Reduced Friction Through Use of CAE Tools

Using specialized simulation software, Schaeffler can achieve efficiency improvements as early as during the product development phase. For example, with the aid of computational fluid dynamics (CFD) simulations, it is possible to reduce the churning losses in hydraulic units and gearboxes to a minimum. Schaeffler’s Bearinx design and simulation software allows very efficient optimization of bearing supports. Bearinx’s “OptiKit” optimization module can compare various load case analyses or also determine suitable parameters for specific target values, so that, for example, the optimum bearing preload can be calculated. Verifiable Savings Potential By using X-life tapered roller bearings in combination with optimized preload, it was possible to increase the efficiency of hydraulic pumps and hydraulic motors by approximately two percent in efficiency projects. Accordingly, a wheel loader equipped with such an optimized hydraulic pump and two hydraulic motors could yield a significant 6 percent energy savings. For a drive power of 140 kW, this corresponds to around 9 kW. Extrapolated to 1,000-wheel loaders working for eight hours per day, this results in an annual savings potential of around 26,000 MWh—which amounts to a savings of approximately 16,000 tons of carbon dioxide. Outlook The solutions for not only hydraulic drives as described above, but also for gearboxes, differentials and axle drives, allow the frictional torque generated by rolling bearings to be reduced by half using standard catalog products. By exploiting all the possibilities, including a bearing design that is based on the load spectrum of the customer’s application, Schaeffler has verified a friction reduction of more than 71 percent as compared to conventional catalog bearings. These advancements are certain to resonate with the demands of the market.