CBCC

FK Bearing Group Unveils Three 2026 Specialized Bearing Unit and Bearing Products

28 Jan,2026

<p class="ds-markdown-paragraph" style="list-style: none; margin-top: 16px; margin-bottom: 16px; padding: 0px; box-sizing: border-box; line-height: 20px; color: rgb(15, 17, 21); font-size: 13px !important; font-family: UniversPro, Arial, sans-serif !important;">FK Bearing, China top bearing unit manufacturer of reliable bearing solutions, proudly announces the new launch of three innovative product lines in 2026 engineered to meet the demanding requirements of modern heavy industry and agriculture. The new FK Spherical Roller Bearing Units, FK Babbitted Split Journal Bearings, and FK Planter Bearing/Row Cleaner Bearing series are designed to deliver superior performance, extended service life, and reduced maintenance costs across diverse applications.<p class="ds-markdown-paragraph" style="list-style: none; margin-top: 16px; margin-bottom: 16px; padding: 0px; box-sizing: border-box; line-height: 20px; color: rgb(15, 17, 21); font-size: 13px !important; font-family: UniversPro, Arial, sans-serif !important;">1. FK Spherical Roller Bearing Units: Robustness for Misalignment and Heavy Loads The newly launched FK Spherical Roller Bearing Units are engineered as comprehensive, ready-to-mount solutions for applications involving heavy radial loads and significant shaft misalignment. Common in mining, conveyors, pulp and paper machinery, and fans, these units combine high-capacity spherical roller bearings with robust, precision-machined housings (typically SN, SD, or SAF series types). The self-aligning capability of the bearing compensates for mounting inaccuracies and shaft deflection, ensuring smooth operation and preventing premature failure. FK bearing units are pre-lubricated and sealed, offering easy installation and reduced downtime, making them an ideal choice for harsh industrial environments where reliability is paramount.<p style="list-style: none; margin-top: 0px; margin-bottom: 10px; padding: 0px; box-sizing: border-box; line-height: 20px; text-align: center; font-size: 13px !important; font-family: UniversPro, Arial, sans-serif !important;"><img src="https://www.fk-bearing.com/ueditor/php/upload/image/20260127/1769502510218042.jpeg" title="2026 FK Spherical Roller Bearing Units" alt="2026 FK Spherical Roller Bearing Units" width="600" height="" style="list-style: none; margin: 0px; padding: 0px; box-sizing: border-box; border: 0px; vertical-align: middle; transform: scale(1); transition: transform 0.4s, -webkit-transform 0.4s; max-width: 880px;"/><p class="ds-markdown-paragraph" style="list-style: none; margin-top: 16px; margin-bottom: 16px; padding: 0px; box-sizing: border-box; line-height: 20px; color: rgb(15, 17, 21); font-size: 13px !important; font-family: UniversPro, Arial, sans-serif !important;">2. FK Babbitted Split Journal Bearings: Precision for Critical, Large-Diameter Rotating Shafts Addressing the core needs of high-power machinery, FK bearing introduces its Babbitted Split Journal Bearings. These bearings are custom-engineered for critical applications in sectors such as hydroelectric and steam turbines, large pumps, compressors, and marine propulsion systems. The split design allows for easy inspection, maintenance, and replacement without requiring disassembly of the entire rotor systema significant advantage for large-scale equipment. The bearing lining is meticulously cast with high-quality Babbitt (white metal) alloy, renowned for its excellent embeddability, conformability, and anti-friction properties. This ensures optimal hydrodynamic lubrication, exceptional load distribution, and protection for valuable shafts, thereby enhancing operational stability and longevity in high-speed, high-load scenarios.<p style="list-style: none; margin-top: 0px; margin-bottom: 10px; padding: 0px; box-sizing: border-box; line-height: 20px; text-align: center; font-size: 13px !important; font-family: UniversPro, Arial, sans-serif !important;"><img src="https://www.fk-bearing.com/ueditor/php/upload/image/20260127/1769502805139694.jpeg" title="FK Babbitted Split Journal Bearings" alt="FK Babbitted Split Journal Bearings" width="600" height="" style="list-style: none; margin: 0px; padding: 0px; box-sizing: border-box; border: 0px; vertical-align: middle; transform: scale(1); transition: transform 0.4s, -webkit-transform 0.4s; max-width: 880px;"/><p class="ds-markdown-paragraph" style="list-style: none; margin-top: 16px; margin-bottom: 16px; padding: 0px; box-sizing: border-box; line-height: 20px; color: rgb(15, 17, 21); font-size: 13px !important; font-family: UniversPro, Arial, sans-serif !important;">3. FK Planter Bearing and Row Cleaner Bearing: Durability for Precision Agriculture To support the agricultural sector's pursuit of efficiency and precision, FK Bearing launches its dedicated series for planting equipment: the FK Planter Bearing and FK Row Cleaner Bearing. These bearings are specifically constructed to withstand the extreme conditions of farming: pervasive dust, mud, moisture, and high impact loads. Featuring advanced sealing technologies, such as multi-labyrinth or heavy-duty contact seals, they effectively prevent contamination from dirt and debris. Made from high-grade, corrosion-resistant materials and often pre-lubricated with specialist grease, these bearings ensure smooth rotation of planter disks, gauge wheels, and row cleaner blades. The result is accurate seed placement, consistent planting depth, improved crop emergence, and dramatically reduced unplanned maintenance during crucial planting seasons.<p style="list-style: none; margin-top: 0px; margin-bottom: 10px; padding: 0px; box-sizing: border-box; line-height: 20px; text-align: center; font-size: 13px !important; font-family: UniversPro, Arial, sans-serif !important;"><img src="https://www.fk-bearing.com/ueditor/php/upload/image/20260127/1769502882691262.jpeg" title="FK Planter Bearing and Row Cleaner Bearing" alt="FK Planter Bearing and Row Cleaner Bearing" width="600" height="" style="list-style: none; margin: 0px; padding: 0px; box-sizing: border-box; border: 0px; vertical-align: middle; transform: scale(1); transition: transform 0.4s, -webkit-transform 0.4s; max-width: 880px;"/><p class="ds-markdown-paragraph" style="list-style: none; margin-top: 16px; margin-bottom: 16px; padding: 0px; box-sizing: border-box; line-height: 20px; color: rgb(15, 17, 21); font-size: 13px !important; font-family: UniversPro, Arial, sans-serif !important;">The specific product catalogs for the above three products will be launched on the official website's product section as soon as possible.<p class="ds-markdown-paragraph" style="list-style: none; margin-top: 16px; margin-bottom: 16px; padding: 0px; box-sizing: border-box; line-height: 20px; color: rgb(15, 17, 21); font-size: 13px !important; font-family: UniversPro, Arial, sans-serif !important;">Commitment to Innovation and Quality "The introduction of these three product lines underscores FK Bearing commitment to providing tailored solutions that solve real-world challenges for our global customers," "From the foundational strength of our spherical roller units and the precision of our babbitted bearings for mega-machinery, to the specialized durability required in modern agriculture, each product is developed with a focus on quality, reliability, and total cost of ownership."<p class="ds-markdown-paragraph" style="list-style: none; margin-top: 16px; margin-bottom: 16px; padding: 0px; box-sizing: border-box; line-height: 20px; color: rgb(15, 17, 21); font-size: 13px !important; font-family: UniversPro, Arial, sans-serif !important;">FK Bearing Unit utilizes state-of-the-art manufacturing processes, rigorous quality control, and extensive testing to ensure every bearing meets international standards and performs reliably under specified conditions. FK offers comprehensive technical support and customization services to perfectly match application requirements.<p class="ds-markdown-paragraph" style="list-style: none; margin-top: 16px; margin-bottom: 16px; padding: 0px; box-sizing: border-box; line-height: 20px; color: rgb(15, 17, 21); font-size: 13px !important; font-family: UniversPro, Arial, sans-serif !important;">Availability The new FK Spherical Roller Bearing Units, FK Babbitted Split Journal Bearings, and FK Planter/Row Cleaner Bearings are now available for order. For detailed specifications, catalogs, or application engineering support, visit <a target="_blank" href="http://www.fk-bearing.com/" style="list-style: none; margin: 0px -3px; padding: 0px; box-sizing: border-box; color: rgb(57, 117, 206); text-decoration-line: none; transition: box-shadow var(--ds-transition-duration)var(--ds-ease-in-out); border-left: 3px solid rgba(var(--ds-rgba-transparent)); border-right: 3px solid rgba(var(--ds-rgba-transparent)); border-top: 2px solid rgba(var(--ds-rgba-transparent)); border-bottom: 2px solid rgba(var(--ds-rgba-transparent)); position: relative;">www.fk-bearing.com</a> or send email to <a href="mailto:export@fk-bearing.com" target="_blank" title="contact now" style="list-style: none; margin: 0px; padding: 0px; box-sizing: border-box; color: rgb(57, 117, 206); transition: color 0.12s ease-out;">export@fk-bearing.com</a><p class="ds-markdown-paragraph" style="list-style: none; margin-top: 16px; margin-bottom: 16px; padding: 0px; box-sizing: border-box; line-height: 20px; color: rgb(15, 17, 21); font-size: 13px !important; font-family: UniversPro, Arial, sans-serif !important;"> <article style="list-style: none; margin: 0px; padding: 0px; box-sizing: border-box; font-family: UniversPro, Arial, sans-serif !important;">About FK Bearing Group: <p style="list-style: none; margin-top: 0px; margin-bottom: 0px; padding: 0px; box-sizing: border-box; font-size: 14px; line-height: 20px; font-family: Roboto, sans-serif; color: rgb(51, 51, 51); background-color: rgba(255, 255, 255, 0) !important;">FK is the abbreviation of <span style="list-style: none; margin: 0px; padding: 0px; box-sizing: border-box; font-family: UniversPro, Arial, sans-serif !important; color: rgb(255, 0, 0); background-color: rgba(255, 255, 255, 0) !important;">Find solution, <span style="list-style: none; margin: 0px; padding: 0px; box-sizing: border-box; font-family: UniversPro, Arial, sans-serif !important; color: rgb(255, 0, 0); background-color: rgba(255, 255, 255, 0) !important;">Keep rotation, which decides that the company should grow the business by providing products and services from the end user's point of view. Founded in 1969, FK has been focusing on bearing units research, production and integrated solutions for applications, our more than 50 years experience in bearing units drive us to strive for Bearing Units Expert and Leading Supplier, FK Bearing Group was awarded Manufacturing Single Item Champion Enterprise (Bearing Units).<p style="list-style: none; margin-top: 0px; margin-bottom: 0px; padding: 0px; box-sizing: border-box; font-size: 14px; line-height: 20px; font-family: Roboto, sans-serif; color: rgb(51, 51, 51); background-color: rgba(255, 255, 255, 0) !important;"> <p style="list-style: none; margin-top: 0px; margin-bottom: 0px; padding: 0px; box-sizing: border-box; font-size: 14px; line-height: 20px; font-family: Roboto, sans-serif; color: rgb(51, 51, 51); background-color: rgba(255, 255, 255, 0) !important;">FK Bearing Group consists of a parent company FK Bearing Group Co., Ltd. (former Nanan Bearing Co., Ltd.) and subsidiaries OTC(Xiamen) Bearing Co., Ltd (former Xiamen Bearing Factory), XIAMEN FK IMP.&EXP.,CO.,LTD. We focus on <a href="https://www.fk-bearing.com/products/Bearing-Units-/534.html" target="_blank" title="FK bearing units" style="list-style: none; margin: 0px; padding: 0px; box-sizing: border-box; color: rgb(51, 51, 51); text-decoration-line: none; transition: color 0.12s ease-out; background-color: rgba(255, 255, 255, 0) !important; font-family: UniversPro, Arial, sans-serif !important;">bearing units</a>, providing suitable products and services with agile delivery to meet different demands from users, we insist on starting from pre-sales service, based on the core characteristics and needs of each user's equipment, we are the first one in the industry to propose different solutions for different users and provide matched solution for different application, now we have developed over 30 bearing units solutions for different sub industries, helping users avoid after-sales service for their equipment. In order to achieve the goal of agile delivery of customized bearing units, we have built an integrated, automated, intelligent and flexible production factory with the whole industrial chain of insert bearing and housing, from strict selection of raw materials, adoption of optimized processes and excellent equipment, to self-developed specialized equipment, supplemented by automated testing and sorting, strict quality control is implemented in each process to ensure high product stability and consistency, this help us surpass competitors one product for all industries or unknown delivery of customized products, help users create more value for their equipment. With an annual output and sales of over 20 million pieces, FK is a globally leading factory for bearing units with leading technology, biggest capacity and best sales for many years.<p style="list-style: none; margin-top: 0px; margin-bottom: 0px; padding: 0px; box-sizing: border-box; font-size: 14px; line-height: 20px; font-family: Roboto, sans-serif; color: rgb(51, 51, 51); background-color: rgba(255, 255, 255, 0) !important;"> <p style="list-style: none; margin-top: 0px; margin-bottom: 0px; padding: 0px; box-sizing: border-box; font-size: 14px; line-height: 20px; font-family: Roboto, sans-serif; color: rgb(51, 51, 51); background-color: rgba(255, 255, 255, 0) !important;">As a member of the National Rolling Bearing Standardization Technical Committee, FK Bearing Group is the main drafter of 7 China National Bearing Units Standards and 7 China Industry Bearing Units Standards. We have a provincial-level enterprise technology center in Fujian, a research institute for high-speed &mute bearing units, a testing center for long-life bearing units, and two production bases in Nanan and Xiamen. We are a national level little giant enterprise that focus on specialization, refinement, uniqueness and innovation and a national high-tech enterprise.<p style="list-style: none; margin-top: 0px; margin-bottom: 0px; padding: 0px; box-sizing: border-box; font-size: 14px; line-height: 20px; font-family: Roboto, sans-serif; color: rgb(51, 51, 51); background-color: rgba(255, 255, 255, 0) !important;"> <p style="list-style: none; margin-top: 0px; margin-bottom: 0px; padding: 0px; box-sizing: border-box; font-size: 14px; line-height: 20px; font-family: Roboto, sans-serif; color: rgb(51, 51, 51); background-color: rgba(255, 255, 255, 0) !important;">Bearing units can be mounted easily, and provide simple and effective bearing arrangements capable of accommodating moderate initial misalignment from mounting errors, they are widely used in almost all factory automation production, such as logistics machinery, environmental protection equipment, automotive inspection lines, packaging machinery, building material production lines, etc.food and pharmaceutical grade production, such as food processing production lines, beverage container and bottling production lines, mask production lines, glove production lines, etc., extreme application such as heavy dust agricultural machinery equipment, mining equipment, high-temperature heat treatment furnaces, wet fruit and vegetable cleaning lines, high pollution waste treatment systems, etc., as well as various living application such as HVAC fans, escalators, central kitchens, mechanical parking equipment, airport luggage transmission lines, etc.<p style="list-style: none; margin-top: 0px; margin-bottom: 0px; padding: 0px; box-sizing: border-box; font-size: 14px; line-height: 20px; font-family: Roboto, sans-serif; color: rgb(51, 51, 51); background-color: rgba(255, 255, 255, 0) !important;"> <p style="list-style: none; margin-top: 0px; margin-bottom: 0px; padding: 0px; box-sizing: border-box; font-size: 14px; line-height: 20px; font-family: Roboto, sans-serif; color: rgb(51, 51, 51); background-color: rgba(255, 255, 255, 0) !important;">In order to quickly serve and deliver continuous value-added services to end users, FK have established sales and service network of 4 regional warehouse in China and 7 continental warehouse around the world with our partners.<img src="https://www.fk-bearing.com/ueditor/php/upload/image/20251110/1762753523117506.jpg" title="FK Bearing Group" alt="FK Bearing Group" width="600" height="296" style="list-style: none; margin: 0px; padding: 0px; box-sizing: border-box; border: 0px; vertical-align: middle; transform: scale(1); transition: transform 0.4s, -webkit-transform 0.4s; max-width: 880px;"/></article><p style="list-style: none; margin-top: 0px; margin-bottom: 10px; padding: 0px; box-sizing: border-box; line-height: 20px; font-size: 13px !important; font-family: UniversPro, Arial, sans-serif !important;">

Correlations for Manufacture-Related Geometric Deviations and Resulting Costs

23 Jan,2026

<img src="/ueditor/php/upload/image/20260123/1769179414190673.png" title="1769179414190673.png" alt="2.png"/>To determine the relationship between geometric deviation parameters and production costs, experience in the form of known values and subsequent interpolation can be used on the one hand, or an arbitrarily detailed modelling of the costs can be aimed for on the other hand, see section “Determining the Manufacturing Process Costs for Conventional Processes in Gearbox Production.” Subsequently, a quality can be assigned to the total costs on the basis of measured values, production simulations or empirical knowledge. Modelling approaches for cost-tolerance functions (C-T functions) were therefore developed with the aim of enabling general applicability. The generally available data basis is not extensive, which poses a challenge. Many investigations were carried out under specific boundary conditions, which makes transferability to other manufacturing processes, tools or quantities challenging (Ref. 5–7).If not only the individual process costs are considered, but the balance sheet limits are extended to the total costs of an assembly, additional costs arise due to fully assembled units. In addition to the individual component manufactured outside the tolerance, these include other good parts that are also discarded. If the individual tolerance is extended, the probability increases that the assembly will no longer fulfil its function. This approach results in the optimum for the total costs of an assembly for a simplified example shown in Figure 1, top left (Ref. 8).For a generalized cost-tolerance description of the individual processes, He presents analytical approaches based on exponential functions and parameterizes these using a survey. He uses the developed correlations as a criterion for a generalized tolerance design. He compiles the costs for an acceptable workpiece property from individual cost items. The machine costs are only a subordinate part of this, see Figure 1, top right (Ref. 9).Existing cost-tolerance modelling covers a wide range in addition to the actual production, which was described by Andolfatto et al. with a generalized formula for the individual costs Ci with hyperbolic, exponential and linear components, see Figure 1, bottom left (Ref. 10). The C-T functions of a manufacturing process should fulfil three conditions, which are in Equations 1–3.The relationship between a manufacturing process and the appropriate analytical description model is not always clear. Sanz-Lobera et al., therefore, present an alternative approach for determining a cost-tolerance relationship using measurement data and the assumed scatter shape of a geometric feature. He comes to the realization that the scatter shape has an important influence on the cost-tolerance function and presents equations for some distributions (Ref. 11).Hallmann et al. also described the selection of suitable cost-tolerance functions as challenging. In addition, the approach with higher-order methods, such as Artificial Neural or Fuzzy Networks, is mentioned there in order to identify suitable functional relationships. In particular, the fact that different processes can achieve identical qualities at different costs is also addressed there, see Figure 1, bottom right (Ref. 5).

Culture Is Just as Important as Quality

22 Jan,2026

<img src="/ueditor/php/upload/image/20260122/1769088621326826.png" title="1769088621326826.png" alt="3.png"/>If you were lucky enough to attend Forest City Gear president Kika Young’s presentation at the Solution Center, “The Human Side of Precision: Why Culture & Story Are Your Competitive Edge,” you learned how company culture as well as prioritizing the values, beliefs and behaviors of your staff are key to building a successful organization. What we need more than anything in manufacturing today is to embrace originality, diversity, critical thinking and dare I say a little more humor and humility.Markets fluctuate, egos run amok, it’s criminally underrated to support every member of the organization as each one brings their own story, work ethic, knowledge and unique qualifications to work every day. I’ve watched this play out at FCG since 2007 and it’s no surprise that the company has been so successful for 70+ years in gear manufacturing.Sure, we live in a data-driven world obsessed with numbers and bottom lines, but there’s so much value to be found in a smaller, more focused trade show environment. 25+ exhibitors I spoke with were thrilled with the quality of sales leads from MPT Expo. Unlike larger events where things can get overwhelming (almost chaotic) the quality of the leads continued to be a talking point during MPT Expo.It’s very rare to find a dedicated event for gear and mechanical power transmission technologies where so much business is not only conducted between exhibitors and attendees but also solely between exhibitors. The focus and relevance of MPT will continue to gain momentum moving forward. The next Motion + Power Technology Expo takes place October 26–28, 2027 in Detroit. We hope to see you there!

Tedious Tasks a Thing of the Past?

21 Jan,2026

<img src="/ueditor/php/upload/image/20260122/1769088480629554.png" title="1769088480629554.png" alt="2.png"/>My conversation with Rahul Garg, vice president industrial machinery vertical at Siemens Digital Industries Software, for the Ask the Expert series reenforced the need for more automation and robotics across all industrial segments including gear and power transmission. While some remain concerned that conveying systems, cobots, AMRs and humanoids are replacing good manufacturing jobs for humans, you can’t argue with the productivity gains when it comes to tedious tasks on the shop floor.Case in point: Chik-Fil-A’s renowned lemonade was once processed by factory workers tasked with sorting, examining and manually squeezing each individual piece of fruit. Today, the company relies on driverless forklifts and robotic arms to sort, squeeze and package the lemons saving the company 10,000+ work hours per day. Another example of using robotics and automation to take on monotonous and dangerous jobs freeing shop workers to focus on more appropriate tasks.

The Power of a Virtual Lab

20 Jan,2026

<img src="/ueditor/php/upload/image/20260120/1768901890852889.png" title="1768901890852889.png" alt="2.png"/>The developed workflow offers numerous advantages, significantly enhancing the efficiency and accuracy of gearbox lubrication analysis. One of the primary benefits is the quick setup and analysis time. Engineers can prepare an analysis in just a few hours, with post-processing and animation generation automated using scripts. This efficiency allows for rapid iteration and comparison of design variations, enabling engineers to make informed decisions quickly.Having a numerical model leads to a powerful virtual lab, allowing for the testing of multiple conditions and scenarios without the need for physical prototypes. Engineers can rapidly iterate designs, run designs of experiments (DOE), and find optimized solutions. By adjusting parameters such as gravity equations and initial lubricant levels, various operating conditions can be simulated, including road slopes, acceleration, braking and turning events. Different weather conditions can be modeled by altering lubricant properties, providing a comprehensive understanding of gearbox performance under a wide range of scenarios.This capability enables the exploration of “what if” scenarios that would be impractical or costly to test experimentally. For instance, simulations can assess the gearbox performance without lubricant, test alternative lubricants, or evaluate the impact of component failures. This flexibility is invaluable for manufacturers, as it enhances their knowledge and expertise, leading to continuous improvement in product design and performance.In the context of our project, the virtual lab allowed for testing several deflector designs intended to guide more lubricant towards the overheating bearing. The initial deflector design created local lubricant recirculation, which was impossible to detect experimentally. Simulations provided critical insights, revealing the inefficiencies of the initial design and guiding the development of optimized deflector configurations. The improved deflector design, shown in Figure 14, was based on the animations of the lubricant movement. It uses double slopes directing both the flow coming up on the left side wall, and the flow moving counterclockwise around the input gear.No recirculation pattern, nor low velocity areas were observed. Figure 14 shows important lubricant motion near the overheating bearing. The table presents the comparison of flow quantity accessing the overheating bearing, indicating better performance. The improvements compared to without the deflector were not significant, but it shows that virtual testing allows us to quickly evaluate and compare designs.Quantitative metrics such as churning loss, volume flow across surfaces, and temperatures allow for the ranking of different designs and sensitivity studies. This ranking helps design teams identify the most effective configurations and better understand the parameters that most significantly affect lubrication performance. By providing detailed insights into the lubricant distribution and heat transfer characteristics within the gearbox, the virtual model enables the development of more efficient and reliable designs.

Correlation with Experimental Data

19 Jan,2026

<img src="/ueditor/php/upload/image/20260120/1768901751151600.png" title="1768901751151600.png" alt="1.png"/>Correlation of the developed workflow is an essential step to ensure its accuracy and reliability. The process involves several stages, beginning with the visual comparison of lubricant splashing. Slow-motion videos recorded using high-speed cameras are matched with animations generated from the CFD analysis. This visual correlation provides a qualitative assessment of the simulation’s accuracy in replicating real-world conditions.The second stage involves measuring the churning loss of the gearbox. The total torque loss on the test bench includes bearing losses, gear friction, seal friction, and churning losses. Accurate evaluation of the other three components is necessary to isolate and compare the churning losses with the torque measured in the CFD analysis. This quantitative comparison validates the simulation’s accuracy in predicting torque losses due to lubricant movement. The solver has been validated based on comparison with experimental data (Ref. 4). Two different scenarios, one single gear and two engaged gears, are tested experimentally and compared with numerical prediction. Figure 13 shows the comparison of experimental versus numerical churning losses estimation using XFlow 2022 solver. It shows a good correlation at various speeds.Temperature measurements represent the third stage of validation. Temperature data collected on the test bench are compared to the simulated overheating conditions. Ensuring that the CAD model used in simulations accurately represents the prototype on the test bench is critical for this comparison. The same lubricant temperature, applied torque, and rotational speeds must be represented in both physical and simulated environments.In our project with the gearbox manufacturer, the prototype on the test bench was an earlier version of the design. The test bench lacked a sensor capable of measuring torque losses, which would have allowed us to extract the total churning loss. Additionally, a few temperature labels were installed on shafts that had been altered between the prototype and the CAD model. These labels provided a range of temperatures reached or indicated if the maximum temperature had been exceeded.The company’s team acknowledged that the lubrication animations we provided were comparable to what they had observed through the casing window of their test bench. Our predictive model was able to reproduce the overhearing problem, estimating a temperature of 176°C, above the limit that the bearing can endure without damage.In many companies, the test team and the CFD analysts work separately. The test team often does not know what information the CFD team needs to correlate their models. Consequently, test reports are frequently incomplete and lack the crucial data required to validate the workflow. Greater collaboration between the test and CFD teams is necessary to build identical prototypes for both the test bench and the simulations. Strategic placement of thermocouples is essential for comparing predicted and actual temperatures, and churning loss measurements should be taken to gain confidence in the accuracy of the simulations.

Transient CFD Scenario Definition

16 Jan,2026

<img src="/ueditor/php/upload/image/20260118/1768712169196698.png" title="1768712169196698.png" alt="1.png"/>Setting up the scenario in XFlow takes less than an hour for the user. A turbulent multiphase transient analysis is defined, considering incompressible flow. The Lattice-Boltzmann method in XFlow uses the Wale-Adapting Local Eddy (WALE) turbulence model. The gravity effects are specified by an acceleration constant in the vertical direction. The lubricant was 75W140 oil with properties defined at 85°C. The initial lubricant level is set by specifying a coordinate in the vertical direction, representing 2L of lubricant inside the gearbox. The motions of gears and bearings are defined using angular velocity equations over time. The input gear rotates at 6000 RPM.The minimum lattice dimension is determined based on the narrowest region where the lubricant flow needs to be captured. A visual of the lattice used in the analyses is shown in Figure 3. To ensure an accurate velocity gradient, at least three to five lattice volumes should be present in the narrowest region, indicated by the red arrow. Local refinement regions must be defined carefully to fully encapsulate the entire rotating body; otherwise, the solid-fluid interface will not be modeled accurately.The total simulation time is based on the geometry’s size and should be set to ensure that the flow is fully developed and stabilized. If the initial simulation time is insufficient, a restart can be performed to extend the total time. Monitoring the analysis during computation helps determine when the flow has fully developed. Using the NVIDIA GV100 card, it took 32 hours to simulate one second.

Simulation Workflow Development: Building the Virtual Model

15 Jan,2026

<img src="/ueditor/php/upload/image/20260118/1768712007111280.png" title="1768712007111280.png" alt="3.png"/>Developing an analysis workflow for gearbox lubrication involves several critical steps that must be meticulously executed to ensure accurate and reliable results. The process begins with CAD preparation in Dassault Systèmes 3DExperience using CATIA applications.CAD PreparationIf the geometry is not native to the 3DExperience platform, it needs to be imported, with STEP files being the most robust option. Once imported, the assembly must be filtered to retain only the relevant parts for the lubrication simulation. Bolts, rivets, and parts not in contact with the lubricant should be removed. Unnecessary features, such as bolt and rivet holes, must be defeatured to avoid small vertices, unsuitable lattice sizes, and poor resolution. The casing, typically composed of several parts, should be merged to create a single watertight envelope. This is crucial for XFlow’s lattice generation to accurately recognize fluid domain boundaries. To expedite the CFD scenario definition, it is recommended to group parts rotating at the same speed into the same sub-assembly, allowing the equation of motion to be set once.Modeling bearings poses a challenge due to their many separate moving parts, such as balls or rollers. A simple donut shape would prevent any lubricant movement across the bearings. Bearings could be considered as porous zones, but this approach requires calibration and experimental data or a specific analysis. Given XFlow’s proficiency in handling rotating parts, we decided to model each ball and roller within the main bearings. The motion of ball or roller is complex, as each rotates around its own center. To simplify the setup, we applied a uniform motion equation to all balls or rollers, averaging the velocities of the bearing’s external (Ve) and internal case ((Vi)) : (Ve+Vi)/2.Once the relevant parts are selected and defeatured, the assembly is reorganized, and the casing is made watertight. The parts are then ready for meshing.DiscretizationHaving a unified shared mesh is crucial for accurate data transfer between the CFD and heat transfer analysis. In the CFD analysis, discretization involves representing a continuous solid in a tessellated environment. Spherical and cylindrical shapes must be finely discretized to ensure realistic interactions with the fluid. A coarse mesh would create a rough interface, leading to excessive interaction with the fluid.For the heat transfer analysis, meshing serves to represent continuous parts within an element-based solver. A mesh that is too fine demands more computing power, primarily RAM, and increases runtime. Additionally, it requires longer data processing to map the heat transfer coefficient accurately. Meshing solid parts involves discretizing them for the conduction equation, balancing the need for detail with computational efficiency. The equation of conduction, also known as Fourier’s law of heat conduction, describes the rate at which heat energy is transferred through a material due to a temperature gradient.Since the equation is linear, the element order can also be linear. We mostly utilized tetrahedral linear elements, applying an absolute sag criterion to refine areas with small radii to capture finer details. The bearings were meshed with linear hexahedral elements. The specific mesh size was determined to balance accuracy and computational efficiency. In total, we had nearly one million elements. This mesh information is then transferred to XFlow to construct the CFD analysis scenario.

Battle-Tested Tech for Aerospace and Defense Operations

14 Jan,2026

<img src="/ueditor/php/upload/image/20260118/1768710734140597.png" title="1768710734140597.png" alt="1.png"/>According to a recent study by Deloitte, the aerospace and defense industry stands at a pivotal crossroads as it enters the latter half of the decade. Forces that have shaped the sector in recent years—digital transformation, supply chain volatility, talent constraints, and geopolitical events—are converging with new catalysts such as agentic AI, emerging vehicles, and the rapid evolution of autonomous systems. On the defense side, budgets are a key focus, with a growing emphasis on enhancing mission readiness. At the same time, defense priorities are shifting to accelerate the fielding of AI-enabled systems and collaborative combat aircraft. “Speed to field” is becoming the unifying metric across portfolios.

Testing Conditions

13 Jan,2026

<img src="/ueditor/php/upload/image/20260113/1768281314678783.png" title="1768281314678783.png" alt="2.png"/>The gear pairs were evaluated within an enclosed acoustic chamber integrated into the gear test rig, effectively isolating the test specimens from external acoustic interference. This setup ensured that only the noise generated by the meshing gear pair was captured, eliminating the influence of extraneous sound sources. Throughout all experiments, rotational speed, applied torque, and gear temperature were rigorously controlled (Figure 4). Given the sensitivity of NVH performance to operating conditions, each gear pair was tested at two discrete torque levels, with three corresponding rotational speeds per torque level, to assess the influence of both parameters. Gear temperature was actively regulated and maintained at 80°C, measured directly in the tooth engagement zone. The complete matrix of test loads is detailed in Table 3. Testing was conducted under both dry and, for selected combinations, grease-lubricated conditions. For each material pairing, three independent test repetitions were performed, with a new gear pair employed in each instance to eliminate the effects of wear. All gear sets operated at a fixed theoretical center distance of 38.45 mm, established using a high-precision positioning mechanism with an accuracy of ±0.01 mm.Seven distinct polymer material combinations, selected from commercially available grades commonly utilized in gear applications, were evaluated in this study. For comparative benchmarking, a steel gear pair of identical geometry was also tested. The evaluated material pairings are as follows:Steel–SteelSteel–POM (run in dry and grease-lubricated conditions)POM–PPA+30%GFPA66–PPA+30%GFPOM–PA66 (run in dry and grease-lubricated conditions)PA6+15%G–POM+10%AFPOM–PA66+30%GFOne key advantage of plastic gears is their ability to operate in dry conditions without external lubrication. However, many gearboxes with plastic gears still use grease, as it typically improves efficiency and reduces wear. To reflect common practical applications, most of the tested material combinations were evaluated under dry conditions, except for the Steel–POM and POM–PA66 gear pairs, which were tested in both dry and grease-lubricated environments. The lubricant used was a grease formulated from synthetic hydrocarbon base oil thickened with a barium complex soap. The kinematic viscosity of the base oil at 80°C was measured at 10.3 cSt. Prior to testing, the grease was manually applied to the gear teeth, ensuring complete coverage of the meshing surfaces on both gears (Figure 5). No additional grease was supplied during the test runs.

Sample Preparation

12 Jan,2026

<img src="/ueditor/php/upload/image/20260112/1768193925133187.png" title="1768193925133187.png" alt="4.png"/>The test gears were fabricated via injection molding using a single-cavity mold. Molding operations were conducted on an Engel Victory 50 injection molding machine (Engel Austria GmbH, Austria). A three-plate mold configuration incorporating a hot-runner system and a centrally positioned pin-point gate with a 1.3 mm diameter was employed. Gear geometry conformed to the specifications outlined in VDI 2736, Part 4, Table 1, corresponding to Size 1 geometry (Ref. 9). The gear body was engineered with a wavy structural design, maintaining a consistent wall thickness of 2.5 mm (Figure 1). A symmetric groove was integrated at the interface between the gear body and tooth region to promote uniform material flow and complete cavity filling during the molding process.The gears were manufactured from seven commercially available thermoplastic compounds widely utilized in gear production. The injection mold was engineered with an interchangeable cavity system, enabling the use of multiple cavity inserts tailored to accommodate the differential shrinkage behavior associated with the various tested materials. This strategy ensured that all gear specimens were produced to a consistent quality standard, thereby minimizing the influence of dimensional and geometric variations on NVH performance. To maintain commercial confidentiality, only the chemical compositions of the employed materials are disclosed:Polyoxamethylene (homopolymer)—POMPolyamide 66—PA66Polyamide 6 + 15% glass fibers—PA6+15%GFPolyphthalamide + 30% glass fibers—PPA+30%GFPolyamide 66 + 30% glass fibers—PA66+30%GFPolyoxymethylene + 10% aramid fibers—POM+10%AFAs a reference for comparative analysis, three sets of steel gears were fabricated from heat-treated 42CrMo4 alloy, maintaining identical gear geometry as specified in Table 1.

The dynamic and complex nature of gearbox operation

09 Jan,2026

<img src="/ueditor/php/upload/image/20260110/1768051976663033.png" title="1768051976663033.png" alt="1.png"/>Extracting precise engineering data from a physical test bench is another major hurdle. The dynamic and complex nature of gearbox operation makes it difficult to gather accurate and comprehensive data, essential for informed design decisions.One of the primary challenges is visualizing the behavior of lubricant within the gearbox. Lubricant splashing, crucial for cooling and lubrication, occurs rapidly and chaotically, making it difficult to observe and analyze. Windows in casings and high-speed cameras are sometimes used to capture these dynamics, but these methods have limitations. The visibility inside the gearbox is restricted, and the high-speed cameras required for capturing fast events are expensive and can only provide limited views.Churning loss, the resistance created by lubricant splashing against rotating parts, is a critical factor affecting gearbox efficiency. Accurately measuring churning loss in a physical test bench is challenging. It requires precise instrumentation capable of capturing the subtle differences in torque. The sensors and equipment needed must be carefully calibrated and maintained to ensure accuracy. Torque loss measurement is the sum of the churning loss, the bearings loss, seal friction losses and the gears friction, making churning loss only estimation challenging.Temperature measurement on fast-rotating parts and small bearings presents another significant challenge. Thermocouples, sensitive paint and labels are commonly used, but placing these sensors on moving parts is complex. Ensuring that the sensors remain in contact and provide accurate readings while the parts are in motion is difficult. Additionally, the small size of bearings and the high rotational speeds make it hard to obtain precise temperature data. Usually, a paint label can be placed on a neighboring shaft, but not on the bearing itself. And it is telling you if the temperature has reached a certain threshold but does not give you the value.The challenges associated with physical gearbox test benches underscore the limitations of traditional prototyping and testing methods. The time and cost of building prototypes, combined with the difficulties in extracting accurate engineering data, significantly hinder the efficiency of the development process. These challenges highlight the need for advanced simulation techniques and virtual models, which can provide a more efficient, cost-effective, and comprehensive approach to gearbox design and analysis. By leveraging these technologies, engineers can rapidly iterate designs, test multiple conditions and scenarios, and extract detailed insights without the constraints of physical prototyping.

Experimental Test Bench Challenges

08 Jan,2026

<img src="/ueditor/php/upload/image/20260110/1768051833305224.png" title="1768051833305224.png" alt="2.png"/>The process of constructing a gearbox prototype is both time-consuming and costly. Each new design requires a unique set of components, often necessitating specialized manufacturing procedures. The lead time for producing these components can be extensive, encompassing material procurement, machining, assembly, and quality checks. Additionally, the cost associated with manufacturing a single prototype is high, as the procedures do not exist yet and the machinery might not be adapted.Once a prototype is built, any design changes mean starting the process over again. This iterative cycle can be exceedingly slow, with each iteration requiring new parts, leading to significant delays in the development timeline. The slow pace of physical prototyping makes it challenging to quickly test and refine new design concepts, ultimately slowing down innovation and optimization efforts.

Allison wet kits

07 Jan,2026

<img src="/ueditor/php/upload/image/20260110/1768035170440430.png" title="1768035170440430.png" alt="2.png"/>Eaton will also introduce Allison wet kits, engineered as turnkey hydraulic solutions for customers using Allison automatic transmissions. These integrated kits are designed to simplify installation while delivering consistent hydraulic performance and long-term reliability across a range of vocational applications, including dump, snow and ice, utility and construction equipment.

Hot shift PTO for Endurant transmission

06 Jan,2026

Designed for the next generation of automated transmissions, Eaton’s new hot-shift PTO for the Endurant transmission enables smooth clutch-free engagement, even in stop-and-go or continuous-duty environments. By allowing PTO engagement under load, the system improves operational efficiency and helps reduce downtime in demanding applications such as refuse, utility and construction.

Active Noise Reduction part of Chassis 2.0

05 Jan,2026

<img src="/ueditor/php/upload/image/20260105/1767622714434620.png" title="1767622714434620.png" alt="1.png"/>Series production of Active Noise Reduction is scheduled to start in 2028. In the future, the software function may also be used in other ZF actuators — for example, for active reduction of brake squeal or in the fully active damping system sMOTION."Thanks to our system expertise, we are able to offer our mechatronic actuators as true innovation drivers with the help of smart algorithms and we will extend our software-based control approach to other ZF actuators in the future. The goal for us is clear: mechatronic actuators that are capable of efficiently reducing both their own and external noise with the help of software," explains Holdmann.The new function fits perfectly into ZF's Chassis 2.0 product strategy. Chassis 2.0 uses intelligent and networkable actuators to enable new chassis functions via software. It combines intelligent actuators such as brakes, steering, and damping, scalable electronic architectures (E/E), and innovative software solutions into a highly integrated, flexible system. "With our Chassis 2.0, we are laying the foundation for the software-defined vehicle," says Holdmann.

Intelligent dampers, brilliant quietness: this is what the future of chassis technology sounds like

04 Jan,2026

<img src="/ueditor/php/upload/image/20260104/1767537005868338.png" title="1767537005868338.png" alt="4.png"/>The achievement of noise reduction is implemented purely on a software basis through intelligent control of the CDC dampers – without additional installation costs or space requirements. The current version of the technology achieves noise reductions of more than 3 dB today – which is a clearly audible difference for passengers. Up to 10 dB is possible in the future. Active Noise Reduction can be adapted to different vehicle types and customer requirements via software. This creates a new market, particularly for lower-priced vehicles – as high-quality acoustic solutions with microphones or speakers have mostly been available only in luxury segments. Approximately 40 percent of all semi-active dampers worldwide already come from ZF, making the technology group the market leader. In view of the trend toward automated driving, ZF expects sales in this area to increase.

Fast Movers

31 Dec,2025

<img src="/ueditor/php/upload/image/20260104/1767456421330699.png" title="1767456421330699.png" alt="6.png"/>MESH's latest project may be its most ambitious yet: a robotic induction system for e-commerce sortation, which debuted at the recent ProMat 2025 trade show. The system uses a vision-guided robot to pick items from bins, scan barcodes on either side of the box, package, or envelope, and place each on a high-speed conveyor feeding a bomb bay-style sorter. Here again, the system depends on NORD worm gearmotors to keep everything moving.London noted that the scanning capability eliminates a key limitation of current systems, where operators must place items with barcodes facing upward. “Our system doesn't care which way the label faces. It also picks 1,800 items per hour—well beyond what a human operator can achieve. We think it’s the first such solution on the market.”When asked a question that’s at the top of mind for many—whether automation is putting people out of work—London pushed back. “Our robotic cells don't replace people—they move them to better jobs. For example, I’ve seen how the companies that implement automation can often expand their quality control efforts. They put more energy into making sure products meet higher standards. And because workers no longer have to perform the repetitive, oftentimes strenuous tasks common in manufacturing, they’re able to spend more time on process improvement, oversight, and other value-added activities. It's better for everyone involved and makes the company more profitable to boot. That's what automation delivers.”

The Latest Cobot Trends

30 Dec,2025

<img src="/ueditor/php/upload/image/20260103/1767455919120243.png" title="1767455919120243.png" alt="5.png"/>What does the future hold? We are already seeing cobots become more intelligent through advanced AI integration. With AI, cobots can adapt to dynamic environments, learn from data, and make real-time decisions. This allows cobots to become even more efficient by optimizing movements and improving advanced inspection tasks. Becoming more common in the marketplace, cobots are getting more affordable. The expansion of the cobots-as-a-service (CaaS) model, where people can rent before buying, has lowered the barrier to entry even further. This means that cobot technology is now available to businesses of almost any size. Cobots are also being used in non-manufacturing applications in industries such as retail and agriculture.As cobots continue to evolve and become more accessible, a wide range of industries are empowered to enhance productivity, flexibility and innovation in their operations.

End-of-Arm Tooling (EOAT) Options

29 Dec,2025

<img src="/ueditor/php/upload/image/20260103/1767455808117734.png" title="1767455808117734.png" alt="4.png"/>Many challenges that our customers face can be solved with a cobot and a gripper. However, depending on the individual needs of the manufacturer and their process, a wide array of end-of-arm tooling options is available. These include electric grippers, pneumatic and vacuum grippers (Figure 2), wrist cameras, vision systems, and dispensing, palletizing, machine tending, welding and screwdriving options. Electric grippers are the most popular tooling option for some common cobot applications, including machine tending and pick and place. They typically come in two- and three-jaw configurations, offering precise control that allows you to vary your grip force, speed and position. This lets them handle different part types with ease.Pneumatic grippers use pressure from a compressed air supply to open and close the gripper fingers. Since most manufacturing facilities have access to compressed air already, deploying pneumatic grippers is easy and cost-effective. The largest benefit of these grippers is that they can provide a high amount of gripping force in a small package.Vision systems consist of 2D or 3D cameras that give the cobot vision. They allow the robot to locate objects, recognize patterns or scan barcodes. This may eliminate the need to present parts to the robot in a structured way since it can locate objects on its own. Vision systems also help the cobot carry out optical inspections, e.g., checking parts for defects.Dispensers are end-of-arm tools that uniformly dispense liquids. The most common applications for dispensers are gluing and sealing. These are perfect cobot applications because of the monotonous and repetitive nature of the work. A dispenser ensures you always use the same amount of product in the same way, reducing errors and waste. Standard, built-in path planning software tools enable a user to quickly implement dispensing about a unique 3-D path for the part contour needed.Screwdrivers are a niche solution, but we are seeing more of them. Recently, our team at Motion Ai automated several applications that required this EOAT type. Our screwdriver version comes with all the software and hardware needed to automate this mundane task. Today’s screwdriving solutions are smaller and less complex than their predecessors, making them viable for manufacturers of all sizes.Palletizing solutions are the ideal answer for many projects for our customers. Motion Ai offers an off-the-shelf solution that includes software and hardware to optimize this task that can be especially tedious for human workers. Once the hardware is set up, simply enter your box dimensions, weight and pallet layout into the software, and you can be palletizing in a matter of minutes—with no motion programming necessary (Figure 3).In both screwdriver and palletizing solutions, the main benefit is ergonomics. Each screwdriver and palletizer installation gets the job done more efficiently and usually faster, allowing workers to take on other, less strenuous tasks.The ecosystem of products that has developed around collaborative robots means that these days, almost any application can be solved with an existing solution. And if an off-the-shelf solution doesn’t exist, check with your distributor for options. A full-service distributor will have experienced engineers who design custom cobots to solve applications like those listed above, plus a full line of motion control and automation products to complete your automation projects.

The Strategic Value of Education

26 Dec,2025

<img src="/ueditor/php/upload/image/20251226/1766740428111125.png" title="1766740428111125.png" alt="4.png"/>From Federtec’s perspective, the collaboration underscores the importance of international cooperation in industrial education. “This strategic collaboration unites our strengths and is essential for spreading industrial culture and promoting technological innovation,” says Mauro Rizzolo, Federtec president. “Together, we can share knowledge, experiences, and resources, strengthening the global competitiveness of our companies.”By combining MPMA’s internationally recognized expertise in gear manufacturing with Federtec’s local knowledge of the Italian industrial ecosystem, the partnership serves as a model for cross-border workforce development. It demonstrates that strategic alliances in education can have a tangible impact on operational excellence, innovation, and global competitiveness.Looking Ahead The Italian-language Workforce Training Series has now been fully integrated with MPMA’s English offerings. Federtec continues to promote the courses among its members, targeting OEMs, suppliers, and training partners alike. As manufacturing continues to globalize, partnerships like this one provide a scalable solution for bridging skills gaps, standardizing knowledge, and preparing the next generation of gear industry professionals.“The Workforce Training Series is more than just a set of courses,” Lewis concludes. “It’s a pathway to ensure that our industry remains competitive, innovative, and prepared for the future.”

Embracing sustainable, lightweight and energy efficient bearing technologies

25 Dec,2025

<img src="/ueditor/php/upload/image/20251225/1766601422490777.png" title="1766601422490777.png" alt="1.png"/>Despite a lukewarm sustainability agenda here in the United States, global bearing manufacturers continue to be motivated by eco-friendly technologies, environmental awareness and energy efficiency regulations. Material innovation is one of the key strategies to reduce environmental impact moving forward. Concerns include energy consumption in manufacturing, waste generation, emissions from lubricants and raw material extraction. The end goal is to provide longer-lasting components with less waste.

Walking Forward

24 Dec,2025

<img src="/ueditor/php/upload/image/20251224/1766543841111719.png" title="1766543841111719.png" alt="1.png"/>Today, whether at Forest City Gear or RRVTMA, Lyford speaks about workforce development with clarity—not as a slogan, but as a commitment. Manufacturing relies on systems, but systems only work if people do.When asked to summarize Forest City Gear’s philosophy in a single sentence, he didn’t hesitate:“Training and workforce development is non-negotiable—that’s something you have to do without consideration to risk or cost,” Lyford said. “Yes, someone may leave after you’ve invested in them. But if you take a holistic view, that investment still develops the capability of our industry as a whole. You’re building the future—whether they stay or not.”Looking back, the common thread is clear—and it brings him to the phrase he first heard in a vocational classroom: Walk with purpose.In an industry searching for talent, clarity, and direction, those three words may be more than personal wisdom. They may be the blueprint—for companies, careers, and the future of American manufacturing.

From Apprentice to President

23 Dec,2025

<img src="/ueditor/php/upload/image/20251224/1766543742433330.png" title="1766543742433330.png" alt="1.png"/>Lyford’s recent appointment to RRVTMA board president represents a full-circle moment in his career. The RRVTMA is a local chapter of the National Tooling & Machining Association (NTMA), serving area manufacturers through networking, training resources, and apprenticeship pathways.“The purpose of the chapter is to organize local manufacturers to get the membership perks of the NTMA and more… one of the main things we provide is training and apprenticeship tracks for people within manufacturing.”The association offers a four-year precision machining apprenticeship with 8,000 hours of on-the-job training for gear manufacturing or a 10,000-hour tool and die track, and includes 160 hours of coursework through a partnership with Rock Valley College. Successful apprentices earn not only state credentials but federal recognition: RRVTMA apprenticeships are accredited by the Department of Labor, meaning graduates are officially indentured journeymen in the trade. Lyford now leads the organization he once went through himself. “My initial ideas are to continue the work the board has started and provide ongoing strategic direction to improve member value—as well as the quality of output for the apprentices—to maintain or provide more offerings.”

Future Mining Priorities

22 Dec,2025

<img src="/ueditor/php/upload/image/20251224/1766543249889854.png" title="1766543249889854.png" alt="5.png"/>MBCC is attempting to capture the potential of digital manufacturing across all its mining operations. Through a partnership with Hexagon, the company launched digital mining capabilities at Mansourah Massarah—a major step in enhancing efficiency, productivity and safety across the site. MBCC actively invests in Saudi Arabia's mining future by developing local talent and skills. By partnering with institutions like King Fahd University of Petroleum and Minerals, MBCC can offer specialized mining degrees equipping future mining leaders with advanced skills and technology expertise. Additionally, the company signed a memorandum of understanding (MoU) with MP Materials to explore a rare earth supply chain in Saudi Arabia. Collaboration with Fleet Space Technologies was also launched to enhance exploration through advanced geophysical methods.

A Clearer Path Toward Skill Development

19 Dec,2025

<img src="/ueditor/php/upload/image/20251220/1766209031497232.png" title="1766209031497232.png" alt="4.png"/>To retain skilled and qualified workers, GROB has identified several key focus areas. Neubert emphasized the importance of initiating conversations about growth opportunities and career pathways early in the employment process. “We need to support employees in pursuing further education, starting with competitive benefits—such as fully covered health insurance premiums and complimentary meals—while also fostering engagement through initiatives including holiday celebrations, company sports leagues, and organized running or cycling groups.”Neubert also highlighted the significance of being receptive to employee feedback. GROB's U.S. apprenticeship program, which mirrors the model used in Germany, has successfully integrated over 600 apprentices since its inception in 1990.Another significant advancement has been in the implementation of an online learning management system. “Our headquarters in Germany began offering online training years ago, and we have recently developed our own library of courses. This format allows employees to access training on-demand and at their own pace,” Neubert stated.Currently, GROB’s apprenticeship program combines paid, hands-on training with classroom instruction, mentorship on the shop floor, and exposure to various career paths. Apprentices receive a fully sponsored associate’s degree in electro-mechanical engineering technology from Rhodes State College of Lima, OH, along with a state-recognized journey person certification. The program has transitioned from offering strictly mechanical or electrical degrees to a comprehensive electro-mechanical degree that equips apprentices with a broader skill set, enabling them to adapt to diverse roles as needs arise.“Our program has expanded dramatically over the past decade, growing from 10 apprentices in 2015 to 60 in 2025. This nearly 20 percent year-over-year growth rate over the last five years reflects both the increasing demand for skilled trades and our commitment to nurturing talent from within GROB,” Neubert explained.In their second year, apprentices receive mentorship from shop floor technicians during departmental rotations. By their third year, they are placed in a specific department for specialized training, continuing to learn from seasoned technicians who provide invaluable insights and training.Additionally, GROB has established a dedicated Learning and Development department focused on creating training initiatives for its workforce. “Our GROB Academy program, available to employees from their first day until retirement, provides various pathways for both technical and professional development. Collaboration across departments allows us to develop training that employees can choose or that management can assign,” Neubert added.The GROB Academy currently offers 143 online courses accessible on-demand. As of July 2025, 646 employees have completed 3,600 courses, dedicating 1,750 hours to learning since the online program's launch in April 2024. Moreover, 189 employees have attended in-person professional development workshops offered within the company in 2025.“Our product lineup is continuously evolving, necessitating ongoing learning in advanced manufacturing processes. The CEO also hosts company meetings to educate employees about our product lines, current projects, and manufacturing trends. With our learning management system, we will keep developing training for new technologies as they emerge,” Neubert noted. “We also leverage Articulate 360, a suite of online tools for creating interactive e-learning content, which includes a learning management system that hosts, delivers, tracks, and reports on employee training. Feedback surveys help us assess training needs.”

Embracing sustainable, lightweight and energy efficient bearing technologies

18 Dec,2025

<img src="/ueditor/php/upload/image/20251218/1766046057571591.png" title="1766046057571591.png" alt="4.png"/>Despite a lukewarm sustainability agenda here in the United States, global bearing manufacturers continue to be motivated by eco-friendly technologies, environmental awareness and energy efficiency regulations. Material innovation is one of the key strategies to reduce environmental impact moving forward. Concerns include energy consumption in manufacturing, waste generation, emissions from lubricants and raw material extraction. The end goal is to provide longer-lasting components with less waste.

Nestlé Purina deployed Spot to automate thermal and acoustic inspections in their packaging lines

17 Dec,2025

<img src="/ueditor/php/upload/image/20251217/1765958655920578.png" title="1765958655920578.png" alt="8.png"/>Nestlé Purina deployed Spot to automate thermal and acoustic inspections in their packaging lines. Autonomous inspections allowed Nestlé Purina to give time back to the maintenance technicians, better predict and plan repairs, and ensure reliable operations.“In the case of Spot and the case of freeing up that manpower to be able to work, if Spot can find these issues for us in between our changeovers in between different production runs, we’re able to catch those issues ahead of time that allows us to be more predictive, more preventative rather than reactive,” said Scott Smith, Nestlé Purina.“We don’t see Spot as just thermal and acoustic inspection. We see Spot as something more of a tool that we can use for other applications. And we’re just starting to explore that and see what we can do in collaboration with Boston Dynamics to make Spot even more useful for our factories,” added Alyssa Carter, senior specialist, robotics engineering at Nestlé Purina.The company has spent some time on digital transformation and saw added value in the use of acoustic compressed air leak detection moving beyond regular predictive maintenance.The Anheuser-Busch InBev (AB InBev) brewery in Leuven, Belgium took Boston Dynamics’ Spot robot on a test run in 2022 to see how many mechanical issues or air leaks it could find in the sprawling facility. Less than two hours later, they were ready to offer the robot a full-time job.Since this test run Spot has become a key part of AB InBev’s “Brewery of the Future” program, which invests in emerging technology to support the company’s ambition of achieving net-zero operations at the Leuven facility by 2028.Spot conducts 1,800 individual inspections each week across ten packaging lines that churn out over 50,000 containers of Stella Artois, Budweiser, and Corona beer every hour. In its first six months of deployment, Spot discovered nearly 150 anomalies and slashed average repair times from a few months to a mere 13 days.“Our machinery experiences a lot of wear over time, so predictive maintenance is a top priority,” said David Gregory, scale and innovation manager at AB InBev. “Spot is seeing more than double the anomalies we were expecting, but we’re also now able to make repairs and see performance increases and energy reduction within the brewery.”With local roots dating back to 1366, the Leuven facility is world famous for its age, as well as being one of the largest breweries in Europe. Established in 1992, the facility covers the equivalent of 30 soccer fields, with four brewing houses and over 800 employees.The packaging floor is a labyrinth of stainless-steel piping and conveyor belts that move bottles and cans through the filling and packaging process. Intricate machinery—including pumps, compressors, gearboxes, and conveyor motors—are critical for production.At this scale, any mechanical issue that threatens to slow or halt production is a major concern, especially since the packaging lines operate around the clock when not under repair. Preventing unscheduled downtime means identifying mechanical problems before they reach critical failure.

Boston Dynamics Spot levels up into condition monitoring and maintenance fieldwork

16 Dec,2025

<img src="/ueditor/php/upload/image/20251217/1765958511678008.png" title="1765958511678008.png" alt="7.png"/>For a few years now, Spot—the agile, mobile robot—has been surveying show floors at Automate, CES and Promat. Last year, Boston Dynamics presented a slew of additional technologies at IMTS 2024, showcasing robotic innovations key to scaling autonomous industrial inspection for components such as bearings, motors, pumps, gearboxes and conveyor systems.Industrial inspectionMany PTE readers have discussed employing AI technologies to tackle shop floor challenges in the coming years. An AI-enabled facility allows management to make better, faster decisions, improve safety and efficiency, and most importantly, reduce overall costs. Boston Dynamics believes the key to this evolution is capturing consistent and reliable data. These robots can now work with minimal variations to deliver frequent and accurate inspection results. Here are a few of the latest technologies, giving companies an opportunity to reduce unplanned downtime and prevent critical failures in the future:Thermal inspectionSpot can collect thermal images of pumps, motors, and electrical equipment with pixel-level temperature data. Users can set up alerts when equipment exceeds a set range or when temperature differences between assets surpass thresholds.Acoustic inspectionNoise anomalies can be an early indicator of impending equipment failure, but leaks, vibrations, and electrical discharge are typically undetectable by people. Acoustic inspections with Spot enable users to autonomously monitor sound signature changes to prevent unscheduled maintenance. Utilizing the Fluke Sv600—a fixed acoustic imager translating sounds into a visual representation to locate problem areas in factory systems—Spot can locate costly leaks in compressed air and gas lines, record acoustic images and videos for post-inspection analysis and alert MRO teams to maintenance issues.Gauge readingSpot uses machine vision models to read and analyze analog gauges that measure pressure, flow, and more. It can trigger alerts for abnormal readings and track asset trends over time.

Inject Mold Paper

15 Dec,2025

<img src="/ueditor/php/upload/image/20251215/1765795757505408.png" title="1765795757505408.png" alt="4.png"/>Injection molding bridges prototyping and full-scale production with its unmatched scalability and precision. By integrating CT technology, manufacturers gain clear insights into mold accuracy and material behavior—accelerating the path from design to high-volume, defect-free plastic parts.Take your parts from prototype to production without compromise. Injection molding delivers the precision and repeatability needed for scale, while CT integration ensures every mold and material meets spec—enabling smoother transitions and consistent quality at volume.

Closing the loop with optical rotary encoders

12 Dec,2025

<img src="/ueditor/php/upload/image/20251214/1765692549110419.png" title="1765692549110419.png" alt="4.png"/>Many SMLAs can be outfitted to provide feedback by adding a rotary encoder. Rotary encoders, also known as shaft encoders, convert the angular position of a shaft to analog or digital output signals. Optical rotary encoders are the most common option for adding feedback functionality to SMLA assemblies. Figure 4 illustrates how adding an encoder to an SMLA can provide feedback to the controller and share important motion data such as position, speed or direction.

Open loop linear actuation

11 Dec,2025

Figure 2 depicts open-loop SMLA architecture that applies to all configurations. Users interact with the system through a human machine interface (HMI). They program the desired motion sequence into the motion controller, which sends it to the stepper motor drive for conversion and amplification before transmitting it to the SMLA, which makes the moves. The communication pathway is unidirectional; neither the motion controller nor the HMI ever receives any notification that the intended move has been completed successfully.

Knowing exactly where a load is positioned is critical for many high-precision applications such as medical instruments, measuring devices and laboratory equipment. Also, certain applications can power off unexpectedly or have their load forced out of position. In such scenarios, it would be impossible to know the exact position of the load without using a feedback mechanism.A good example of an application that benefits from the functionality of an encoder is automated pipetting machine. (Figure 3) These devices utilize an encoder on the horizontal axis to accurately track the location of the dispensing pipette and ensure fluid is transferred to the proper test tube. Other examples include fluid pumps, 3D printers and XY stages.

SMLA core configurations

10 Dec,2025

<img src="/ueditor/php/upload/image/20251214/1765692318642163.png" title="1765692318642163.png" alt="2.png"/>Figure 1 (above) shows three of the most common SMLA constructions: a motorized lead screw (MLS), motorized lead nut (MLN) and motorized linear actuator (MLA). Each of these constructions has a stepper motor, lead screw and nut at its core, but differ in how it obtains motion.For MLS units, the lead screw attaches directly to the motor shaft, which translates the nut on rotation. MLN units integrate the nut inside the motor shaft, which when rotated, translates the lead screw instead of the nut. MLA configurations are essentially MLS units with additional components that house the lead screw and nut while also providing integrated support and guidance.

Stepper motor linear actuators

09 Dec,2025

<img src="/ueditor/php/upload/image/20251214/1765692204108659.png" title="1765692204108659.png" alt="1.png"/>Stepper motor linear actuators (SMLAs) combine a stepper motor, precision lead screw and nut in one compact envelope, providing a highly configurable, customizable and robust solution for linear motion. With the help of a motion controller and a stepper driver, all SMLAs can be programmed to position a load to a precise location. However, standard configurations do not provide a feedback mechanism that tells the operator whether the move is completed or not.Although not essential for many applications, feedback can be a powerful tool to utilize in more sophisticated linear motion systems. Because of this and the increasing demand for precise load positioning information, outfitting an SMLA with an encoder can be an effective and simple solution to get real-time motion feedback about your application.

Stator housing holds both bearings in line, keeping lathe bore diameter and straightness variance to within 1 to 2 microns.

08 Dec,2025

<img src="/ueditor/php/upload/image/20251208/1765183573106288.png" title="1765183573106288.png" alt="4.png"/>A ground shaft can normally meet a straightness requirement of less than 5 microns. Bearings have a positive effect on runout however, greatly reducing runout.Mount both the front and rear bearings in a stator bore that has a single diameter. The single bore lines up the bearings precisely with each other. It is possible on certain lathes to hold that bore to within 1 to 2 microns of diameter and straightness variance.Use a threaded bearing preload adjuster and wave spring to precisely set the preload. Until now, most designs use spacers and wave springs. There may be several thicknesses of spacers and wave springs stacked. An adjustable threaded spacer, combined with a single wave spring, is screwed into position while monitoring the effect on motor starting torque to reach a target close-loop preload.

Gearbox Example

05 Dec,2025

<img src="/ueditor/php/upload/image/20251207/1765078684120131.png" title="1765078684120131.png" alt="11.png"/>In a final step, the response of the housing in a stage railway gearbox is studied. In a prior step in the project, the original gear macro- and microgeometry was optimized. A forced response analysis was conducted using the gear mesh force variation during the meshing cycle as excitation. The housing response was calculated for both the original and optimized gear macro and micro geometry and the gearbox equivalent radiated power as an indicator for airborne noise was compared. No waviness was applied to the gears.Using the same methodology and tools, the gear mesh force variation was calculated using the optimized gear, once without waviness, once with waviness applied. For this, the LTCA as implemented in KISSsoft was used. For the gear without waviness, the gear mesh force variation was 2,110 N, whereas for the gear having waviness, it was 2,500 N (rounded to 10 N each).Left column: results without waviness. Middle column: results with waviness, amplitude = reference amplitude. Right column: results with waviness, amplitude = 2 x reference amplitude. First row: Profile modification, superimposition of profile crowning plus waviness. Second row: Contact force over mesh. Third row: Transmission error. Fourth row: Amplitude spectrum of transmission error.The variation in gear mesh force, calculated in the forced response analysis in KISSsoft, resulted in variation of bearing forces as shown on the left side of Figure 15. The bearing forces (in the time domain) are exported from KISSsoft and imported into RecurDyn, where the housing is subjected to dynamic analysis. On the housing, several virtual accelerometers are placed at critical locations and displacement, velocity and acceleration in the nodes where these virtual accelerometers are placed are recorded in the time domain.Converting the time domain results by Fourier transformation into a frequency domain result allows for plotting of the e.g., velocity vs. frequency. On the left side of Figure 16, the velocity of the node where the virtual accelerometer is placed is shown for the gear without waviness applied. We see a few peaks at low frequencies and then a peak at the gear mesh frequency of 825Hz. We see the same peak, but at a higher amplitude, for the gear with waviness applied on the right side of Figure 16. The velocity increases from 3.58 m/s to 4.75 m/s, an increase of 33 percent.With this, we may conclude that the process, methods and tools are likely to be suitable for the assessment and optimization of waviness aiming at a reduced gearbox noise level. Obviously, further work to deepen the understanding of the approach and results is needed. Also, this approach is not automatized and requires experience and engineering judgement for the assessment of results. It is currently suitable for specific projects or troubleshooting, but not for use in quality control of thousands of gears. In sound critical applications where a few units of gears are used, e.g., marine gearboxes, the above process looks promising. It also looks promising for critical applications where many units with consistent manufacturing are manufactured, e.g., for aerospace or EV gearboxes.

Gear Mesh Example

04 Dec,2025

<img src="/ueditor/php/upload/image/20251207/1765078550125553.png" title="1765078550125553.png" alt="9.png"/>To illustrate the effect of waviness on calculated performance characteristics like transmission error and load distribution, we use a pinion gear mesh. Both gears are spur gears. As a reference calculation, only profile crowning is applied to the pinion. For a second calculation considering gear waviness, a waviness is applied on the pinion, having a reference amplitude. For a third calculation, the waviness amplitude is doubled. An LTCA for the three meshes is performed and the results are shown in Figure 12.We observe that the line load changes very little, far less than what would be needed to indicate the need for a change in design. It is interesting to note that the PPTE value does not change proportionally to the waviness amount. The most interesting result is that for the gears having waviness, the higher-order amplitudes in the spectrum of the transmission error increase. Here, we see the influence of the waviness on the transmission error.Approximation of the measured waviness by superimposition of a few sinus-shaped forms with different amplitude, phase and wavelength. Right: Same form of waviness but increasing amplitude to study the effect of e.g., tool wear.The above is not a systematic approach to the phenomenon of waviness and its influence on the performance of a gear mesh. Far more extensive parameter studies are required. However, it does illustrate thatThere is an influence of the waviness on performance characteristics.They are accessible through LTCA.Results are plausible and encouraging.The influence of waviness is negative (stresses and PPTE increase).The increase in PPTE indicates that the excitation of a gearbox housing by the gear mesh will be more in case waviness is present. This aspect is investigated in detail in the next section.

Definitions and Description of Waviness

03 Dec,2025

<img src="/ueditor/php/upload/image/20251207/1765078428868768.png" title="1765078428868768.png" alt="8.png"/>The waviness is shown as a three-dimensional image. The vertical axis shows the deviation of the manufactured and measured geometry from the designed geometry. Note the waviness in one direction. Note that the plane is twisted due to the natural twist from manufacturing. Note that this waviness is concerning one flank. In a mesh, several flanks are in contact at one point in time, and the waviness in one contact and the waviness in the next contact (for contact ratio above unity) overlap. On the right side of Figure 9, the definition of waviness on the flank, inclined by an angle, is shown. The amplitude, wavelength, inclination angle and phase shift are needed to define the waviness where the shape is a sinusoidal form. If the angle is set to zero, a waviness in profile direction results; if set to 180 degrees, a waviness in lead direction results.Several such waviness definitions may be superimposed. On the left of Figure 10, waviness patterns in lead and profile direction are superimposed, creating a “rough” gear flank. Depending on the amplitude of this “roughness”, different maximum peak stresses result. Such an approach may be helpful to explain the formation of micropitting in a pattern resembling grinding marks. In the right of Figure 10, several waviness definitions having different phase shift, amplitude and wavelength are superimposed in the profile direction. This results in a composite waviness in profile direction that is not intuitively recognized as a superposition of sinusoidal shapes but looks realistic.To represent the measured waviness, e.g., in profile direction, the user must come up with several sinusoidal curves and superimpose them. By adjusting phase shift, amplitude and wavelength for each sinusoidal curve, different patterns for the resulting waviness are achieved. With this approach, by increasing the amplitude, wear of a tool and an increase in waviness in production between dressing of the tool may be considered. Currently, the software lacks the functionality to create the individual sinusoidal shapes, again, a function to be added.

Measuring Flank Waviness as Next Step

02 Dec,2025

<img src="/ueditor/php/upload/image/20251207/1765078332900224.png" title="1765078332900224.png" alt="7.png"/>In the above process, only 8 × 8 = 64 points are measured and the shape of the flank between the measured points is not known. A more refined approach is to not only transfer individual points of information from the measurement but whole traces in lead and profile directions (which is just a much higher number of points). Traces are measured and displayed in Gleason GAMA software, see the yellow lines on the left side of Figure 8. These traces show a waviness; they may also be visible in printouts, as shown in the top right of Figure 8. These traces are now to be represented in the gear design software so that the gear model there also includes the waviness as it is present in the manufactured gear. At the time of writing this paper, this was not yet automatically possible but required a manual approximation of the shape of the trace in the gear design software, using functions to approximate it there. Note the comment in the section on “Future Work” where this point is addressed as a subject for improvement of the software interface.With this approach, the digital twin contains far more information on the manufactured gear since a much higher number of data points is considered. At the time of writing this paper, however, it is only possible to import one trace in lead and one trace in profile direction (or one trace with an inclination as explained in the following section). This is again a shortcoming of the current software version to be addressed in the future. The underlying assumption is that waviness is a systematic result of the manufacturing process, manufacturing machine and tool properties. Hence, it is reasonable to assume, in a first approximation, that the waviness in profile direction is constant along the face width or the waviness in lead direction is constant in profile direction. In the next section, definitions and descriptions of how the waviness is defined in the gear design software are given.

Experiments at supersonic speed

01 Dec,2025

<img src="/ueditor/php/upload/image/20251201/1764523643123750.png" title="1764523643123750.png" alt="8.png"/>The operating principle of the tube wind tunnel uses the interaction of pressure and vacuum, where the accumulator tubes serve as pressure vessels in which the air is compressed. To prevent air condensation in the ultrasonic nozzle, which occurs due to the strong expansion and the associated cooling of the air, the accumulator tubes must be heated to simulate high supersonic velocities.The accumulator tubes are connected to the ultrasonic nozzle via a quick-action slide valve. The measuring section is found at the end. This is where experiments are carried out. At the end of the measuring section is the vacuum vessel, which the vacuum pump is connected to. A vacuum slide valve between the measuring section and the vacuum vessel enables access to the measuring section as required. The vacuum vessel is evacuated using the vacuum pump. A COBRA NX screw vacuum pump from Busch Vacuum Solutions is used for this. It generates vacuum of approximately 10 to 40 mbar in the vacuum vessel. In the accumulator tubes, there is overpressure of approximately 2 to 40 bar.To perform a test, the test model is placed in the measuring section using a movable model holder. Test models include aircraft models, sensors or material samples. Opening the quick-slide valve creates a running dilution wave that flows into the accumulator tube and accelerates the accumulator air towards the nozzle. Due to the differential pressure between the accumulator tube and the vacuum vessel, and thanks to the specially shaped ultrasonic nozzle, an ultrasonic flow is created in the RWG measuring section. Speeds of up to Mach 7 can be achieved – corresponding to seven times the speed of sound. Measurement times of up to 350–400 milliseconds are realized in the RWG. This is a peak value for wind tunnels of this type and gives researchers enough time to study the flow around the test models. During this time period, statistically relevant data or image sequences can be recorded to enable reliable data averaging and analysis.