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Press Release

EMO 2013: Solutions for Feed Spindles, Main Spindles, Rotary and Linear Axes,

and Condition Monitoring

Transparent Machine Tool:Schaeffler Presents its System Expertise

HANOVER/SCHWEINFURT, September 17, 2013. With its “Transparent Machine

Tool,” Schaeffler is not only making a visual splash at the EMO 2013. With its

numerous innovative solutions for feed spindles, main spindles, rotary and linear

axes, as well as for condition monitoring, Schaeffler showcases its broad

competence in high-performance and efficient machine tools, creating tools that

offer reliability, cost effectiveness, as well as dynamics and precision. Schaeffler’s

“Transparent Machine Tool” provides an exciting glimpse into the heart of a machine

tool – right where forces are transferred and performance is realized in precision and

productivity.

“With the Transparent Machine Tool, Schaeffler is highlighting its strategy of using

extreme customer proximity and system understanding to develop products and

solutions that enhance our customers’ competitiveness and make them successful,

in other words coming up with ideal ways to satisfy their demands both technically

as well as economically,” explains Martin Schreiber, the new manager of

Schaeffler’s Production Machinery Business Unit since August 1, 2013. “Optimizing

the overall system is always front and center in our minds. Our system level

expertise is the prerequisite for developing perfectly harmonized individual

components and modules,” continues Schreiber. Along with bearing supports and

guidance systems, this opens up for Schaeffler not only the entire direct drive

technology, but also the integration of additional functions into rotary and linear

bearing systems, such as damping and measuring systems.

The new leadership of the business unit signals continuity: Martin Schreiber has

more than 20 years of experience under his belt in the area of production machines.

Together with his predecessor Helmut Bode, he has been key in helping to shape

and globally underpin the strategy of the business unit, most recently in his work as

Manager of Market Development & Application Technology. Since April 2012, he

has been working as Senior Vice President Sector Management Industrial (OEM &

Industrial Aftermarket) in the Asia/Pacific region. Martin Schreiber is filling the place

of long-time head Helmut Bode, who is now taking over the responsibility for

Schaeffler’s industrial business in China as President Industrial Schaeffler Greater

China.

Schaeffler’s Product Highlights at the EMO 2013:

Rotary Axes: Absolute Angular Measuring System Integrated into the BearingSchaeffler has developed an angular measuring system integrated into the bearing

with an inductive mode of operation that is ideally suited to the demands of direct-

driven highly dynamic and precise rotary axes in machine tools. This has resulted in

further developments to the principle of integrating the SRM measuring system into

a rotary axis bearing that was already implemented successfully in the YRTM series.

The SRM measuring system combines high measuring speeds and precision as well

as installation space reduction and robustness. It is not sensitive to contamination,

features a center opening in the rotary axis, and impresses with how little alignment

work it requires. It therefore represents a convincing alternative to optical assembly

angular measuring systems. Bearings of the new INA series YRTSMA are available

in borehole diameters ranging from 200 mm to 460 mm. This is the mechanical

equivalent to the highly rigid YRTS high-speed bearing series.

Direct Drive Technology for Turning and Milling OperationsThe rotary high-performance direct drive series RKI of INA Drives & Mechatronics

AG & Co. KG (IDAM) offers outstanding performance characteristics that have not

been achievable up until now. The drives have 30% more torque compared to

conventional torque motors. This gives speed and mechanical performance that is

five times greater. At the same time, power loss is reduced by as much as 60%. This

means that less heat is produced. Energy efficiency is improved, and the operating

costs drop significantly since cooling requirements are lower. For improved

performance, it is possible to use smaller motors for the same capacity, thus

reducing costs for the converter and motor. In providing a compact bearing support

for rotary axes, Schaeffler has optimized the inner design of the double row

ZKLDF..B axial angular contact ball bearings so much that the achievable limiting

speed has been doubled, while the frictional torque goes down at the same time.

The high precision and rigidity of the bearing remain uncompromised. Especially

when combined with speed-optimized RKI torque motors from IDAM, this opens up

new possibilities in turning and milling operations that have previously not been

attainable with standard components.

Main Spindle: High-Speed Axial Bearings for High Performance and PrecisionThe use of high-speed FAG axial bearings of the BAX series now makes speed

parameters possible for combinations of open axial bearings with cylindrical roller

bearings on main spindles that were previously only able to be attained with spindle

bearings. At the same time, this bearing combination features a separation of the

axial and radial load in the bearing support. Since this means that there are no tilting

effects that have to be absorbed, the kinematics are not adversely affected when

there is a combined load. This makes the bearing support particularly robust. The

user profits from a high degree of operating precision as a result of the high rigidity.

The load carrying and rotary capacity are both excellent, giving good cutting

performance and high productivity.

Main Spindle: Friction Optimization by Means of Modern BearingsWith the FAG RS (“Robust and Speedy”) for spindle bearings and TR (“Thermally

Robust”) for cylindrical roller bearings, Schaeffler offers a combination of high load

carrying capacity and high performance reserves for increasing speeds. At the same

time, the friction-optimized inner design makes it possible to reduce the friction loss

of the bearing support. This is primarily noticeable when the spindle runs for a long

time at high speeds. The option to lubricate the bearing support with grease even at

high speeds increases the operating safety of the spindle and lowers costs by

eliminating the need for compressed air to supply the bearings with lubricant.

Linear Technology: Integrated Magnetic LMSA Travel Measurement SystemSchaeffler has developed the LMSA (“Length Measuring System – Analog”) series

measuring system for integrated travel measuring in main axes. It is based on an

inductive analog measuring principle that attains a precision of +/- 3 µm/m. With its

high degree of robustness, it is not sensitive to magnetic interference fields and is

free of hysteresis in its operation, without any magnetism or residual magnetism.

Similar to the integrated LMST and LSMD measuring systems that are already

known, the complete linear recirculating ball bearing and guideway assembly of the

KUVE..LMSA series consists of a carriage with an adaptable housing for the

measuring head and a guideway for locating the dimensional scale. Measuring is

carried out according to the inductive principle of a transformer with a moving

reluctance core. A sensor head probes the incremental dimensional scale in the

guideway head by means of a high-frequency alternating field, producing two sensor

signals that are displaced by 90°. A stainless steel band with high-precision

photolithographic etched partitioning forms the dimensional scale. The motion

between the probe head and the measuring tape produces a compensating mutual

inductance of the individual spools, thus generating sine-wave signals. In this way,

the LMSA measuring system has a 1Vss analog output with a non-partitioned signal

period of up to 10 µm. This allows the measuring system to be easily combined with

existing control systems.

Diagnosis Systems for Quality and Process ReliabilityComponent replacement based on actual conditions during planned downtimes,

consistently high processing quality, reducing costs caused by lost production – all

are important for today’s operators and manufacturers of modern machine tools. As

a manufacturer of components and condition-monitoring systems, Schaeffler

Industrial Aftermarket is a reliable sector partner with its proven products and

valuable consultation service. There are various bearing diagnosis systems

available to suit the demand and monitoring strategy chosen, such as FAG Detector

III, FAG DTECT X1 s, and FAG ProCheck. For use in machine tools, Schaeffler is

offering an innovative online system in FAG SmartCheck that provides

comprehensive information on the condition of the machine components while taking

additional parameters into consideration. Machine tools can be monitored in three

expansion stages using FAG SmartCheck. In the first stage, individual components

are monitored in a decentralized fashion. It is possible to access the device directly

in line with the data. Based on the measuring data, FAG SmartCheck generates the

proper alarm thresholds. A SmartCheck app enables data to be accessed via a

smartphone. If the user selects the second phase, the device is integrated into the

machine control system in an intelligent fashion. Process integration can be realized

through communication interfaces. The third phase allows for service activities to be

expanded. This may involve remote access via an Internet connection or even

consultation and other services. Process integration of the FAG SmartCheck into the

control system can be carried out using the communication options provided by the

available inputs and outputs. This represents a possibility and a basis for

communication with the machine using interfaces – which also applies within the

context of Industry 4.0 – meaning that machines will be capable of functions such as

self-diagnosis in the future. Moreover, there is a series of additional monitoring

systems that can be implemented depending on customer demand.

* * *Schaeffler with its product brands INA, LuK and FAG is a leading provider of rolling bearing and plain bearing solutions and of linear and direct drive technology, as well as a renowned supplier to the automotive industry of high-precision products and systems for engines, transmissions, and chassis applications. The globally active group of companies generated sales of approximately 11.1 billion euros

in 2012. With over 76,000 employees worldwide, Schaeffler is one of the largest German and European industrial companies in family ownership. The Industrial division supplies components and systems for around 60 industrial sectors via its worldwide organization and its application support service. The range comprises more than 225,000 products from miniature bearings only a few millimeters wide, e.g. for dental drills, to large-size bearings with an outside diameter of several meters, e.g. for wind turbines.

Images: Schaeffler

Schaeffler’s “Transparent Machine Tool” provides an exciting glimpse into the heart

of a machine tool. With numerous innovative solutions, Schaeffler showcases its

broad competence in high-performance and efficient machine tools at the EMO

2013.

New INA bearing YRTSMA: Rotary axis bearings with an integrated absolute

angular measuring system for precision rotary axes.

In providing compact bearing support for rotary axes, Schaeffler has optimized the

inner design of the double row ZKLDF..B axial angular contact ball bearings so

much that the achievable limiting speed has been doubled. Especially when

combined with speed-optimized RKI torque motors from IDAM, this opens up new

possibilities in turning and milling operations that have not previously been

attainable with standard components.

The use of high-speed FAG axial bearings of the BAX series now makes high speed

parameters possible for combinations of open axial bearings with cylindrical roller

bearings that could previously only be attained with spindle bearings.

FAG cylindrical roller bearings of TR design have a flexible outer ring. This prevents

the bearing from being sensitive to varying temperature differences and exhibits

considerably lower friction loss.

The new FAG RS series has a friction-optimized inner design with large rolling

elements and a contact angle of 20 degrees. It combines high load carrying capacity

with the most ideal suitability for high speeds. This can greatly reduce the frictional

torque of the bearing support on the working side.

Schaeffler has developed the LMSA (“Length Measuring System – Analog”) series

measuring system for integrated travel measuring in main axes. With its high degree

of robustness, it is not sensitive to magnetic interference fields and is free of

hysteresis in operation.

FAG SmartCheck: An innovative solution for monitoring vibration and other

parameters.

Contact: Martin AdelhardtSchaeffler AGVice President CommunicationsSchaeffler IndustrialGeorg-Schäfer-Strasse 3097421 Schweinfurt, GermanyTel.: +49 9721 91-3400Fax: +49 9721 91-3375

Mobile:+49 172 [email protected]

Johanna KatzenbergerSchaeffler Technologies AG & Co. KGCommunication - Schaeffler IndustrialGeorg-Schäfer-Strasse 3097421 Schweinfurt, GermanyTel.: +49 9721 91-3873Fax: +49 9721 91-3375Mobile: +49 151 4066 [email protected]

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