Innovation for the real world: Reliable rotation by SKF

Victoria Van Camp – CTO and President, Innovation & Business Development

Providing reliable rotation –how?

© SKF Group

Detect Solve Rebuild or Remanufacture

© SKF Group

Detect Solve Rebuild or Remanufacture

Gain insights and make customers better

© SKF Group

The P-F* curve

Time

Vib

ratio

n

Defect starts

Failure

Reaction time for maintenance planning

28/11/2018Slide 5

P-F: Potential failure – Functional failure

Technology development enabling our REP business models

© SKF Group

The more we can detect, the more insight and opportunity we generate

➢ # of points monitored is important but…

➢ # of points connected to REP Centers is KEY

How do we get there?

• Ease of connection and use: your daily work tool

• Seamless and enjoyable UX

• Connected to bearings / housings from the start

• AI for detection, analysis and action

© SKF Group

Quick Collect: Seamless connections

API API API

Create asset Measure assetCreate profile Pulse Check

API

SKF Digital Platform

21 3 4

© SKF Group

SKF Multilog IMx-16Plus

Connectivity:

• Mobile data connectivity (4G)

• Wi-Fi

4G

Extended modbus capabilities for data sharing

• Dual master and slave mode

• Up to 4 connections to slaves and/or masters

© SKF Group

Next Generation Systems

IMx-1 low cost sensor computer:

• 2.4GHz ISM band mesh

• Acceleration, velocity, enveloping,

temperature

• Onboard alarm assessment logic

• Configurable measurement and transmit

rates

Smart Gateway:

• Sensor interface for configuration and control

• Patented 2.4 GHz coexistence technology

• Fast time synchronization between sensors

• Enables data sharing with 3rd party systems

© SKF Group

Data

ge

ne

rati

on

Pa

ram

ete

r e

va

lua

tio

n

Test

Simulation

1

𝐹,𝜔, 𝑙 𝑒𝑡𝑐.2

SKF small damage

propagation model

Verification tests

SKF

large damage

propagation

model

Spall growth

prognosis

Spall information

Influence factors

AI and physics for real life prognosticsD

ete

cti

on

alg

ori

thm

Pro

gn

osti

c

alg

ori

thm

Developing ”REP Ready” bearings

© SKF Group

Detect Solve Rebuild or Remanufacture

Gain insights and make customers better

© SKF Group

Cement roller press in Thailand

Bearings need protection!

© SKF Group

241/1250: SKF’s largest sealed SRB design – patented!

• Seal is almost 1.9m in diameter

• Seal weighs about 20 kg

• Possible to screw in outer-ring

• Possible to remove seal lip without discarding

entire seal

=

© SKF Group

Vibration levels of sealed and open SRBs

12 months

© SKF Group

Fee-based models in process industries

Customer’s need: Improve reliability

and reduce total cost of ownership

Customer’s problem: CAPEX cap

Solution: Function provided OPEX

Provide product every time it needs replaced

Monthly fee for providing a function

Equipment performance

Products

Cost

Time

© SKF Group 28 November 2018Slide 18

When one seal is not enough – the Three Barrier Solution

• 1st barrier: external housing seal

• 2nd barrier: housing grease

• 3rd barrier: integral bearing seal

© SKF Group

4-row CRBs face challenging conditions:

• Flooded housings => smearing

• Water in oil (5% to 25%) => surface wear and

severe corrosion

• Fretting corrosion causing bearing to jam

The result: Bearing runs 300-2000 hrs when it

could run 12000 hrs or more.

Providing a function: Steel- and aluminum production

Sealing improvement

Bearing solution

© SKF Group

Coated 4-row CRB for metal production: WISCO China

• August 2017: Start of operation

• November 2018: 6 400h and still running

Lab tests and simulations showed 4x life improvement with new design => prototype built and in field trial

FF

Water in oil

Voice of the customer:Very satisfied with the achieved running hours

Competitor running hours to failure:Competitor A: <2000h ring crack

Competitor B: <2000h

Competitor C: ~5000h

50%cost out

© SKF Group

Before and after remanufacturing

REP ready for extreme environments

© SKF Group

Large air conditioning units: lubricating with refrigerant

Bearings, normally oil-lubricated

Rotor wheel to compress refrigerant

• Cooling capacity ~ 1 MW

• ~ 5-8 % savings on system

efficiency with SKF solution

• Weight > 10 Tons when running -

of which one ton refrigerant

© SKF Group 28 November, 2018Slide 24

Film thickness analogy: Oil vs Refrigerant

Refrigerant lubr. ~ 20 nm

Oil lubricated ~ 500 nm

© SKF Group

Bearing grade silicon nitride

(ceramic) rolling elements

Bearing grade super-tough

steel rings

Balls

Rollers

Speed

Lubrication -

Contamination

Weight

Insulation

+20% higher speed of rotation

> increased efficiency in machine tools

3 times longer grease life

Less sensitive to contamination

> longer mainentance intervalls

Lower weight > lower fuel consumption

in aero applications

Eliminated electrial damage on bearings

> reduced risk for failure and replacement

Hybrid bearings main advantage

Longer Service

Life

Higher System

Efficiency

Performance based approach

Innovation - “Drop in” solution

Why hybrid bearings?

Engineering polymer cage

© SKF Group

For the design engineer: New life calculation for Hybrid bearings

0

2000

4000

6000

8000

10000

12000

14000

16000

15 12 9 6 3

L10 [

Mre

v]

C/P

L10 hybrid

L10 steel

Not covered with standard ISO life calculation

2x life under worst possible conditions

Increasing load

Designing for cost

© SKF Group

Value

innovation

Value

Cost

Everything you need, nothing you don’t

Design with value

in mind

Flexibility

Predictability

Serviceability

Remanufacturing

Mounting

Design with cost

in mind

Manufacturing

Purchasing

Cost-driver removal

© SKF Group

Kossan Glove manufacturing

• 12 months in operation, no issues

• Lower cost, longer life

• Engineering knowledge to optimize

dimensions, material, seal and grease

Food producers world wide

• Hygienic design to FDA standards – wash

it down at night

• No detergent ingress

• Low friction yet protective seal

Design for what matters, save cost on the rest

SKF Competitor

© SKF Group

Detect Solve Rebuild or Remanufacture

Gain insights and make customers better

Control process

• Hands-on realization of Industry 4.0. Bearings ideal for IoT

• SKF partners with Telecom to digitalize rotating equipment

• Bearings become Process Control instruments

• REP Technology leap: Control the process & prevent failures

• Scalable. Potential to make in “normal” SKF factory

SKF Fibre Optic SensingSensing load by light alone

© SKF Group

Our focus: Reliable Rotation at Lowest Cost

Fee based agreements – capture the value as it is being deliveredInsights from every touchpoint - making us and the customer better