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2011-09-19 | 000-003-094 DE-EN
SCHAEFFLER GMBH, HANOVER/SCHWEINFURT

Components and systems for heavy duty linear guidance systems

The trend towards the machining of large and heavy workpieces using high machining forces, for example in plant for the harvesting of regenerative energy, is also having an influence on the performance capacity of linear guidance systems. INA Linear Technology, as part of Schaeffler Group Industrial, has a wide portfolio of linear guidance systems and accessories which, based on rollers or needle rollers as rolling elements, offer the necessary performance density for the economical, high quality machining and handling of heavy duty workpieces.

Flat cage guidance systems
INA flat cage guidance systems of series M/V are characterized in particular by their high load carrying capacity in combination with extremely high precision. Their load carrying capacity can be attributed to the large number of load-bearing rolling elements in the load zone and the possibility of further increasing the number of needle rollers through the use of longer cages. The trend towards increasingly dynamic operation, which is also present in heavy duty plant, can be addressed with the aid of an integrated positive control mechanism for the cage. This positive control mechanism prevents cage creep even under highly dynamic conditions and thus increases the rating life. A typical application example for such guidance systems can be found in press transfer systems that provide precise and rapid handling of heavy components between the various stages in presses. The components weigh up to 200 kg. The transfer arm has a feed length of 8500 mm and a travel velocity of 8 m/s.

Linear roller bearings
Linear roller bearings of series RUS and PR based on cylindrical rollers can achieve a load carrying capacity of up to 840,000 N and thus offer a high degree of flexibility and design freedom. The roller bearings, which have sealed end faces, give particularly smooth and quiet running. In addition, the end piece gap dimensions and entry geometry have now been revised and adapted in line with the patented knowledge derived from monorail guidance systems. This has resulted in improved running behavior with optimum preload setting even under very high load. In series RUS, the rolling elements are kept apart by spacers. In contrast, series PR is of a full complement design and does not involve the use of plastics. As a result, the robust PR bearing is ideally suitable for use in high temperature and high speed applications. A classical area of application for these linear recirculating roller systems is the main guidance component of presses. Extremely high forces occur in these cases. The customer can combine the linear roller bearings with the appropriate adapters for integration directly in his adjacent construction, thus achieving the highest possible performance capacity within a very small space.

Monorail guidance systems
With the series RUE..E, INA Linear Technology is now offering the fifth generation of linear recirculating roller bearing and guideway assemblies. High load carrying capacity, robust, very rigid, precise and with excellent sealing – these are the most important features of this latest generation. In contrast to other manufacturers who use barrel-shaped rollers in their roller guidance systems, RUE..E is based on cylindrical rollers with profiled ends as rolling elements. Due to the larger contact area of the cylindrical roller, very high load carrying capacity and rigidity are achieved. Contact pressures are also reduced as a result. The pure line contact allows slippage-free rolling. In line with market trends, larger designs have also been included in the product portfolio. The range of sizes has been expanded to include the RUE 100 E-L. A carriage of this size has a dynamic load carrying capacity of 1,490,000 N. Such guidance units are used, for example, in ring reshaping machines for large rolling bearings in the wind energy sector. For the processing of rings with a mass of up to 4 t and a diameter of 4,500 mm, the RUE 100-E-L must be able to support forces of up to 2 meganewtons in the tensile axis. Where necessary, the length of a carriage (RWU 100 E-L) can even be extended for specific applications. With such an increase in carriage length in the XL design, a larger number of load-bearing rolling elements enter the load zone. This gives an increase in the load carrying capacity and thus also in the rating life. The guideway has reduced deflection, which leads to a further improvement in the machining accuracy.

Vibration damping
In addition to the high loads as a result of large workpieces and new materials, there are also continuing increases in machining speeds and cutting depths. As a result, excitations and vibrations may occur during machining. The Schaeffler Group has therefore applied the range of damping accessories to the large, high load capacity series. For RUE 100 E, therefore, damping carriages of series RUDS 100 are available in lengths of 150, 300 and 450 mm. These are positioned on the guideway between the carriages. The carriage has a defined gap filled with oil under zero pressure between the top surface of the guideway and the underside of the carriage. The resulting squeeze film gives damping of the vibrations.

Furthermore, INA Linear Technology offers the fully hydrostatic linear guidance system HLE, a ready-to-fit and sealed system with integrated pressure control, which combines the functions of "guidance" and "damping" within the design envelope of a monorail guidance system. It is thus a substitute for the monorail guidance system and allows optimum damping behavior.