New bearing concepts for renewable energy
Bearings and simulation software will prove key to the future of renewable energy systems, argues Dr Steve Lacey.One of the greatest engineering challenges that we face today is in meeting global energy requirements while preserving the environment. Although solar energy will certainly play its part, in the UK, wind, wave and tidal energy systems will be the most likely future sources of renewable energy. In the UK wind energy sector, for example, experts predict that by 2020, more than 6,000 wind turbines will need to be installed in the UK if the country's future energy targets are to be met.
Investment in renewable technologies requires a significant financial commitment. Protecting this investment by ensuring maximum availability of wind, wave and tidal turbines is therefore critical. As a manufacturer of high precision rolling bearings, Schaeffler will continue to play an important role in improving the reliability and safety of wind, wave, tidal and solar energy systems.
Rolling bearings are a core component of renewable energy systems and are key to reducing operator costs. The design of low friction bearings for a wind turbine rotor shaft and gearbox, for example, are important considerations, as well as the associated lubrication methods for the bearings, mounting, maintenance and the use of remote condition monitoring and diagnosis techniques to ensure that maintenance costs are minimised and service life is increased.
In a typical wind turbine drive train, rolling bearings are used to support the rotor, alternator and gearbox. Plain bearings are found in blade adjusters in pitch-controlled wind turbines and in geared motors that drive the tower slewing ring and pitch control. Over the next decade, the significance of rolling bearings will increase as new, larger, multi-Megawatt class wind turbines are developed. This trend towards larger, multi-megawatt wind turbines will lead to more radical changes in the design of the bearings. And 'single bearing' designs will become increasingly important.
With single bearings, the wind turbine rotor is supported only by a single, double row tapered roller bearing, typically in a back-to-back arrangement that supports all forces and moments. This concept can take many different forms, for example, with a shaft and gearbox and a high-speed generator, as a hybrid solution with shortened gearbox and medium-speed generator, or as a direct drive without a gearbox. Single bearings always result in more compact designs. For example, the wind turbine nacelle can be fully integrated with the bearing-gearbox-generator unit. This means that it is possible to eliminate drive train components and reduce weight. This in turn reduces the head weight of the wind turbine, allowing smaller foundations to be used and simplifying logistics.
Another advantage of the single bearing design is that preloaded tapered roller bearings can be utilised, which prevent axial clearance and small axial misalignments. This narrow, tight guidance of the rotor shaft means that less movements act on the system, reducing the negative effects on the gearbox and generator.
Spherical roller bearings from Schaeffler are already playing an important part in several high profile European wave and tidal energy systems, including the Pelamis P2 wave energy converter. Key to the success of this development is a new joint concept that utilises a new low friction material developed by Schaeffler. This modified PTFE fabric liner has low friction characteristics that effectively eliminate the problem of 'stick-slip'. This has enabled the operating envelope of the P2 machine to be extended beyond the capabilities allowed by standard bearing materials. Rolling bearing calculation software, Finite Element Analysis (FEA) and dynamic simulation tools will also play a critical part in developing next-generation renewable energy systems. For this to succeed, collaborative development projects between multiple component suppliers will be necessary.
Schaeffler is currently working closely with three companies - a gearbox manufacturer, a wind turbine manufacturer and a software developer - to develop new simulation software that is able to calculate the dynamic operating loads acting on wind turbine powertrains. Used in combination with FEA tools, this complex, multi-body simulation (MBS) model will enable design engineers to optimise the design of individual powertrain components and to establish how these interact with other systems across the entire powertrain. Simulation tools such as these, which can be used at the initial wind turbine design stage, will prove invaluable in helping to make future wind turbine designs more reliable and cost effective under a wide variety of load conditions. New bearing designs can be developed and tailored to specific wind turbine requirements, including turbines for both onshore and offshore wind farms.
Other News from Schaeffler (UK) Ltd

- Schaeffler introduces CONCEPT1 lubricator
- Automatic lubricators and Arcanol grease ensure conveyor motor bearings run reliably at opencast mine
- Unique data matrix codes help in the fight against fake bearings
- Plain Bearings from Schaeffler - tried and trusted for 75 years
- Schaeffler UK supports local charities
- High cost savings through online condition monitoring and automatic lubrication of flood pumps
- Schaeffler provides custom rotating direct drive motor for one of the world’s largest reflecting telescopes
- Schaeffler forges ahead with technology transfer
- Robots get greater range with plug-and-play linear actuators
- Condition monitoring test rig helps ensure high train availability
- Schaeffler presents electric motors ready for volume production
- Improved brass cage and insulation coating prolongs bearing life in rail applications
- Counterfeit bearings put end users and distributors at risk
- Plain bearings optimise bobsled chassis and steering systems
- Vibration analysis prolongs the life of critical motors
- Schaeffler takes over remainder of Compact Dynamics
- Vibration analysis helps crisp producer reduce downtime
- Lubrication of rolling bearings on a paint shop ventilation fan
- Top five considerations for replacing linear systems
- Rolling bearing selection: look at the bigger picture
- Schaeffler UK launches condition monitoring services
- Dispelling the myths about linear guidance systems
- Schaeffler bearings keep lock gates and valves moving on the Panama Canal
- Refurbishment of tilt bearings for Pendolino trains keeps Alstom on the right track
- Keeping wind turbines running with high reliability
- Schaeffler receives 2015 Quality Supplier Award from Danfoss
- Plug-and-play linear systems for production machines
- Schaeffler receives 2015 Quality Supplier Award from Danfoss
- Schaeffler celebrates 125 year anniversary of ball grinding mill
- High precision bearings for printing machinery
- Germanischer Lloyd certifies Schaeffler test method for calculating the rating life of rolling bearings
- Planetary screw drive offers high load carrying capacity and high power density
- Schaeffler supplies custom bearings for Pioneering Spirit
- Schaeffler launches online rolling bearing calculation software for electric motors and generators
- Schaeffler lends it support to winning Teen Tech team
- Monorail guides for wing assembly jig
- Swap scheme broadens skills of apprentices
- Wear of rolling bearings: signs, causes and remedies
- Schaeffler supplies monorail guides for Airbus A350 wing assembly jigs
- All you need to know about the lubrication of rolling bearings
- Monitoring the health of cable car drive systems
- Schaeffler becomes an e-F@ctory Alliance partner
- A guide to selecting the right linear guidance system
- Schaeffler becomes exclusive technology partner of ABT Sportsline in FIA Formula E
- Schaeffler receives award for carbon-based coating system
- 700 page technical guide
- Understanding how fatigue contributes to bearing failure
- Schaeffler to work with Porsche on new hybrid sports car for Le Mans
- Multi-point lubricator for rolling bearings
- Schaeffler unveils compact 48V electric drive module for hybrid electric vehicles
- New plummer block housing increases bearing operating life by up to 50%
- Unique multi-point lubricator caters for up to eight different bearing positions
- Precision components for e-bikes ensure higher efficiency and improved rider comfort
- Linear actuators
- Rally success for E-Wheel Drive concept car
- Schaeffler expands its range of innovations for all-electric and hybrid vehicles
- Corrosion-resistant and media lubricated bearings for water power applications
- Improve your skills and knowledge on rolling bearings and condition monitoring
- New large size, high performance tapered roller bearings reduce frictional torque by up to 50%
- Water power systems turn on corrosion-resistant bearings
- Screw drives for machine building and automation
- Schaeffler extends ballscrew drives to include new rolled version
- Split sphericals save €220,000 for chemical plant
- Schaeffler destroys 26 tonnes of counterfeit rolling bearings
- Materials and coatings increase operating life of bearings in harsh food and beverage applications
- Correct bearing mounting saves time and extends life
- Fully integrated linear actuator and rolling bearing units designed for solar tracking systems
- Schaeffler and Ford unveil concept Fiesta with new space-saving electric wheel hub drives
- Rolling bearings: a guide to material selection
- X-life large cylindrical rolling bearings offer new design opportunities
- Device enables fast, easy alignment of rotating plant
- Online guide to mounting rolling bearingsOnline guide to mounting rolling bearings
- Schaeffler replaces main Trunnion Bearings on BOS Plant Vessels at Tata Steel Port Talbot
- Prevention is better than cure
- Bearing and condition monitoring training
- Precision bearings for solar energy offer long life and high efficiencies
- Wind Power Standard ensures improved reliability
- Schaeffler provides online condition monitoring of turbines at Crystal Rig wind farm
- Novel, lightweight designs cut vehicle fuel consumption and CO2 emissions
- Smooth movement of kinetic sculptures
- Hybrid bearings prevent premature failures in short stroke ball screw applications
- Linear actuators ensure precise positioning of sheet metal parts for transformer cores
- Prevent unplanned downtime of drill rig plant and machinery
- Intelligent sensor simplifies condition monitoring tasks
- Linear actuators enable faster delivery of prescription medication to patients
- Compact online sensor monitors condition of vibrating screens, pumps and motors
- Improved bearing design for wind turbines
- System know-how and solutions for all bearing positions on wind turbines
- Online condition monitoring of grease in rolling bearings
- Composite plain bearings for wind, wave, tidal and solar energy systems
- New improved online condition monitoring system for wind turbines
- Needle roller bearings enable more energy efficient systems due to downsizing and reduced friction
- Schaeffler receives 2011 Supplier award from Porsche
- Investment in new plant and machinery gives Schaeffler UK the edge
- Schaeffler's lightweight balancer shaft receives PACE Award for lowering CO2 emissions
- Corrosion resistant, low friction, lightweight hybrid bearings boost performance of inline skates
- Rolling bearings and condition monitoring ensure safe elevator rides at The Eiffel Tower
- Schaeffler unveils new four-wheel drive, battery electric vehicle
- Axial ball bearings for household appliances cut energy consumption by 5%
- Schaeffler supports top level sports with engineering know-how
- Condition monitoring offers insurance against downtime
- New technologies drive vehicles towards a sustainable future
- Novel bearing and electric motor technology is critical to a new design of electric vehicle
- Linear guidance systems ensure accuracy and reliability of DMG milling centres
- Schaeffler scoops national sustainability prize
- Precision bearings make electric bikes more reliable and energy efficient
- Mounting and dismounting of large sized bearings
- New Awareness Campaign to prevent bearing counterfeiting
- Monitoring system detects early damage signs in gears
- Maintenance-free spherical plain bearings support new retractable roof at Olympic Stadium in Kiev
- Tube roller bearing prevents slippage in wind turbine gearboxes
- Low friction rolling bearings enable greater drive train efficiency in tractors and graders
- Robust, high performance spherical roller bearings withstand harsh heavy duty operating environments
- New bottom bracket bearings for cycles provide more energy efficient, smoother ride
- New powertrain simulation tool will improve wind turbine performance and reliability
- Reducing vehicle CO2 emissions by replacing plain bearings with rolling bearings
- Prince learns of green drive in Wales
- Bearings enable precise adjustment of wind turbine blades
- New low friction, maintenance-free plain bushes suit dry-running applications
- Schaeffler joins Low Carbon Vehicle Cluster
- Schaeffler's complete bearing replacement service minimises downtime for Subsea 7 pipe-lay vessel
- improving safety and fuel efficiency of Dakar Rally vehicles
- Bearings drive breakthrough in wave power technology
- Bearings keep on rolling with the wind
- Schaeffler plant produces one-millionth ball screw drive for electromechanical steering systems
- Bearings increase machine availability
- Mounting and dismounting rolling bearings
- Fiat contract boosts fortunes of UK manufacturing plant
- Monorail guidance systems get new calculation software
- Volvo recognises Schaeffler as an added value supplier
- New linear systems partnership offers complete motion control & automation solutions
- FAG spherical roller bearings selected for new retractable roof at Wimbledon's Centre Court
- Ball bearings reduce noise and friction
- Tailored training in roller bearings
- Bearings improve efficiency and safety of marine drives
- Actuators drive ground printing machines
- Metering valves cut lubricant consumption by 25 percent on linear guides
- Rolling bearings
- Actuators ideal where space is tight
- Linear motion products
- Operational costs are reduced
- Schaeffler wins manufacturing prize
- Reference library
- Linear bearings and guidance systems
- Miniature guides deliver high accuracy in harsh environments
- Shaft guidance
- Profiled rail linear guides carry loads of up to 149 tonnes
- Guide to valve train systems
- Lead-free and custom designed plain bearings
- Protective materials and coatings for harsh environments
- Warnings of bearing failure using vibration analysis
- Vibration analysis detects early failure of bearings
- Actuator for heavy duty applications
- Custom bearings are the key to high performance
- Precision machined components
- Bearing maker recognised for its investment in people
- Rolling element offers the best of both worlds
- Wheelset bearing kits reduce maintenance costs
- Cost-effective continuous lubrication
- Tools help with bearing mounting and dismounting
- New damage diagnosis instrument
- Highlighting the good from the bad
- Coatings improve INA FAG bearings in tough conditions
- Ingenious solution to highlight good bearings from bad
- Measurements on hard to reach machinery
Latest news about Rotary bearings