All in One: Montage und Montageservice

Customer Success Story

Saves Time, Reduces Costs, Prevents Accidents

Mounting bearings on roller presses is a challenge the maintenance team at the Batisöke cement plant near Izmir, Turkey, faces regularly. Conventional methods, such as oil bath or blowtorch, are time-consuming and cost-intensive and carry a high risk of occupational accidents. The cement manufacturer therefore looked for an alternative solution. Their choice for the future: the induction system with medium-frequency technology.

The result: more than 85 percent time savings during maintenance work.

“Mounting large bearings used to be challenging and time-consuming. By using the MFT, the professional mounting team has shown us that mounting bearings can be easy.

My conclusion: With the Schaeffler mounting service and MFT, maintenance work is child‘s play.“
Çağdaş Alp, Mechanical Maintenance Chief

Benefits
Challenge
Solution
What's Special
Technical Information
Download
Contact

Benefits

Customer Benefits

More opportunities: suitable for thermal mounting and dismounting, also of large work pieces
More flexibility: choice between flexible and fixed inductors
More sustainability: energy-efficient heating process
More mobility: the MFT goes to the workpiece, not the other way round
More efficiency: lower costs and higher productivity, no mechanical wear of tool
More safety: for both man and machine

Challenge

The roller press performs an important task in a cement plant. It is used to crush hard to medium-hard materials such as clinker or crushed raw stone. The bearings of the roller press are subjected to high stresses in the process. Therefore, the bearings of the roller press have to be checked regularly and, if necessary, reconditioned or replaced. After reconditioning two bearings, the maintenance department was faced with the question of how these bearings could be mounted within a minimum amount of time. At the same time, the mounting procedure should not pose any safety risk to the employees. Therefore, methods such as heating with an oil bath or „blowtourch“ were no longer an option. The maintenance department of Batisöke Cement turned to Schaeffler Turkey for order to be able to use an alternative mounting method.

Technical information - Roller press

Machine type	KHD COMFLEX ® SC16-320 clinker grinding Roller Press
Nominal value	2 x 799.950 Nm
Power	2 x 1600 Kw
Size	RPS 16-170/180 with ROLCOX®

Solution

Schaeffler Turkey recommended the use of its medium frequency technology (MFT) induction system, an environmentally friendly and innovative solution that heats bearings in an energy efficient way.

The customer decided to rent a Schaeffler MFT induction system and commissioned the corresponding Schaeffler mounting service to carry out the work. First, the outer ring of the bearings was heated by attaching the inductor to the outer ring. The inner ring was then heated by attaching the inductor to the inner ring. The bearing could then be drawn onto the shaft. The Schaeffler transport and mounting tool was used for this purpose. This tool prevents the inner and outer rings from oscillating.

What's Special

The customer was impressed. The two engineers worked accurately and quickly. After only two hours, the mounting work was completed. In the past, this work took a total of 16 hours.

Schaeffler induction system with medium frequency technology in the old design.
Flexible Inductor

Technical Information

Induction units with medium frequency technology

Induction units with medium-frequency technology are not only suitable for thermal mounting but also for removal. They can also be used to heat up very large and heavy components.

Each unit comprises a generator and inductor that is positioned on the workpiece. A rigid or flexible inductor is used, depending on requirements.

Depending on the application, flexible inductors can be fitted in the bore or on the outside diameter of the workpiece. They are suitable for heating of bearing inner rings or for large components.

Rigid inductors are particularly well suited for volume production. Flexibility is less of a priority here than short setup times and a high level of process reliability.

Technical information on the new medium-frequency system

MFT	MF-GENERATOR3.0-44KW
Power	44 kW
Outlet frequency	10-25 kHz
Frequency	50 to 60 Hz
Dimensions (L x W x H)	600 x 650 x 580 mm
Weight	78 kg

Learn more about our MFT devices

Mounting service as well as tools and systems are part of the Schaeffler Lifetime Solutions portfolio, which offers a comprehensive range of products, services and solutions for industrial maintenance. It is designed to support maintenance engineers throughout a machine’s entire lifetime.

To Schaeffler Lifetime Solutions