A Schaeffler Group customer journal for the production machinery industry
Issue 2006/2007
Quiet power!
Crystal clear advantages thanks to hydrostatic dampening control
Flexible, dynamic,
lightning fast
INA parallel kinematics page 3
An eye for your
Service and products for
roller bearings for spindles
page 4
VIP Moments
50th Assembly training by
page 5
Asse g
Creative Techniques
Managing equals perfection
page 6
Company News
Maschinenfabrik GmbH
page 7
System precision and performance: hydrostatic linear module with gauged profile rails
Hydrostatic technology has emerged with a
great future in operating equipment. Working
machinery should stay in constant and smooth
motion, however, vibration in machinery
causes a much less positive effect on work
results. Many modes of vibration cannot be
greatly improved by roller bearings or by
utilizing vibration isolated carriages (e.g. INA
RUDS). Hydrostatic guide systems are considered throughout the industry to be the best
technical solution to these inefficiencies.
These systems are hardly given serious
consideration as they are still thought to be
too expensive and difficult to use.
Vibration problems will result in poor performance and precision. If no other options are
available, companies create their own wraparound guide constructions, which require
larger physical space, increased effort of
assembly and installation, and elevated
End this dilemma! – a linear concept
The Schaeffler Group developed a concept for
the EMO 2005, which makes the hydrostatic
system more economical, compatible and
dimensionally interchangeable with conventional linear guide systems. The inspiration for
developing the new hydrostatic solution was a
study carried out by the INA linear experts and
WZL in Aachen, Germany on hydrostatic guide
systems within the standard envelope
specified in DIN 645. This study now has
concrete results: A high-tech linear guide
system, optimized trough superior geometry,
hydraulic controls and conventional external
Compact assembled components in
standard sizes
This guide is statically as rigid as a rail guide
in the direction of load. It fits within standard
installation space for these guides and has
the same sustainable bearing capacity in the
load region. The standardized construction
component is a compact solution that
includes an all encompassing seal with selflubrication and integrated hydraulic control.
Machine designers can now furnish standard
units, including roller bearings, rail systems,
and/or hydrostatic guides depending on
individual customer requirements. Implementation of the so-called hybrid machine concept
provides additional options as well. Manufactures can now precisely define further
machine components (especially bearings)
based on specific customer requirements with
the option of replacing the roller bearing guide
with a hydrostatic guide. This provides
maximized flexibility in the selection of the
technology appropriate to the specific
High-tech production machine at
profitable cost
The cost effectiveness of the new solution is
great news in that the new hydrostatic guide
by INA is a tailored solution from the most
distinguished linear systems provider. In cooperation, sufficient quantities of the newly
produced product makes production much
less expensive than the machine manufacturers’ own construction. Upgrades, previously
economically unprofitable, are now quite
attractive and affordable. For the first time,
the additional cost of hydrostatic guides can
be clearly justified in relation to the increase
in performance of the entire system.
Prototypes are already being tested in the
market and serial production of the hydrostatic guide is to begin mid-2007. This new INA
product converts standard systems into hightech product lines with the highest precision
output with minimal extra construction effort.
By implementing this new technology , YOU
TOO may soon be able to see your machine
tool moving at its highest performing level
with the best vibration-absorbing qualities.
The only vibration that should be felt
afterwards are the customers and operators
jumping for joy.
Issue 2006/2007 – Page Editorial
Competence, with a very
personal note!
You hear a lot about “added competence” in conjunction with
our production machine sector. In recent publications, we have
introduced product highlights from our machine manufacturing
sector which we will continue to include in future articles.
However, the focus of today is another type of “High-Light”.
Many of you are personally familiar with Dipl.-Ing. Mr. Oswald Bayer as specialist of
the former FAG ACSP Spindellager GmbH. Some of you may have enjoyed his lectures
at our technical conventions or valued his publications in various trade journals.
Most of you are certainly profiting from his innovations in one way or another as a
significant number of the developments that he has introduced are now a standard
in machine tool spindles. Sealed B spindle bearings (B..2RSD), floating displacement bearings (FD..), hybrid spindle bearings (HCN..) and a spindle bearing calculation program (SPiCaS) are just a few of his many contributions. After 40 plus years in
service with FAG rolling bearings and especially spindle bearings, Mr. Bayer began
his well-earned retirement on July 1, 2006 and has handed over responsibility for the
spindle bearing product range to Dr. Oliver Schellberg. It is impossible to replace the
person or the knowledge of someone such as Mr. Oswald Bayer. Nonetheless, he
carefully planned this retirement. Mr. Oswald Bayer has been working extensively
with Dr. Schellberg for over six years, therefore, many of you are already familiar with
him. He has been head of spindle bearing production at Schaeffler KG since the year
2000 and has now taken over the responsibility for managing the spindle bearing
product range.
At the farewell event for Mr. Bayer, my predecessor, Dr. Markowski, head with FAG
ACSP spindle bearings, summarized the essence of Mr. Bayer’s importance by
explaining the “M & M” factor as not just as a name of an excellent confection, but,
as in our case, represents the successful unification of “Mankind and Mechanics”.
Only when these two elements work well together (as is the case with Mr. Oswald
Bayer), can the highest level of both personal and technical perfection be achieved.
Change of hands in the spindle bearing product sector.
Oswald Bayer
Oliver Schellberg
I believe you will agree with me that these principles should remain in full force.
I feel certain that in continuing this theory, a great part of our future success be
assured and always growing. I hope you enjoyed this personal side of “added
competence” and we look forward to the opportunity of working with you!
Sincerely yours,
Helmut Bode
Leiter Branchenmanagement
Measure, simulate, compare
INA development project:
“Thermally stable
rotary axis systems”:
On the path towards an engineering tool for
highly dynamic rotary axis systems
Machining centers with combined
milling, drilling and lathe processing, as
well as the growing integration of direct
drives, have increased requirement of
possessing the rotary axis in production
machining. As is widely known, heat
limits process performance. Schaeffler
KG has initiated an integral project
surrounding this problem of creating
“thermally stable rotary axis systems”.
Knowledge pertaining to the thermal
properties between all assembly
components is one of Schaeffler KG’s
key strategies. Schaeffler possesses the
highest levels of system expertise as
manufacturer of relevant individual components such as direct drives and bearings within the application technology
The subjects of examination were
primarily composed of system responses
such as temperature development in
addition to thermal and mechanical
deformations. The study’s focus is on
determining dependencies between the
step response of the systems’ rotary axis
and the input parameters. During close
exams, including temperature measurements on over 50 individual points, two
different complex simulation models are
being studied. In place of a simple analog
model, the study was applied on electro
technology levels of a highly complicated
FEM model. The effects of conditions
such as heat conduction, convection and
thermal radiation are given special
attention in this study.
the construction drafts. We will also be in
position to inspect your selected combination concerning performance and
operational safety.
Make contact
We are happy to announce that we have
already made considerable progress in
this field. The obtained results are
absolutely fascinating and we expect to
continue in receiving positive results.
Once the final test results are in and
compared to the simulation scenarios.
We are currently testing the rotary axis
system and will keep you updated on the
exciting new developments of this study.
Please contact us directly about this
project as your interest and involvement
is most appreciated and welcomed.
Engineering tool for customer
The objective of this study is to provide an
engineering tool for customer applications. With this tool, we can easily supply
quick and inexpensive support for the
maintenance of highly dynamic rotary axis
systems. We will then be able to make
quick decisions as to the proper drive,
motor and measurement system based on
INA test setup for the project:
“Thermally stable rotary axis systems”
Issue 2006/2007 – Page Flexible,
dynamic and
lightening fast
INA parallel kinematics for
airplane components
…are extremely flexible, and highly
accurate. One could use this description
to refer to a hummingbird going after its
sweet lunch. What occurs in nature is
often mimicked in the mechanical world.
As seen in the production of airplane
parts, for example, parallel kinematics,
which are perfectly suited for implementation in all areas where such examples
are of the finest webs, honeycomb
structures and filigreed load-carrying
construction geometrics of the highest
precision are required (Image 1).
INA and FAG provides all of the specific
components such as joints, guides and
feed spindle bearings for parallel kinematics machines (PKM) as a complete
assembled solution. (Image 2). One of
the special solutions in this context is the
tripod concept in which DS-Technologie
implemented its Ecospeed machine. The
Ecospeed concept is based on construction designs with rigid “webs” and driven
“bases” that are moved over ball screws.
The machine, designed as a hybrid and
consisting of a conventional linear
machine including PKM for optimum use
with all PKM specific advantages, such as
the highest possible level of dynamics.
This can be utilized to optimize the
relationship between machine size and
work space.
In collaboration with Schaeffler KG, DSTechnologie integrated a PKM concept
into series production for the first time.
Implementation of this by the company
EADS in its Augsburg based plant for
airplane components is reducing not only
the mass moved, but also the costs since
March, 2000. Downtimes have been reduced and the entire process chain has
been optimized. Production times have
been reduced by 30–50 %. This is made
possible by feed speeds of up to 50 m/min
and acceleration of up to 1 g in the linear
axis with a rapid metal removal rate of up
to 7,000 cm³ aluminum per minute.
Component precision is also well worth
mentioning as honeycomb structures
with wall thicknesses of under one millimeter are reliably and readily produced.
FAG X-life ultra bearings are used in the
spindles. Added strength and durability
of all participants is the only way to carry
out an idea of building modern airplanes
such as the Airbus 380 or jets like the
Euro Fighter.
The brochure PKS DA, which you
can download from www.ina.com,
contains more detailed information pertaining to INA parallel
kinematics technology.
Parallel kinematics in volume production
Ball screw support
bearing ZARF
Universal joint GLK3
Needle roller bearing
Slewing bearing
(Special bearing ZARF)
Parallel kinematik
technology with INA
product ecerything
from single source
Linear recirculating
roller bearing and
guideway assembly
1 Production of high-precision lightweight
components: area of implementation for INA
parallel kinematics
3 Already in the air: components manufactured by DS-Technologie for the A300 with INA
parallel kinematics technology in the PKM
More “drive” in the application
Example: direct-drive automatic test station
Every seven seconds, a gear shift dome
cover leaves the test stations at REGE
(A member of the Schaeffler Group) in
Eisenach, Germany, 24 hours around the
clock, 300 days a year. Reliable drive
technology is required to implement such
continuous operation. The MKUVS 42-LM,
an actuator with linear recirculating ball
bearing units and direct drive was the
perfect application in this case. This
extremely compact and completelyequipped unit is ideally suited for precice
and consistent motion sequences. MRB
Automation, based in Ilmenau, Germany,
were very pleased by what they saw
during the development of the test
stations. Dr. Guenter Weber, Managing
Director of MRB AUTOMATION GmbH,
implemented direct drive technology for
the first time during the development of
the gear shift dome cap automatic test
stations. “Technically, it is a better and
more intelligently engineerd solution” he
explained. Dr. Weber also stated “there
are distinct advantages compared to the
spindle and gear drives” and that the
company had only good experience with
direct drives during this project.
For MRB, a crucial decision-making factor
was the posibility of the positioning of
two carriages on one axis completely
independent of one another. The use of
the MKUVS in the horizontal axis of the
REGE test unit facilitated the operation of
two independent handling systems. Each
slide carries a pneumatically-driven
vertical axis with one gripper. The first
gripper removes the parts from the
conveyor and places them into the
inspection station. The second gripper
removes the inspected parts and places
them on the appropriate “Accept” or
“Reject” track.
These modules, developed by IDAM and
INA Lineartechnik, consist of a very
compact and strong support rail, a
carriage with cast-in primary part (linear
motor) as well as an attached pre-loaded
KUVS 42 recirculating ball and return
units with an integrated magnetic
incremental length measurement system,
therefore, highly dynamic single and
multi-axis positioning and handling
systems are constructed by utilizing just a
few mechanical parts. Friction loss and
wear, which rarely occurs in system
solutions with toothed drive belts, can be
prevented by using direct drive technology while operational output will be
considerably increased. Together with
server controls, a complete system
solution from a single source is available
to the customer/user.
These compact linear modules are suited
for an wide range of applications such as
those preferred in horizontal applications, production automation, measuring
and inspection technology, optical
devices, printing and packaging industry
as well as tool and material handling
systems, wood processing and machine
tool construction. Soon you should put
more “DRIVE” in your application!
Issue 2006/2007 – Page An eye for your application
Service and products for roller
bearings for spindles
F`IS for production security and precision:
online grinding disc monitoring
FAG enveloping circumference measuring equipment for the precision adjustment of the radial play
in cylindrical roller bearings
FAG Industrial Services GmbH (F’IS) has
its main office in Herzogenrath, Germany
near Aachen and branches out into
Schweinfurt and Wuppertal. We provide
maintenance services, service products
and training. No one appreciates machine
and equipment down times. It pays to
keep your equipment with its most
efficient output by initiating regularly
scheduled maintenance. This minimizes
operating costs, keeps production at a
free-flow, optimizes system availability
and avoids those unexpected machine
downtimes. F’IS provides global service
for the Schaeffler Group brands INA and
When it comes to production machines,
F`IS has a special eye for machine tool
spindles and the handling of these
spindles in assembly or maintenance
procedures. Professional installation of
these bearings plays a significant role in
optimum functioning of the spindle. One
of the most important factors includes, as
an example, proper pre-stressing or setting
of bearing play. If assemblies are to be
carried out by a company’s own employees, F’IS also offers an intensive training
course on installation and maintaining machine tool spindles. In addition, regularly
scheduled courses for spindle bearing
assemblies and maintenance are offered
on regular basis. F’IS also sells and rents
out accessories required for professional
assembly, such as boundary circlemeasuring instrument, heating devices,
hydraulic nuts, pumps, etc.
Condition Monitoring is another important factor for optimizing machine tool
maintenance. Vibration diagnosis can be
used to identify initial bearing or spindle
damage to machines (e.g. lathes, milling
machines, grinding machines or drilling
machines) in the beginning stages of
installation of equipment. Machine
operators are often the first to notice that
their machines are not performing
properly. However, without Condition
Monitoring, precise localization of the
damage can take days or even weeks
causing dreaded equipment down time
and costing precious production time.
Condition Monitoring uses vibration
diagnosis to carry out fast, targeted error
analysis. Not only does this allow for
prompt and precise repair, but considerably reduces repair costs and down time
as well. Unplanned downtimes are
High-Precision Bearings – Lexicon
Calibration of cylindrical roller bearings for spindles
With high-precision cylindrical roller bearings, the
performance and life span of a roller bearing relies on
the correct adjustment of the bearing clearance and
the anticipated pre-load weight. The correct adjustment and pre-load, in turn, depend upon the speed
and the anticipated temperature differences from the
inner ring to the outer ring. The correct adjustment of
bearing clearance is of paramount importance as it
controls the quality of the machined-work pieces.
These factors must be determined beforehand so that
even the most precise bearings can be calibrated
correctly and efficiently for the longest wear possible.
The circle over the rollers is measured with and
instrument known as MGA31. The radial clearance of
the mounted bearing can only be determined together
with an internal dial gauge. There are two opposed
steel segments of the measuring instrument for the
exact boundary’s circle. One portion is stationary while
the other can be moved. This movement can be
measured and read from the dial gauge.
During the measurement process, the bearing outer ring
must be mounted in the housing. After having determined the outer ring raceway diameter with the aid of an
internal dial gauge, the value is then transmitted to the
measuring instrument of the boundary’s circle.
The measured diameter under rollers is transmitted to
the dial indicator snap gauge. The boundary circlemeasuring instrument known as FAG MGI 21 is used for
cylindrical roller bearings with separable inner ring,
such as FAG NNU49SK. The boundary circle measuring
instrument known as FAG MGA31 is used for cylindrical
roller bearings with separable outer ring such as FAG
NN30A, N10 and NN30. Over the rollers is the circle
which circumscribes all rollers when they are in contact
with the inner ring raceway.
During mounting, the inner ring with cage and roller
assembly is pushed onto the tapered shaft until
positive seating is made. Once the boundary circle
measuring instrument is in place the inner ring is then
driven onto the tapered seat until the dial gauge
indicates the required value of exactly to 1µ. Our
catalog #AC 41 130/6 (page 167) provides accurate
reference values for these bearings. Positive values
indicate pre-load while negative values indicate radial
clearance. A zero value indicates a clearance-free
*FAG Industrial Service GmbH (F`IS) provides the enveloping circumference
measurement devices of the MGI 21 and MAG 31 series for sale or rental
to determine these enveloping circumferences. Proper implementation of
enveloping circumference measurement devices is also covered in F`IS assembly
and maintenance training courses
virtually non-existant and machine
availability and productivity is increased
significantly. Condition Monitoring also
contributes positively to quality assurance because even the smallest
damages can be recognized early in
The primary causes of spindle bearing
damage are sudden and unexpected
impacts between the spindle and the
workpiece as well as the penetration of
foreign particles (grinding debris). This, in
turn, results impact momentum which
can significantly damage the contact
surfaces and lead to a decrease in
quality. Even the smallest of damages to
spindle bearings can have enormous
impacts. Spindles used in mobile units
are monitored using the mobile detector
FAG Detector III at regular intervals
(offline monitoring). Stationary spindles
are monitored on an ongoing basis
utilizing a unit known as the FAG DTECT
X1. This unit provides a much higher level
of security for critical or fast spindles.
Stationary spindles can also be monitored offline, if necessary.
F`IS’s informational brochure
pertaining to F`IS enveloping
circumference measuring
equipment for internal and
external circumference bearings is available upon simple
Issue 2006/2007 – Page 50
“VIP” training with
FAG spindle bearings
50th Assembly training for FAG high precision
bearings at DaimlerChrysler
The FAG Assembly training for highprecision bearings at DaimlerChrysler is a
true success story for both parties. This
company with its world renowned emblem
indicating land, sea and air surrounded
by the earth, has now called upon the
spindle bearing specialists from FAG for
the 50th time. Since 1995 DaimlerChrysler
has been training its maintenance staff
for machine tools in theoretical and
practical training on FAG spindle bearings
in groups of 10-12 people. The participants are Mercedes employees from the
plants in Untertürkheim, Mettingen and
Bad Cannstatt. In the educational center
in Bruehl, FAG Industrial Services GmbH
(F’IS) provides all the information they
need about the spectrum of the FAG high
precision bearings, assembly-related
engineering, important tricks for spindle
bearing handling, lubrication and
installation. The participants always
receive an acknowledgement document
upon completion of their training.
Experienced answers are provided to
questions such as “Can you randomly
replace the rings of cylinder roller
bearings?”, “How should I lubricate open
spindle bearings?” or “Where can I get
enveloping circumference measurement
equipment at inexpensive rates for shortterm usage?”. This exchange of information is by no means a one-way street. As an
example, the initiative to indicate width
tolerances on all FAG universal spindle
bearings came from this type of event
many years ago. This is added competence at all levels. Further “emblem”
training courses have already been
booked by DaimlerChrysler. Please let us
know if you would consider having this
training session at your company soon.
New standard:
The TX-Generation……
On-site assembly training for FAG high-precision bearings can be scheduled any
time with machine tool and spindle manufacturers, repair centers and roller
bearing salespersons. These courses are also offered on a regular basis at the
Schaeffler KG plant in Schweinfurt.
Tippf the FAG
The next dates for spindle bearing
assembly training in Schweinfurt:
ation earing
le b
it is
n un
uctio light!
March 1, 2007
June 14, 2007
September 13, 2007
November 29, 2007
FAG Industrial Services GmbH (F’IS),
Tel.: +49 (0) 2407 9149-0
e-mail: [email protected]
…with TX-Cage
Changeover to the new FAG spindle bearing
– standardization has begun
The new spindle bearing standard, which
is intended for almost all FAG spindle
bearings has now become a reality with
introduction of the TX cage. The first basic
models HS7014.. and B71920.. have
already been altered to conform and
another eight are to be converted by the
end of the year. Big steps will continue to
be made after that as well. The new TX
cage has many advantages for FAG
customers such as lower bearing
temperatures which means greater
operating security and increased
precision. Furthermore, it allows for
higher rotation speeds. The new generation of spindle bearings is suitable for
rotation speeds of up to 10 % higher.
These improvements were the result due
to the optimization of the internal bearing
construction with the new cage design.
The objective is its design optimization,
with improved lubricant supply to the
cage guidance surface. Cage guidance
was redesigned from the large shoulder
to the small shoulder to follow the flow
of lubricant in the bearing. With the
improved lubricant supply to the cage
achieved, this allows significant reduction of friction, which is of increasing
importance as rotation speed increases.
This has a positive impact on the
operating temperature development and
on the overall lubricant life-cycle. In light
of these clear advantages, FAG strives to
successfully convert all spindle bearings
to the TX design.
The new TX-Cage design.
Compare the existing design to the new design
T-Cage design
(existing version)
TX-Cage design
(new version)
1 “Cool” solution with options for rotation speeds: The TX-
2 Two spindle bearing generations
Generation reduces the operating temperature by up to 10 %.
meet: T and TX-Generation
3 Upon converting a core model line, all of its various versions (sealed, DLR, hybrid or X-life ultra
versions with rings made of Cronidur 30) will be available as well.
For more detailed information, please
visit www.schaeffler.com and search for
The new TX-Generation is indicated in the type description of a FAG X-life ultra bearing with the new
TX-Cage as follows for example: XCS71920-E-TX-P4S-UL.
In addition to this, a label on the bearing package indicates the new TX standard.
Issue 2006/2007 – Page How to beat
the pressure
of printing costs
TRIONDUR coating offers complete wear
resistance to track rollers
This was a very “tough nut to crack” for
everyone involved; high wear of the outer
ring repeatedly resulted in the failure of
the PWTR15 standard track roller in the
gripper shaft control of the KBA Ra105
sheet-fed offset press. The Heidelberger
XL105 had the same problem. The track
roller itself is not expensive, however, the
fact remains that when one component
fails, the entire system is forced into
unproductive down-times, which, in turn,
“leads to increasing costs”. The solution:
Coating the outer ring of the track roller
with TRIONDUR. Such a coating system is
produced in a vacuum using physical
vapor deposition (PVD) and plasma
chemical vapor deposition (CVD). The
thin functional layer, only a few µm thick
and the base material surface to be coated,
are considered a complete system. The
friction coefficient of TRIONDUR is up to
80 % lower compared to a dry steel to
steel compound. This coating provides
continuous protection from maximum
wear under conditions of high tribomechanical stress, inadequate lubrication
and oil contamination. Extensive research
had lead to some very exciting results!
Presently, the Schaeffler Group provides
standard TRIONDUR-coated track rollers
for both applications and equipment
“down-times” have been significantly
reduced. The best solutions are not
always expensive. With this application
expertise and always striving for excellence, the Schaeffler Group always
provides a solution that helps customers
cut costs and increase efficiency.
1 Application: track roller in the gripper shaft of a
sheet-fed offset press
2 Comparison of a TRIONDUR-coated roller after
100 operating hours versus a conventional steel
roller after only 17 hours. The TRIONDUR-coated
roller shows no signs of wear whatsover, while
significant signs of wear are already clearly visible
on the uncoated outer ring of the conventional
added competence – creativity techniques for engineers, part 14
Managing equals perfection
How you can develop numerous
new solutions with your
co-workers in a short
amount of time
In the search for solutions to technical problems,
competence does not only include deciding between
existing solutions or giving one’s own professional
input. It requires promoting, supporting and implementing the creativity of co-workers for innovative
projects. Morphological analysis is one popular way of
problem-solving which can produce several good
ideas within a relatively short time. The morphological
analysis is, therefore, one of the most commonly used
creativity techniques.
This mind tool is a systematic analytical creativity
technique, which was developed in 1966 by the Swiss
astrophysicist Fritz Zwicky. This method primarily consists of breaking a problem down into all of its individual parameters and searching for new combinations
of existing partial solutions. Therefore, the problem is
dissected into its various factors and graphically arranged as one under the other in graph. As many solutions as possible are then written beside each problem
element. The combination of these can provide new
solutions for the whole problem. The best solutions or
those with the highest innovative potential can then be
selected from the reservoir of combinations.
The individual phases of the morphological analysis:
1.Either precise or general description and definition of the problem
2.Determining the problem parameters and task description (these factors are entered in the matrix header)
3.Drawing up the morphological analysis by graph
implements entry of all solution proposals for
problem parameters of each line of the matrix
4. Selection and assessment of all possible solutions and applying suitable analysis procedure
5. Selection and recognition of the best solution
Numerous other approaches may develop from the
combination of solutions to the individual components.
The high number of possible useful ideas is one of
the significant advantages of this method. Each
solution proposals should be subsequently subjected
to testing for evaluation by experts. In order to
implement the morphological analysis method, an
interdisciplinary work group with a maximum of 10
people is established. Executives and those possessing special knowledge of each relevant problem
area would be suitable candidates for this task.
Meeting time should be no longer than one hour.
Generalization of the problems and the combination
of partial solutions prove surprising results. Each
individual search, even after initial satisfactory
solutions have been found, should be continued. This
increases the probability that all essential aspects of
the problems have been addressed and even more
innovative ideas will possibly be the result.
Variants of the morphological analysis:
1.Problem recognition: addressing all of the aspects
of the problem while retaining the overview, problems
can simply be broken down into individual problem
fields and each field is studied individually.
2.Sequential morphology: a problem solution is
selected for each parameter BEFORE turning to the
next problem and/or selection of a solution for the
next problem. This will increase clarity and reduce
irrelevant solutions.
Morphological analysis for product development:
Product development and innovation management are
the main areas of the application of the morphological
analysis. The ideas obtained from this method are often
unconventional and prove that even seemingly far-off
solutions can be the perfect answer for a particular
problem. If these solutions also correspond to the
customer’s expectations and manufacturing can be
retained within a reasonable cost, then the path is
cleared for “product innovation”.
Issue 2006/2007 – Page K-Box – providing added value
A new customer-friendly packaging concept
The Schaeffler Group has developed an
innovative, customer and environmentally-friendly packaging concept for FAG and
INA’s rolling bearing range. A container
implemented for repeated use, known as
the “K-Box”, has been introduced. This
robust, sturdy, plastic and patented box
replaces the non-returnable wooden crates
used in past years. This new design offers
optimal protection for products during
transport including the prevention of prod-
ucts being contaminated with wood dust
or shavings. The bearings are safely secured in the K-Box by means of an adjustable fastening system so that one box size
can be used for various roller bearing
product and size variations. This considerably reduces the number and assortment of required packaging. The recipient
can open the box quickly and easily without any tools or risk of injury. “The K-Box
is used worldwide. In Europe, we have
Excellence in manufacturing –
using optimized solutions to
save time and reduce costs
Products and technological expertise of the STAMA
Maschinenfabrik GmbH in Schlierbach, Germany
“Excellence in manufacturing” is the
challenging slogan of the STAMA
Maschinenfabrik GmbH in Schlierbach,
Germany. It represents flexibility,
absolute precision and product quality in
addition to high levels of operational
availability and productivity. With
approximately 400 employees, our
company implements vertical turning
and milling machine processing centers
and can identify approximately 200
production solutions for the cutting
machining industry in almost all industry
sectors around the world annually. The
STAMA product ranges consist of 18
types of vertical processing centers and
milling/turning centers from single-item
production (batch size 1) all the way
through to small, medium-sized and
large batch production.
The modular build drive control centers in
the various performance categories are all
designed as single and dual spindle
systems (TWIN) and can be used as single
workstation centers or as dual workstation centers for simultaneous loading and
unloading during peak times. Among the
most important components are the main
spindles with INA/FAG bearing technology; approximately 800 of which are
assembled annually in in-house spindle
assemblies. All centers are additionally
designed for 5-axis processing and are
ideal for large parts or multiple-clamping
with ranges of motion from X to 10000
mm. A patented tool management system
serves to reach consistently short clampto-clamp times of 1.9 seconds. Space for
up to 60 tools in the internal magazine or
90/180 in the external magazine allow for
complete and complex processing.
Core capability “MT technology”:
As a leading producer of milling/turning
centers, STAMA manufactures two
excellent production systems for 6-sided
full processing from the rod or feed since
1999. With revolutionary results such as
70 % less production time and 50 % lower
part cost, the milling/turning centers are
in high demand. This is especially
important among the manufacturers of
tools, hydraulic/pneumatic and medical
technology components. It is simply a
fact that full processing/operation of work
pieces with milling/turning (MT) technology
in a single processing center is an
excellent way to increase productivity and
reduce costs. It is also true that combining the two different technologies for full
processing in one or two mounting
positions, increases precision while
minimizing operation time.
For example, by implementing STAMA
milling/turning centers with specialized
repetitive processing, an implant
manufacturer can drastically reduce the
amount of individual part discrepancies
of the implant due to the ability to
combine milling and turning processes in
numerous ways. This helps increase
safety for a patient due to increased
implant stability. Furthermore, seeing
most of the implants processed in the
milling/turning centers leaves the conveyor belt virtually ready for assembly.
The occasional surface finishing required
in some cases, represents the final stage
of the production process. The process is
both innovative and is far less time
consuming. After all, “time is money”
introduced a return system to ensure that
the K-box is indeed used several times”,
says Mr. Martin Haßdenteufel, who is
responsible for Packaging Technology
within the Schaeffler Group. Returning
empty K-Boxes is easy and efficient for
the customer; small quantities can be
picked up by an express service, while
larger amounts are collected by the Schaeffler Group’s own forwarding agency – both
options are free of charge to all Schaeffler
Group customers. The “request for collection” is simply sent via the a dedicated
website. As an incentive for our customers
to support the system, the Schaeffler Group
raffles off attractive prizes to the participants
in that every box is considered as a lottery
ticket. Initially, the new packaging will be
used for spherical roller bearings with
outer diameters between 250 and 480
millimeters. The concept will be extended
to other product lines in the near future.
Core competence – “TWIN technology”:
strength has become patently obvious.
STAMA possesses extensive knowledge
based on numerous designed and
developed processes involving a wide
variety of differing materials, product
ranges and batch sizes. STAMA works in
close proximity with customers to create
optimum solutions for that customer’s
individual processing needs in order to
achieve significant advantages (i.e.
saving time and reducing costs).
The TWIN dual spindle centers, which
STAMA presented for the first time in
1982, are currently being implemented in
over 900 projects around the world. More
productive and flexible than in specialized
machines, dual spindle processing
guarantees cost reduction per piece of
30 % due to the “2 plus 4” concept (2 main
spindles and 4 clamped workpieces). In
light of this, it is understandable why
manufacturers of medium and large-sized
orders do not worry about the higher
initial investment required for TWIN
centers and usually decide in favor of
dual spindle processing due to the cost
per piece being the deciding factor.
This new innovative and returnable “K-Box” offers
optimal protection for Schaeffler Group products
and represents another active contribution to the
protection of the environment.
STAMA engineering – one-stop turnkey
With a percentage of turnkey solutions of
over 60 % of products and the goal of
providing customers with the highest
optimum production solutions, STAMA’s
www.stama.de, [email protected]
6-sided full processing from the bar with milling
and turning in a single center. Full flexibility at
the highest level of precision according to the
principle “batch size 1 – setting-up time 0”.
Both TWIN technology and MT technology in one!
For full processing of batch production with dual
spindle milling and turning in a single processing
STAMA turnkey solution based on single-workstation processing center type MC 531 with portal
load gripper automation. The solution is designed
to be integrated in a full process chain.
STAMA Engineering: an optimum production
solution always requires the know-how and
experience of both partners.
Issue 2006/2007 – Page WIN!!!
Win a navigation
Yes, I want to participate in the lottery for a
navigation system.
ANSWER: ______________________________________________________________
Lastname, first name: ____________________________________________________
Our Question:
When is production
starting for the hydrostatic
Guidance System?
Company: ______________________________________________________________
Adress: _ _______________________________________________________________
City, ZIP: _______________________________________________________________
Tel.: ___________________________________________________________________
Just complete the client newsletter
form (right), stating the correct answer
and send it to:
Fax: _ __________________________________________________________________
E-Mail: _________________________________________________________________
Schaeffler KG
Production Machinery
Georg-Schäfer-Straße 30
D-97421 Schweinfurt
We would appreciate it if you would answer the following questions:
Did we get your address right? Please let us know of any changes to be made
(please use capitals).
Fax: +49 (0) 97 21/91 14 35
Closing date is Mar 01, 2007
Who else in your company should receive FAG “added competence”?
Legal recourse ruled out. The drawing is
closed to employees of the Schaeffler KG
and its trading partners.
What improvements would you like to see at Production Machinery
in the future?
PREVIEW of Issue 1/2007
The lucky winner of our competition 1/2006
1.EMO highlights
2.Technical convention Germany
3.Team work between Germany
and Chile
José Javier García Binas (left) of Mungimatik S.A. is the lucky winner of a “Nokia
N70”. It was presented by Ager Serna
Deep thought moments of
Joe Bloggs
Recently my wife, Barbara, was so cheerful
while doing the housework that I began to
worry. First, she danced around me and my
beloved lazy chair like a dust mop gone crazy.
She then began ironing and singing so loudly
and so off-key that Dieter Bohlen (a controversial European entertainer) would have cried
out in pain. At the peak of this experience, I
could feel the walls of the house beginning
to vibrate. Seeing as how my better-half
doesn’t have an off switch, I tried to explain
that staying in motion while working could
be a good thing at times, however, this often
results in undesirable consequences.
“Now how am I to understand that” asked
my private entertainer and bound-in-marriage superstar. “It’s very simple”, I said, my
thoughts buzzing the entire time, “It’s the
same with the machines we have at work.
The more they vibrate, the shoddier the
work results. Only one thing can help. The
vibration must be reduced. INA now has new
hydrostatic guidance for vibration reduction.
It absorbs significant amounts of vibration in
equipment and is proficiently cost effective
as well. Without much effort, this process
turns a standard machine into a high-tech
piece of equipment.” I was resolved that I had
explained myself thoroughly and, therefore,
had put a stop to her boisterous singing and
dancing throughout the house. Her response
was completely unexpected. Calmly and collectively she stated, “Oh Joe, then why don’t
you please have one of those hydrostatic guides installed in this house immediately. Then
you’ll be less nervous and more relaxed.” I sat
there stunned. This having been stated, she
turned around and loudly sang on, cheerfully
with the walls shaking right along with her. Oh
well, I thought to myself smiling, at least there
are only “good vibrations” in the air here. Bad
vibrations can be “reduced” or eliminated
through hydrostatic guidance.
See you at the next FAG added competence!
Best regards
the reader with information about all
innovative solutions ranging from
bearings to power transmission as well
as showing novel approaches with added
value under the slogan “added competence.”
Fax order number +49 (0) 91 32/82 21 30
Your local distributor:
Schaeffler Group USA Inc. · Tel: 803-548-8500 · Fax: 803-548-8599
Schaeffler Group USA Inc. · Tel: 800-243-2532 · Fax: 203-830-8276
The Barden Corporation
Tel: +1 203-744-2211 · Fax:+1 203-744-3756
Tel: +44(0) 1752 725506 · Fax:+44(0) 1752 725506
Far East: Tel: +65(0) 7348223 · Fax: +65(0) 2352170
E-Mail: [email protected]
Joe Bloggs
Published by:
Schaeffler KG
Production Maschinery
Editor in chief:
Claudia Kaufhold
Schaeffler KG
Georg-Schäfer-Straße 30
D-97421 Schweinfurt
Tel. +49 (0)9721‑/‑91 19 11
Fax +49 (0)9721‑/‑91 63 16
A Member of the Schaeffler Group
Editorial team:
Helmut Bode
Martin Schreiber
Claudia Kaufhold
Norfried Köhler
Produced by:
Buena la Vista AG, Würzburg
WL 02 125 EA
“added competence” from bearings to
power transmission
The capabilities of the Schaeffler Group
with respect to printing presses were
assembled in a new image brochure
“Bearing Solutions for Printing Presses”
(PDM 005172071). This brochure provides

for professional