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Advanced Engineering 2020

NEC, Birmingham(B40 1NT)

04/11/2020 - 05/11/2020

The UK's largest annual advanced manufacturing trade show, Advanced Engineering is your opportunity to (more)

Drives & Controls Exhibition

NEC, Birmingham(B40 1NT)

25/01/2021 - 27/01/2021

The show brings together key suppliers of state-of-the-art equipment representing the multi-tasking culture (more)

Wheelset bearing kits reduce maintenance costs

Wheelset bearing kits reduce maintenance costs Germany's most advanced subway system was brought into service in Nuremberg earlier this year. The 'DT3' two-car unit (manufactured by Siemens Transportation Systems and operated by VAG Verkehrs-Aktiengesellschaft Nürnberg) is a new, fully automated, driverless vehicle. The FAG wheelset bearings (rolling bearings and housings) for the DT3 bogie frame were supplied by the Schaeffler Group. The wheelset bearings on the DT3 are 'FAG 808246' double-row cylindrical roller bearings with 120mm bore diameter, 200mm outside diameter and a width of 130mm. The bearings are pre-lubricated for one service interval and require no maintenance for six years or 1.2 million kilometres. A special surface coating of the inner ring bore helps avoid damage to the axle journal during bearing mounting and dismounting. Specialists at Schaeffler's Railway Bearings division pulled out all the stops when it came to the development, design and choice of materials for the wheelset bearing housing. For maintenance purposes, a split housing was required. This offered the advantage that only the bottom part had to be dismounted during maintenance, while the top of the housing stayed on the bogie. This meant the axle could easily be taken out of the bogie. But the housing also had to resist the extreme loads that occur as a result of the design of the primary suspension, a steel suspension with a rubber guiding element. Additional demands for weight reduction and high security standards also had to be met. The optimum solution that met all these requirements was achieved only by using a combination of FEM calculations and 3D modelling. The FEM calculation results were verified during test rig trials. FAG design engineers decided to use heat-treated, hardened spheroidal graphite cast iron, which offered the advantage of high strength combined with good ductility. It is the only material that met the compact, lightweight design requirements for the housing.
 

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