Mounting
Features
The Schaeffler industrial service experts offer mounting services for plain bearings that are applicable across industrial sectors. They have detailed knowledge and extensive experience in all industrial sectors.
The mounting personnel in the Industrial Service function are trained and skilled personnel who can provide reliable, rapid and competent assistance. The services are provided either at the customer’s location or in the Schaeffler workshop facilities.
Mounting services
The mounting services, ➤ Figure, include:
- mounting and dismounting of plain bearings of all types
- approval inspection of adjacent parts (shafts and housings)
- measurement and production inspection of tapered shaft seats, together with provision of the necessary measuring equipment
- maintenance and inspection of bearing arrangements
- support in achieving optimum mounting operations
- the use of modern mounting tools, such as heating by means of the versatile medium frequency technique
- the design and manufacture of special tools.
Mounting services
Advantages
The mounting services give the following advantages:
- extended bearing life
- considerable cost reductions
- less unplanned downtime
- increased plant availability
- correct use of plain bearings.
Further information
Enquiries: tel. +49 9721 91-3142, fax +49 9721 91-3639..
Equipment rental
Customers who require special mounting and measuring equipment only infrequently, for example in order to carry out repairs, can rent these from Schaeffler on a weekly basis for a fee.
Schaeffler offers rental of the following equipment:
- hydraulic nuts
- hand pump sets
- heating devices.
The devices are checked after each use by the Schaeffler experts and, where necessary, returned to full working condition.
Further information
Enquiries: tel. +49 9721 91-1133, fax +49 9721 91-3809
Service Hotline: tel. +49 2407 9149-99..
Mechanical tools
Mechanical tools are designed for the mounting and dismounting of bearings. The mounting forces are transmitted by the form fit effect.
Further information
Detailed information on mechanical tools can be found in Catalogue IS 1, Mounting and Maintenance of Rolling Bearings..
Thermal tools
Induction heating devices HEATER with mains frequency technology are used to heat plain bearings and other components with a cylindrical bore where a tight fit on the shaft or in the housing is intended.
Adequate expansion of the bearings is achieved in most cases at +80 °C to +100 °C. During the heating operation, the maximum heating temperature must be observed. In the case of plain bearings, the temperature may not normally exceed +130 °C, in order to avoid damage to the seals. In all devices for heating, the temperature can be steplessly controlled.
ACHTUNG
Wear protective gloves during mounting and dismounting of heated parts.
Induction heating devices HEATER
The induction heating devices HEATER for spherical plain bearings up to a mass of 1 200 kg have been improved further in terms of their performance capability and safety compared with their predecessors. They can also be used to heat sealed and greased spherical plain bearings. In addition to the tabletop devices HEATER10 to HEATER300, the range also includes the standalone devices HEATER600 and HEATER1200 for larger bearings. HEATER300 can also be converted to a mobile unit by means of accessories.
The scope of delivery of the induction heating devices HEATER covers a basic setup for the initial applications, ➤ Figure.
The spherical plain bearing to be heated is either placed horizontally on the support rails or is suspended on the ledge.
Scope of delivery:
Induction heating device HEATER
Advantages of heating devices
The advantages of induction heating devices are as follows:
- very safe operation
- high reliability (certified in accordance with the German inspection and certification body TÜV)
- effective, energy-efficient heating (high efficiency level)
- uniform, controlled heating
- automatic demagnetisation
- simple operation
- high cost-effectiveness through selection of the device size most suitable for the particular application.
The heating devices have various functions, see table.
Functions
Function | HEATER | ||||||
---|---|---|---|---|---|---|---|
10 | 20 | 40 | 150 | 300 | 600 | 1200 | |
Demagnetisation | ● | ● | ● | ● | ● | ● | ● |
Program shutdown | ● | ● | ● | ● | ● | ● | ● |
Display of actual | ● | ● | ● | ● | ● | ● | ● |
Temperature display | ● | ● | ● | ● | ● | ● | ● |
Display of actual | ‒ | ‒ | ● | ● | ● | ● | ● |
● | present |
Operating modes
The induction heating devices can be operated in the following modes:
- temperature control
- time control
- ramp control (size HEATER40 and above).
Induction units with medium frequency technology
The heating device with medium frequency technology gives rapid, simple and effective heating of medium-sized to large spherical plain bearings and similar steel parts for mounting and dismounting. The device always comprises two parts: an inductor and a generator.
The inductor can be of a flexible or rigid design. The rigid design is particularly suitable for batch applications. The flexible design of inductor can be wound around the components.
Each device is designed for the specific application and is fitted, depending on the workpiece, with flexible or rigid inductors.
Due to its compact construction, the device can also be used for mobile operation. The device can therefore be moved to the location of the workpiece. It can therefore be used, for example, at construction sites for wind turbines or for other large components that are difficult to transport.
Advantages
The advantages of the heating device with medium frequency technology are as follows:
- suitable for mounting
- suitable for dismounting
- operating frequency from 10 kHz to 25 kHz
- efficiency of the generator higher than 90%
- low energy requirements
- short heating times
- control of heating according to time and temperature
- automatic demagnetisation
- flexible and fixed inductors available
- suitable for use either inside or outside component
- lower mains connection power than heating devices with mains frequency
- almost silent
- air-cooled system.
Hydraulic tools
Hydraulic tools can be used to apply large forces. These tools are therefore particularly suitable for the mounting and dismounting of large bearings or parts with a tapered bore.
Hydraulic nuts are used as a mounting tool. Pressure can be generated using oil injectors, hand pumps or hydraulic units.
Hydraulic nuts
Hydraulic nuts HYDNUT, see table, are used to press components with a tapered bore onto their tapered seat. Presses are mainly used if the drive-up forces required cannot be applied using other accessories, e.g. shaft nuts or pressure screws.
The main area of application is:
- the mounting and dismounting of spherical plain bearings with a tapered bore.
- Spherical plain bearings are available by agreement with a tapered bore. The bearings can be seated directly on a tapered shaft, an adapter sleeve or a withdrawal sleeve. The hydraulic nut can also be used for the dismounting of adapter or withdrawal sleeves.
Available hydraulic nuts
Designation | Design | Application |
---|---|---|
HYDNUT50 to HYDNUT200 | With metric fine pitch | Standardised adapter and withdrawal sleeves |
HYDNUT205 to HYDNUT1180 | With trapezoidal thread to DIN 103 | With metric dimensions |
HYDNUT90-INCH to HYDNUT530-INCH | With inch size thread to ABMA | Sleeves with inch |
HYDNUT100-HEAVY to HYDNUT900-HEAVY | Increased capacity design with smooth bore | For high mounting forces, for example |
Further information
For detailed information, see TPI 196, FAG Hydraulic Nuts.
Enquiries: industrial-services@schaeffler.com,
+49 2407 9149-66..
Pump for drive-up distance
The hand pump PUMP1000-4L-CONTROL is particularly suitable as a pressure generation device where special spherical plain bearings are to be driven onto their tapered seat using a hydraulic nut, ➤ Figure.
First, the bearing is driven smoothly onto the tapered seat as far as the initial position. A suitable hydraulic nut is then screwed onto the shaft and the hand pump is connected. The hand pump is then operated until the pressure to reach the start position is achieved. The pump is then operated further to drive the bearing by the required drive-up distance and thus achieve the final position.
The user manual for the pump PUMP1000-4L-CONTROL contains a table that shows the number of strokes necessary to achieve the required drive-up distance of the bearing. The required drive-up distance is calculated using the software Mounting Manager.
Mounting of a spherical plain bearing using PUMP1000-4L-CONTROL
Scope of delivery
- Hand pump with digital manometer
- High pressure hose with coupling sleeve
- Spacer ring (HYDNUT50 to HYDNUT150)
- Plug-in coupling nipple
- User manual
- Metal case.
Ordering designation
- PUMP1000-4L-CONTROL.