Schaeffler UK Training s Improve your skills and knowledge on rolling bearing selection, operation and maintenance to improve machinery utilisation and reliability Schaeffler (UK) Ltd Forge Lane Minworth Sutton Coldfield West Midlands B76 1AP Email: info.uk@schaeffler.com Web: www.schaeffler.co.uk
Schaeffler UK Engineering Excellence Training your staff for the future challenges in the selection, operation, maintenance and reliable operation of rolling bearings The correct selection, maintenance and monitoring of rolling element bearings is crucial to maximising the life and reliability of plant and equipment. Just selecting the bearing is not enough, it must be mounted properly in the first place, have the correct type and amount of lubricant and be relubricated at the right interval. The loss of a critical piece of plant or equipment will often result in costly lost production or downtime, so Condition Monitoring can be successfully used to minimise disruption and hence save costs. The challenges facing our customers are important to us and the training courses outlined here have been structured to ensure that we give our customers the maximum support possible during the initial design process through to the successful operation and monitoring of their plant and equipment. As a company, we believe that flexibility is key to the future and, in addition to the training modules outlined here, we can offer bespoke courses to meet the individual needs of our customers. Supported by staff with many years' experience in the design and application of rolling bearings, our instructors can offer expert guidance and advice both during and after the training course. We look forward to seeing you at our new training facilities in Sutton Coldfield. Kate Hartigan Managing Director Schaeffler UK PAGE 2 PAGE 3
Our Training Schaeffler UK has developed comprehensive training programs that address the needs of engineers involved in numerous aspects of rolling element bearings. From maintenance fitters to designers of complex rotating equipment, we have an effective training program to suit your needs. Schaeffler training programs offer a comprehensive range of courses covering all aspects of machine reliability from bearing selection through mounting/dismounting to maintenance including vibration analysis and condition monitoring. The benefits of training include: Increased plant efficiency through reduced downtime due to machinery problems Knowing what bearing to select and how to maximise machinery performance Gaining skills in mounting/dismounting of bearings and eliminating costly mistakes Obtaining a better understanding of maintenance requirements, including grease selection, quantity and relubrication intervals Learning how Condition Monitoring can improve plant utilisation and the techniques available Understanding how to use Vibration Analysis to monitor the performance of plant and equipment What We Offer Training is delivered by experienced engineers with many years' experience in the design, application and operation of rolling element bearings. We have specialists in vibration analysis and condition monitoring who can provide ongoing support and share their experience. While training takes the form of standard modules for ease of selection, the training can be tailored to meet the specific requirements of the customer. We would be very pleased to discuss your particular training requirements. We offer both basic and advanced training courses. Our Facilities Our courses are designed for a wide and varied audience, from Managers, Engineers and Technicians involved on a day-to-day basis in the selection and operation of rolling bearings through to maintenance professionals responsible for mounting the bearings on shafts and in housings and specifying the correct type and quantity of lubricant. The training is also of benefit to Condition Monitoring Engineers and Technicians who need to identify when plant and equipment is starting to go wrong and the reasons for these problems. Training s Rolling Bearings Applications Training Condition Monitoring Product Training Code Days Page Introduction to Rolling Bearings RBIL1 1 6 Rolling Bearing Technology RBTL1 2 7 Introduction to Bearing Lubrication RBLL1 1 8 Bearing Failure Analysis RBFAL1 1 9 Mounting of Bearings RBML1 1 10 Bearings for Electric Motors RBEML1 1 11 Condition Monitoring - Introduction CML1 1 12 FAG Detector III FDIIIL1 1 13 At the Schaeffler UK site in Sutton Coldfield, West Midlands, we have a full range of facilities to offer both classroom based and practical hands-on experience. If required we can also offer courses at your own premises. Dr Steve Lacey, Engineering Manager, Schaeffler UK Vibration Analysis Vibration Analysis - Level 1 VAL1 2 14 Vibration Analysis - Level 2 VAL2 3 15 PAGE 4 PAGE 5
Rolling Bearings Rolling Bearings RBIL1 Introduction to Rolling Bearings RBTL1 Rolling Bearing Technology Overview The course gives a basic introduction to rolling element bearings, covering types, basic functions, load directions and bearing fits. It covers the basic rating life calculation and influencing factors and provides a brief introduction to bearing lubrication, including grease quantities, relubrication intervals and life. A brief overview of typical bearing failure modes is included. Overview The course gives a more in-depth description of rolling element bearings covering bearing types, load directions and bearing fits. It introduces the calculation of basic and adjusted life values and influencing factors and covers bearing lubrication, including grease quantities, relubrication intervals and life. A brief overview of typical bearing failure modes is provided. participants an overview of the key factors affecting rolling bearing selection and operation. It is intended to describe some of the main bearing types and give practical guidance on the selection and use of lubricating greases. Engineers, technicians and maintenance personnel who have some involvement with the specification or the operation of rolling bearings. The course is ideally suited to personnel with limited knowledge of the selection of rolling element bearings. Content Introduction to Rolling Friction Rolling versus sliding friction Basic concepts - boundary, mixed and fluid friction Friction and temperature Introduction to Bearing Types Ball and roller bearings Contact pressure Radial and axial loads Concept of misalignment Self aligning bearings Spherical roller bearings Dimension series and sections Application examples Tapered roller bearings Shaft and Housing Fits Tolerances Typical fits Bearing precision Bearing clearance Material and temperature effects Introduction to Bearing Life What life is required What affects bearing life Basic life calculation Dynamic equivalent load Fatigue failure Fatigue load limit Bearing Static Capacity How to calculate static load capacity Index of static stress Lubrication Basic concepts of friction Oil versus grease lubrication Initial grease selection Important points to consider Selecting the right base oil Selecting the correct operating viscosity Grease lubrication - the correct amount Grease lubrication - relubrication interval Greases available from Schaeffler Grease data sheet Grease operating life - calculation Bearing Failures Why do bearings fail? What is fatigue? Types of failure Information Fee participants more in-depth knowledge of the factors affecting rolling bearing selection and operation. It is intended to describe some of the main bearing types and arrangements and covers life, lubrication and failure analysis. Engineers, technicians and maintenance personnel who require a more detailed understanding on the selection and operation of rolling bearings. The course is ideally suited to design or application engineers who require in-depth knowledge of bearing design and operation. Content Introduction to Rolling Friction Rolling versus sliding friction Basic concepts - boundary, mixed and fluid friction Friction and temperature Introduction to Bearing Types Ball and roller bearings Contact pressure Radial and axial loads Concept of misalignment Self aligning bearings Spherical roller bearings Dimension series and sections Application examples Tapered roller bearings Bearing Arrangements Locating, semi-locating and non-locating Shaft and Housing Fits Tolerances Initial bearing radial internal clearance (RIC) Mounted RIC Operating RIC - effects of temperature Bearing Friction Sources of friction Stribeck curve Load and viscous friction Heat Generation Bearing temperature Heat dissipation Introduction to bearing life Bearing Life Basic life calculation Adjusted life Expanded adjusted life Fatigue load limit Dynamic equivalent load Fatigue failure - subsurface Fatigue failure - surface initiated Lubrication Basic concepts of friction Oil versus grease lubrication Initial grease selection Important points to consider Selecting the right base oil Selecting the correct operating viscosity Grease lubrication - the correct amount Grease lubrication - relubrication interval Grease data sheet Grease operating life - calculation Bearing Failures Why do bearings fail? What is fatigue? Types of failure Information Days 2 Fee PAGE 6 PAGE 7
Rolling Bearings Rolling Bearings RBLL1 Introduction to Bearing Lubrication RBFAL1 Bearing Failure Analysis Overview This course covers the fundamentals of bearing lubrication including both oil and grease, with an emphasis on grease lubrication. The course will explain the need to select the correct lubricant for the application and describe how the bearing operating parameters such as speed, load, temperature etc. influence the lubricant selection. The importance of viscosity and providing the right quantity of lubricant is explained. Overview The course covers the fundamentals of bearing failure modes and analysis and shows how to identify the more common failures through knowledge of the load patterns on the bearing raceways and rolling surfaces. It provides an understanding of where things go wrong and why and knowledge of preventive methods, particularly during assembly of bearings in the housing and on the shaft. The aim of the course is to help participants understand the fundamentals of bearing lubrication and why selecting the right type and quantity of lubricant is vital in order to maximise bearing life. It is intended to show the importance of viscosity and how failure to meet the necessary cleanliness can severely impact bearing life. Engineers, technicians and maintenance personnel responsible for bearing selection, bearing lubrication specification and selection and lubrication system design and management. Content Introduction to Rolling Friction Rolling versus sliding friction Basic concepts - boundary, mixed and fluid friction Friction and temperature Introduction to Bearing Life What life is required What affects bearing life Basic life calculation Dynamic equivalent load Fatigue failure Fatigue load limit Bearing Life Basic rating life What is L10 life? Adjusted rating life Expanded adjusted rating life Lubrication Basic concepts of friction Oil versus grease lubrication Selecting the right base oil Selecting the correct operating viscosity Grease Lubrication Types of grease Selecting the correct grease Initial grease selection Important points to consider Grease lubrication - the correct amount Grease lubrication - relubrication interval Greases available from Schaeffler Grease data sheet Grease Operating Life Influencing factors How to calculate grease life Example calculation Bearing Failures Why do bearings fail? What is fatigue? Types of failure Information Fee participants the knowledge required to recognise reasons for failure from the load patterns on bearing rolling surfaces and to perform damage analysis, understand terminology and recognise the appearance of different types of damage. Engineers, technicians, fitters, apprentices, maintenance personnel and Condition Monitoring personnel. The course is ideally suited to personnel who require a basic understanding of bearing failure modes. Content Introduction to Rolling Bearings Rolling versus sliding friction Basic concepts - boundary, mixed and fluid friction Friction and temperature What affects bearing life Basic life calculation Dynamic equivalent load Fatigue failure Fatigue load limit Bearing Static Capacity Dynamic load capacity Static load capacity Index of static stress Bearing Failures Why do bearings fail? Incorrect fitting Fitting - the do's and don'ts Mounting methods General types of bearing failure Raceway markings Damage and failure overview Basic rating life Subsurface fatigue Surface initiated fatigue Types of wear Fretting corrosion Contamination Water contamination False brinelling Brinelling Fatigue fracture Practical experience Hands-on experience Information Fee PAGE 8 PAGE 9
Rolling Bearings Applications Training RBML1 Mounting of Bearings RBEML1 Bearings for Electric Motors Overview The course provides an understanding how to get the most from machinery by ensuring that the correct methods and procedures are in place for the mounting of bearings. It also gives guidance on how to avoid the simple mistakes often made during assembly and understand where problems occur and why. It describes preventive methods that can be used, particularly during assembly of bearings in the housing and on the shaft. Overview The course provides a thorough understanding of the types of bearings and bearing arrangements used in electric motors. It presents the considerations to be made during the selection process and covers the installation, lubrication and maintenance of bearings. participants a good understanding of the correct methods for mounting bearings in order to achieve the predicted bearing life. Following a short theoretical overview, the course will focus on practical training where the student will use various heating devices and mounting tools/methods. The intention is that participants will gain a good appreciation of best practice that can be implemented immediately to gain real benefits in terms of improved machinery performance. Personnel involved either directly or indirectly in the mounting or dismounting of rolling bearings. This may include engineers, technicians, fitters, supervisors, apprentices, maintenance personnel and Condition Monitoring personnel. Content Basics of Rolling Element Bearings Bearing types Bearing terminology Selection of bearing type and size Lubrication Types of lubricant and methods Importance of maintenance Mounting of Rolling Element Bearings The do's and don'ts Preparation Having the correct tools Working in the correct environment Cold mounting Hot mounting Using the correct tools Dismounting Practical Training Mounting of bearings using heating plate, induction heaters, adaptor sleeves Dismounting Information Fee Sutton Coldfield participants an understanding of the fundamentals of bearing selection, lubrication and maintenance to maximise bearing service life in electric motors. Engineers, technicians and maintenance personnel responsible for bearing selection, operation and maintenance. Content Introduction to Rolling Friction Rolling versus sliding friction Basic concepts - boundary, mixed and fluid friction Friction and temperature Overview of Bearing Types Types of bearing - ball and roller Load considerations Ball versus roller bearings Types of sealing Limiting speeds Bearing designations Bearing Life Basic rating life Bearing loads Dynamic load capacity Static load capacity Adjusted rating life Expanded adjusted rating life Typical Bearing Arrangements Fixed and floating bearings Adjusted bearing arrangements Compensating for axial thermal shaft expansion Bearing Failures Why do bearings fail? Types of failure - fatigue, contamination, skidding etc Skidding - minimum load Current insulated bearings Lubrication Basic concepts of friction Oil versus grease lubrication Bearing basic rating life Grease Lubrication Types of grease Selecting the correct grease Initial grease selection Bearing friction torque Important points to consider Grease lubrication - the correct quantity Grease lubrication - relubrication interval Greases available from Schaeffler Grease Lubrication Methods Manual and automatic systems FAG lubricators Bearing Mounting and Maintenance Fitting - general considerations Some do's and don ts Brinelling and false brinelling Manual assembly methods Mechanical and hydraulic presses Mounting sleeves and tools Shaft and Housing Fits Interference and clearance fits Fretting corrosion Axial and radial clearance Bearing radial internal clearance Maintenance Products Heaters Mounting/dismounting tools Laser alignment Condition monitoring Information Fee PAGE 10 PAGE 11
Condition Monitoring Product Training CML1 Condition Monitoring - Introduction FDIIIL1 FAG Detector III Overview The course covers the fundamentals of noise and vibration, starting from the basic concepts, and gives an introduction to Fast Fourier Transform (FFT) as a diagnostic technique. Some practical examples and case histories are presented to show how vibration analysis can be used to solve problems. Overview The course provides a basic introduction to the use and operation of the FAG Detector III vibration data collector, comprising a solid foundation in the configuration and use of the Detector III including how to set up routes. The course includes a basic introduction to vibration analysis. This course is intended for engineers/technicians with limited knowledge of vibration analysis who wish to become more familiar with vibration based condition monitoring. This course is intended for engineers/technicians with limited knowledge of vibration analysis who wish to become more familiar with vibration based condition monitoring. Content Principles of Vibration Time signal Amplitude and frequency More complex time and complex signals Vibration Measurement Considerations Sensor types and location Sensor mounting Selecting machinery to be monitored Vibration Measurement ISO guidelines Assessing vibration severity Trending Spectrum analysis Data Acquisition Analogue to digital conversion Spectrum resolution Complex signals Beat frequency and amplitude modulation Demodulation and envelope signal Frequency classification Spectral Analysis Spectral analysis - basics Sidebands Harmonics Damping Impacts Vibration Signal Processing Average, RMS, crest factor Spectrum analysis Enveloping Cepstrum Rolling Bearings Ball and roller bearings Kinematic zones Kinematic frequencies Types of defect and spectrum Typical Machine Problems Unbalance Misalignment Fundamental belt frequency Eccentricity Typical Rolling Bearing Faults Calculating defect frequencies Failure stages Measuring defect frequencies Types of damage and spectra Case Histories Examples of faults/defects and the resulting time data and frequency spectra Participative discussion of case histories Information Fee Sutton Coldfield participants essential information on the use of FAG Detector III, covering basic operation, configuration and analysis and interpretation of results. Personnel who intend to use FAG Detector III for monitoring machinery condition. Content Introduction What is Detector III? Advantages and limitations of Detector III Features of Detector III Vibration Basics Sinusoidal motion Displacement, velocity and acceleration Time and frequency domain More complex signals Signal Processing and Signal Analysis Harmonics Low and high pass filters Amplitude modulation and demodulation Resolution in the time and frequency domain Characteristic values Trending Faults in Machinery Rotating and impact forces Bearing defect frequencies Gear frequencies Simplified defect frequency patterns Detector III Measurements Principles of operation Filters, number of lines and resolution Characteristic values Crest factor Temperature, speed and trigger Sensors Accelerometers Mounting methods Frequency response and sensitivity Maintenance Machine life cycle Maintenance strategies Benefits of CM Getting Started Getting started - system requirements Connections on Detector III Trendline structure Plant structure - paths and routes Creating a new path How to configure a measuring point Significance of a trend measurement Connecting and measuring with Detector III Displaying measured data on PC Machine classes, ISO 10816 Practical Task 1 Simple exercise to configure Detector III and measure vibration Use of available tools with the Viewer Signal analysis using FFT, cursor functions, harmonic and sideband cursor Advanced Monitoring Planning the measurement Setting low pass filters Number of lines in spectrum Selecting bearing from database Pre and main alarms What to do if an alarm occurs Options in Viewer Example of defect bearing Reporting Information Fee PAGE 12 PAGE 13
Vibration Analysis Vibration Analysis VAL1 Vibration Analysis - Level 1 VAL2 Vibration Analysis - Level 2 Overview The course covers the fundamentals of noise and vibration, starting from the basic concepts, and gives an introduction to Fast Fourier Transform (FFT) as a diagnostic technique. Some practical examples and case histories are presented to show how vibration analysis can be used to solve problems. Overview The course gives comprehensive and detailed coverage of the principle and application of vibration analysis and its role in investigating machinery defects. The investigation of machinery defects and their associated time waveforms and spectra is described. Some aspects of signal processing and data collection are also covered. Case histories are considered in a participative manner. participants a basic understanding of vibration analysis and how it can be used to monitor the performance of plant and equipment. The course is suitable for engineers/technicians or maintenance staff entering the field of PCM (Plant Condition Monitoring) but who have limited relevant experience. It will also be useful to other professionals who would like to understand condition monitoring with a focus on vibration analysis. Content Principles of Vibration Motion, RMS/peak/peak-peak, frequency/period Displacement, velocity and acceleration Units and unit conversion Time and frequency domain - sinusoid Time and frequency - more complex signals Harmonics in time and frequency Basic Vibration Analysis Low and high pass filters Amplitude modulation Demodulation Resolution in time and frequency Filters and lines (Detector III) Characteristic values and trends Spectrum analysis: Harmonics, sidebands and the analysis process Alarm limits, trending and exception reports Fault diagnosis: Unbalance, misalignment, looseness, eccentricity, resonance Defects associated with bearings, gears, belts, electric motors Defect Frequencies Rolling element bearings Kinematic frequencies Defect frequencies Simplified FFT patterns Sensors Accelerometer Correct mounting Sensor selection ISO 10816 Machine classes Case Histories Examples of defects and associated time signals and frequency spectra Information Days 2 Fee The aim of the course is to provide participants having some experience of vibration analysis with more detailed knowledge and experience of the subject. Engineers/technicians involved in PCM (Plant Condition Monitoring) with six to nine months' experience of vibration analysis and data collection who wish to expand their knowledge and experience and who wish to perform machinery vibration measurements. As a prerequisite for attending this course, participants must already have completed the Level 1 course VAL1. Content Principles of Vibration Complete review of basics Waveform, spectrum (FFT), phase and orbits Understanding signals Data Acquisition Analogue to digital conversion Spectrum resolution Complex signals Beat frequency and amplitude modulation Demodulation and envelope signal Frequency classification Types of Vibration Deterministic, stochastic Damping Impacts Vibration Measurements Placement of sensors Rolling Bearings Ball and roller bearings Kinematic zones Kinematic frequencies Types of defect and spectrum Belt Drives Types Fundamental belt frequency Eccentricity Misalignment Gearboxes Gear mesh frequency and sidebands Sensor position Types of damage and spectra Other Sources of Vibration Shaft unbalance Couplings Blade pass frequency Mechanical looseness Successful Condition Monitoring Program Setting baselines and alarm limits Report generation, reporting success stories Case Histories Examples of faults/defects and the resulting time data and frequency spectra Participative discussion of case histories Information Days 3 Fee PAGE 14 PAGE 15
Our Facilities Enquiry Form At the Schaeffler UK site in Sutton Coldfield, West Midlands, we have a full range of facilities to offer both classroom based and practical hands-on experience. If required we can also offer courses at your own premises. Schaeffler UK Training s Complete your details and send to our Marketing Services department by FAX: +44 (0)121 313 0080 OR e-mail: info.uk@schaeffler.com Delegate Details Name: Job Title: Email: Company Name: Address: Postcode: It was very well presented and the technical/practical mix was just right. The lads came away with a good understanding and have already started looking at what we do. The whole day provided food for thought and we came away with a number of actions and tasks so it was hugely beneficial. Matthew Orme Senior Mechanical Engineer, Mechanical Testing Support Lubrizol Tel: Mobile: Name: Code: Number of Delegates: Fax: Preferred Date(s): PAGE 16 PAGE 17
Together we move the world Schaeffler UK Training s Enquiry Form Complete your details and send to our Marketing Services department by FAX: +44 (0)121 313 0080 OR e-mail: info.uk@schaeffler.com The Schaeffler Group is one of the world s leading engineering businesses, employing about 70,000 people at 180 locations worldwide and achieving global sales in excess of 9.5 billion (in 2010). The Group, which remains a family-owned concern, markets its products under three world class brands INA, FAG and LuK. INA was formed just after the Second World War and made its big breakthrough in 1949 with the invention of the needle roller and cage assembly. This product is still in use in its original form and the INA product range has been expanded to include ball and roller bearings, spherical plain bearings, housed units and linear bearings and systems. In addition to its bearing products, INA has developed into one of the world s foremost suppliers of automotive engine components and works in partnership with many automotive manufacturers to develop solutions to their requirements for more efficient, economical and environmentally friendly vehicles. The history of FAG dates back to 1883 and the development of a ball grinding machine which made it possible, for the first time, to produce a perfectly round steel ball. In the intervening years, the FAG product range has expanded to include cylindrical, spherical and tapered roller bearings, angular contact and deep groove ball bearings. The combined INA and FAG standard catalogue now comprises over 40,000 standard products for use in over 60 industrial sectors ranging from power transmission, mechanical handling, construction, mining and quarrying, steel and paper to automotive and aerospace. Support for these industries is provided by Schaeffler's Industrial Aftermarket Division (IAM) which develops and supplies a wide range of online and offline condition monitoring equipment designed to provide warnings of potential problems and to minimise unplanned plant and machinery shutdowns. IAM also supplies a wide range of specially developed maintenance tools and equipment. The Schaeffler Group maintains its leading edge by constantly developing products to meet the specific needs of its customers. To this end more than 5000 staff worldwide are directly involved in research and development, and, on average, their efforts result in over 1200 patent registrations per year. located at Sutton Coldfield in the West Midlands, is the headquarters for all sales, marketing, engineering and logistics for both the INA and FAG brands in the UK. In-house application and design engineers work with carefully selected distributors and direct with end users to deliver the best engineered and most cost effective solutions to each individual requirement. In addition, Schaeffler UK operates a manufacturing plant in Llanelli in South Wales, which is a world class facility for the production of mechanical tappets for the automotive industry. The plant also operates a Linear Quick Centre and provides refurbishment services for industry. PAGE 18 PAGE 19