically to enhance how they perform in highly corrosive environments and against exposure to moisture and chemicals. But how can bearings withstand the vacuums of space, and increasing demand for their use in space applications?

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Longer life

The harsh conditions of space include demanding factors like absolute vacuum, fluctuating temperatures, and also the extreme and violent G-forces rocket components are subjected to during lift-off. To withstand these conditions, bearings should be space approved — but what does this mean, exactly?

For a start, bearings for use in space should ideally meet the AS9102 Aerospace First Article Inspection standard that covers processes for manufacturing parts, from small electrical components to large structural assemblies, which are used in in aviation, space, and defense. This is part of the AS9100 series of regulations, which is the ISO 9001 quality management system equivalent for aerospace. These standards put engineering demands on the bearing itself.

Take the ball cage, for instance — also called the retainer, which separates the bearing’s balls from the central rolling component. The cage can be made from AISI 304 austenitic stainless steel because of its excellent corrosion resistance and good performance at high temperatures. Coating stainless steel bearings in Polytetrafluoroethylene (PTFE), one of the world’s most versatile known plastic materials, is also beneficial. PTFE is becoming more used outside spacecraft and has exhibited tensile, elongation, flex and impact properties that are up to ten-times better in vacuum environments than more commonly-used fluorine-based plastics, like Tefzel (ETFE).

The bearings’ life should also be considered — especially if they are to be used in rolling elements aboard spacecraft that must remain operational away from Earth for years, decades or indefinitely. Lubrication is vital here, and low outgassing and low-vapour pressure oils have been developed especially for space applications. Synthesized hydrocarbon or Perfluoropolyether (PFPE) liquid lubricants have been used in the aerospace industry for more than 30 years.

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Aggressive environments

Let’s look at other materials: ceramics, which are commonly used in thermal protection systems or heat shields in space. Ceramics are shown to effectively withstand extreme temperature changes — such as when a spacecraft enters any type of atmosphere at high speeds, be it Earth or Mars. Ceramics have excellent low and high temperature stability which means they can be used in deep space and cryogenics as well as furnace applications.

This brings us to ceramic bearings, which are often overshadowed by their steel bearing counterparts due to their pros and cons. First the cons: the roundness of ceramic bear rings is not as good as those in high precision steel bearings. Although ceramic bearings are harder than steel, the material is also more brittle. For this reason, full ceramic bearings are not used in very high speed applications like machine tools or turbines. Super-precision hybrid bearings are preferred for these applications. Ceramic bearings are also more costly.

Nevertheless, ceramic bearings are used in aggressive environments where are other materials are not suitable. They are most-commonly used in applications where excellent corrosion resistant is required, along with exposure to extremely low or high temperatures. In other words, ceramic beings are ideal for use in space. 

The most common materials used in SMB Bearings’ ceramic bearings are zirconia (ZrO2) and silicon nitride (Si3N4). Both have excellent corrosion resistance, These materials have a low friction coefficient, which brings us to a key advantage of full ceramic bearings: they can run constantly at speed without lubrication, which is why Si3N4 is often used in vacuum environments.

ZrO2 bearings can be used up to 400 degrees Celsius and Si3N4 bearings up to 800 degrees Celsius. Also, for these temperatures, SMB Bearings recommends the bearings should be full-complement. This means the bearing doesn’t have a ball retainer and, instead, the free space allows additional balls to be fitted. This increase in ball complement allows for significant increases in radial bearing capacity although maximum speed is greatly reduced. Down to approximately minus 200 degrees Celsius, ceramics also have excellent low temperature performance provided a suitable cage is used.

With their lightweight and vacuum-compatible properties, silicon nitride bearings will be greatly relied-upon in space-exploration applications. They will particularly benefit satellites and spacecraft, which need optimal weight capacities in order to perform enhanced flight dynamics and acceleration. These specialist bearings, along with their stainless steel counterparts, will be vital to ensuring that the next giant leap for mankind is a far-from risky business.

Published in Technology News
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Tuesday, 10 January 2023 09:04

Are drones in the pipeline?

~ The buzz around drones in the oil industry ~

A bee can travel over five miles and then remember its way home, despite possessing a brain the size of a pinhead. Scientists have been putting them in virtual reality simulators to help improve unmanned aerial vehicle (UAV) or drone technology. While the honey bee currently has the edge, drone technology is catching up. Here, Chris Johnson, managing director at miniature bearings specialist SMB Bearings, explains the challenges and opportunities when using drones to monitor and inspect oil and gas pipelines.

Drones are being employed in a wider range of sectors and for myriad purposes. The further growth and adoption of this technology will be encouraged by consumer market growth, spill overs from the military sector and the possibilities opened up by 5G. The potential for drones to revolutionise the world of maintenance is clear. They certainly pass the ‘D test’: tasks that are dirty, dangerous and dull could all be left to drones.

BP, Shell and Exxon have already begun using drones for asset inspection and other tasks. Following an incident in 2008, where Exxon’s use of sonar technology was implicated in the deaths of 100 whales near Madagascar, the company recently used drones to help monitor the locations of whales off the coast of Santa Barbara.[i] But what about the benefits for pipelines?

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Opportunity in the pipelines

From Alaska to the Niger Delta, oil pipelines are often located in inhospitable or even dangerous environments. In addition to their vast size, this fact makes maintenance through visual inspection a dangerous task. By handing the task of visual inspection over to drones, human workers are no longer in harm’s way.

Making the task of maintenance safer is not the only incentive. Early investors in the technology are seeing significant cost savings. Although it is difficult to quantify the precise saving, research by Roland Berger, has estimated that drone-based inspection of oil and gas rigs leads to cost savings of around 90 percent. The same research estimated that the use of drones has cut maintenance times from eight weeks to five days. The bottom line is that drones will provide a more cost-effective alternative to traditional asset inspection methods such as helicopters and ground vehicles.

However, drones are not simply replacing existing methods. Their agility allows them to offer visualisation and data analysis that existing methods cannot compete with. For example, satellites are limited by their orbit and weather can disrupt the accuracy of the images they provide. An engineer would have to assemble scaffolding to physically access a potential problem.

Scientists now claim that sophisticated sensors are developed enough and small enough to be mounted on UAV systems. As well as capturing high resolution visual data, drones can be equipped with other sensors to monitor pipelines, such as thermal imaging or ultrasound inspection. 

Challenges for take off

Companies wanting to adopt this technology must also make sure they understand the evolving regulatory environment. Those that already use aviation, for example with helicopters, are probably in a better position to confront this hurdle due to their existing knowledge of aviation regulation.

Beyond visual line of sight (BVLOS) is among the most discussed things in the drone industry. This refers to where a drone is operating beyond the pilot’s line of sight. BVLOS activity will be necessary to enjoy the full benefits this technology could offer for asset inspection of pipelines, but in some countries it is not permitted.

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In the United States, for smaller drones flying below 400 above ground level (AGL), BVLOS is currently not permitted without the necessary authorisation from the Federal Aviation Administration (FAA). To navigate around this restriction an FAA waiver is required. According to Geospatial World, 99 percent of waiver applications fail.

The restrictions are different when you enter different airspace classifications (those above 400 AGL). For pipelines that traverse national boundaries, these regulatory issues become even more complex.

Another consideration many businesses must make is what business model to adopt. In its guidance for the industry, the American Petroleum Industry outlines three alternative models.

Although the technology is constantly improving, there are limitations that are relevant to their potential for surveying pipelines. The limitations of the batteries that power the vehicles gives rise to range anxiety, a problem that is more significant for pipelines that cover significant distances. It is likely the industry will focus on using drones for inspection of oil rigs and other infrastructure before taking on the challenge of vast pipelines.

Something to bear in mind

If maintenance engineers are to exploit the benefits of UAV technology, keeping the drones in tip-top condition will be essential. Understanding the maintenance needs of these vehicles will be important for those companies who adopt the internal model referred to above. Engineers will need to be quick to acquire fresh expertise in this area.  

Maintaining and replacing the bearings in drones will be an essential part of this. Many oil installations face significant risks from corrosion. Bearings too, need protection from corrosion. If your drone is operating in an environment where this risk exists, speak to a reputable supplier like SMB Bearings for the best information on bearing choice for your application.

The buzz surrounding drones is only set to grow and their use in monitoring and maintaining oil installations will allow the oil industry to improve worker safety, reduce the time taken to complete key maintenance tasks and realise substantial cost savings. If you are thinking of adopting an unmanned aerial vehicle program to monitor your assets, consider the benefits of partnering with a reliable supplier of high-quality precision bearings to help keep your drones in the air.

SMB Bearings is a specialist supplier of miniature bearings. To find out more visit smbbearings.com

[i] Stephanie Roker (2016), ‘Exxon Mobil using drones to track whales,’ 13 July, available at: https://www.worldpipelines.com/equipment-and-safety/13072016/exxon-mobil-using-drones-to-track-whales/

About SMB Bearings: SMB Bearings originally specialised in miniature bearings, thin-section bearings and stainless steel bearings. By natural progression, the company expanded the range to include other corrosion resistant bearings such as plastic bearings, 316 stainless bearings and ceramic bearings.

Remaining a specialist business, SMB Bearings provide a high level of product knowledge, providing bearing and lubrication solutions to existing or potential customers, whether individuals or large corporations. SMB Bearings does not just sell bearings, but helps to solve your problems.

For further information please visit http://www.smbbearings.com/    

Published in Oil & Gas
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~ SMB Bearings on how to make the right lubrication choices for bearings ~

Specialist bearings supplier, SMB Bearings, has produced a new infographic illustrating some of the key considerations that need to be made when choosing lubricants for bearings. Bearings are often supplied with standard lubricants. Yet there are many applications where specialist or non-standard lubrication is required. Knowing what considerations matter and what is appropriate for your application can help make the right decision when choosing lubricants.

2022 02 25 121022Whatever industry you are working in, chances are you rely on bearings for your equipment to work effectively. According to one study, up to 80 percent of bearing failures can be attributed to problems with lubrication. Getting this decision right will save you and your facility money.

The lubrication choices infographic identifies some of the priority factors to consider when choosing lubricants. It identifies five key areas where standard lubrication will not suffice: high-speed applications. extreme temperatures, vertical shaft applications, low torque applications and applications in the food and beverage sector.

‘‘Our new infographic highlights some of the key factors that are relevant in choosing the right lubricant and can serve as a quick way of guiding your choices,’’ explained Chris Johnson, director of SMB Bearings. ‘‘However, should you require more detailed information, a specialist bearing supplier like ourselves is always willing to offer advice on what lubricants are best for your application.

SMB Bearings has always sought to be more than a standard supplier of bearings. The company also offers its own inhouse relubrication service. ‘‘Many customers have asked us to supply non-standard lubricants such as food grade, high temperature or military specification greases and oils,’’ added Johnson. Since successfully launching its own relubrication facility over 25 years ago, SMB Bearings has grown this part of its business further, with an additional processing room, additional staff and specialist relubrication equipment.

The experience of providing this service has strengthened the company’s expertise in this area, which it is keen to share with customers. The company has made available a host of free educational resources, including its series of downloadable guides and whitepapers on different bearing-related subjects. ‘‘For me, a key part of what we do is not just sell bearings – we solve problems too,’’ offered Johnson.

The infographic is intended to serve as an accompaniment to the SMB Bearings’ ‘‘Choose your grease’’ quiz. The quiz is free to access and can be completed on the company’s website. By correctly answering the questions, participants are guided to the appropriate choice of lubricant for their application.

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About SMB Bearings: SMB Bearings originally specialised in miniature bearings, thin-section bearings and stainless steel bearings. By natural progression, the company expanded the range to include other corrosion resistant bearings such as plastic bearings, 316 stainless bearings and ceramic bearings.

Remaining a specialist business, SMB Bearings provide a high level of product knowledge, providing bearing and lubrication solutions to existing or potential customers, whether individuals or large corporations. SMB Bearings does not just sell bearings, but helps to solve your problems.

For further information please visit http://www.smbbearings.com/   

Published in Food & Materials
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Thursday, 24 February 2022 20:05

Energy efficient bearing design

~ Three bearing design considerations to reduce friction ~

It is estimated that a ten per cent reduction of friction in all large bearings in use would provide an energy saving equal to the output of 18 large power stations. Cutting friction in bearings of any size is a key method to improve energy efficiency. Here Chris Johnson, managing director at miniature bearings supplier SMB Bearings explores the bearing design possibilities for increased efficiency in industrial applications.

In recent years, bearing manufacturers have increasingly focused on creating energy-efficient bearings — making use of new materials, lubrication techniques and advanced geometry designs to reduce losses without sacrificing the load carrying capacity.

However, energy losses in bearings are not considered the primary focus of plant optimisation efforts because they are already considered a high efficiency component. On the other hand, some argue that bearings are so ubiquitous — with a huge number of installed bearings in industry — that this overall energy consumption and potential energy savings should not be ignored. Let’s take a closer look at three bearing design considerations to decrease friction and increase efficiency.

Advanced materials

Energy-efficient bearing designs focus primarily on reducing the contact between the rolling elements and the raceways or the cage. By reducing the roughness of the contacting elements, friction will be reduced. Furthermore, the osculation of the bearing at both the inner and at outer rings significantly effects the friction by reducing the contact area and thus the microsliding of the contact.

According to a 2021 study, friction-optimised designs can have a significant impact on the reduction of the global energy losses of bearings. Based on the design of one bearing manufacturer, a preliminary estimation of this reduction is about 0.15 – 0.20 per cent of global energy consumption.

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Traditionally, steel has been the material of choice in bearing design, but polymer-based materials, such as PTFE and nylon, offer many benefits when used in less demanding environments. These benefits include corrosion resistance, reduced need for lubrication and a reduced weight.

Geometry

Geometry considerations such as special cage designs and the number of balls in a bearing influences the amount of friction generated, as this determines the number of frictional contacts during operation. The geometry, as well as the process by which the retainer is manufactured, have an influence on the friction generated. For example, opting for a 3D printed retainer in nylon (PA66) or another polymer material can help to reduce the weight of the whole bearing.

In some cases, ceramics offer a feasible alternative to metal. They have properties that offer similar benefits to metal, but they’re much lighter too.

Carbon-fibre reinforced nylon is one of the most popular combinations for nylon-printed materials. It offers many of the same benefits as standard nylon including high strength and stiffness, but it produces significantly lighter components. Surface coatings can have a significant effect on bearing friction reduction. Coatings such as molybdenum disulphide and tungsten disulphide increase wear resistance, fatigue durability, and reduce friction during bearing motion.

Lubrication

A proper lubricant will reduce friction between the internal sliding surfaces of the bearing’s components and reduce or prevent metal-to-metal contact of the rolling elements within their raceways. While this is a good way of reducing wear and preventing corrosion, there are new materials that, when used on bearings, dramatically reduce friction compared to the lubrication and surface treatment options that are currently on the market. The material in question is graphene.

The process of adding a graphene coating to bearings would be relatively simple and similar to adding a traditional lubricant. When graphene becomes readily available, we will examine this form of lubrication more closely.

As well as not being harmful to the environment, graphene flakes that are added to the surface of a bearing can last a considerable amount of time, due to the ability of the flakes to reorient themselves during the initial wear cycles, providing a very low coefficient of friction (COF).

In a study on the potential of graphene as a new emerging lubricant, researchers estimated that the reduced loss of energy to friction offered by new materials would yield potential energy savings of 2.46 billion kilowatt-hours per year, equivalent to 1.5 million barrels of oil.

By optimising each element of a bearing’s design to consider friction, it is possible to reduce bearing friction. By multiplying this saving for each bearing in a machine, plant or industry, significant energy savings can be realised.

For further information about SMB Bearings’ range of products and services visit the website

About SMB Bearings:

SMB Bearings originally specialised in miniature bearings, thin-section bearings and stainless steel bearings. By natural progression, the company expanded the range to include other corrosion resistant bearings such as plastic bearings, 316 stainless bearings and ceramic bearings.

Remaining a specialist business, SMB Bearings provide a high level of product knowledge, providing bearing and lubrication solutions to existing or potential customers, whether individuals or large corporations. SMB Bearings does not just sell bearings, but helps to solve your problems.

For further information please visit http://www.smbbearings.com/    

Published in Metals
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