CASE 1: Assembly line pallets
| BEARING TYPE: |
Tapered roller bearing |
| CONDITIONS: |
Pallets traveled through a transmission washer, which washed the oil out of the bearings. Bearing life 3 months. |
| RESULTS: |
With installation of MicroPoly, bearing life has been extended to over 2 years. Cost savings are estimated to be $122,500 per year. |
CASE 2: Truck assembly transfer conveyor
| BEARING TYPE: |
2-1/2” Cam Follower |
| CONDITIONS: |
Bearing in conveyor could not be lubed. Dirt and contamination were working into bearing causing bearings to fail in 1 or 2 months. |
| RESULTS: |
With installation of MicroPoly, bearing life has been extended past 1 year and bearings are still operating. |
CASE 3: Towmotor, front wheel spindles
| BEARING TYPE: |
Tapered roller bearings #14116/14274 & 14114/12123A |
| CONDITIONS: |
Bearings were heavily loaded and the vehicles were operated until the bearings failed, causing the hubs or wheels to be damaged about 50% of the time. Average bearing life 6 months; range 3 to 12 months. |
| RESULTS: |
The bearing life was increased to 3-1/2 years, increasing the utilization of these vehicles. According to customer records, this created a cost savings of $337,314.76 for the fleet of 47 vehicles. |
CASE 4: Tire grinder/shaper
| BEARING TYPE: |
Tapered roller bearing |
| CONDITIONS: |
Inadequate lubrication. Bearings were lasting 3 to 9 months. |
| RESULTS: |
Bearings with MicroPoly have been running 12 months without failure. |
CASE 5: Grinder chuck bearing
| BEARING TYPE: |
Single row ball bearing #6018 2RS |
| CONDITIONS: |
Grease was washed out by constant coolant flow. Bearing life 7 to 10 days. Bearing speed approximately 1,200 RPM. |
| RESULTS: |
Life extended to 6-7 weeks without seals on bearings; over 12 months with seals reinstalled on bearings. |
CASE 6: Multi-spindle screw machine
| BEARING TYPE: |
Single row ball bearing #87507 |
| CONDITIONS: |
Manual greasing blew out the seals, causing the grease to be washed out by constant coolant flow and allowing metal chip contamination in the bearings. Bearing life only 2 months. Bearing speed approximately 2,300 RPM maximum; intermittent rotation. |
| RESULTS: |
At least a 50% life increase with no seals on bearings, increasing uptime and reducing scrap. |
CASE 7: Special machine, index table bearing
| BEARING TYPE: |
Kaydon #KG300XPO – 30” bore |
| CONDITIONS: |
The bearing could not be re-lubricated. Coolant washed out the grease. The seals did not adequately protect the bearing from metal chip contamination, which caused premature bearing failure. Changing out bearings required several days of machine downtime and high maintenance labor costs. Bearing life less than 1 year. |
| RESULTS: |
Eliminated early bearing failures. Bearing life increased to over 4 years. Machine uptime was increased and maintenance costs substantially reduced. |
CASE 8: Crankshaft grinding line, overhead conveyor wheels
| BEARING TYPE: |
4” conveyor wheels |
| CONDITIONS: |
Continuous lubrication required as conveyor goes through washer. Wheels are sprayed with oil, which drips on to the floor causing severe safety hazard and housekeeping problems. Washer solution becomes contaminated. Bearing life 6 to 9 months. |
| RESULTS: |
With MicroPoly, the bearing life was increased to 3 years. Safety hazards and housekeeping problems have been completely eliminated, with no need for any maintenance of the lube system. A quote from the maintenance foreman—“It’s the smartest thing I could have done”. |
CASE 9: Shot blast screw conveyor – stamping plant
| BEARING TYPE: |
Roller bearing |
| CONDITIONS: |
Grease attracted shot blast material. Machine required partial disassembly to lubricate bearings. Bearing life short and unpredictable. |
| RESULTS: |
Bearing life has increased more than 6 fold, substantially increasing uptime and reducing maintenance costs. |
CASE 10: 4-slide wire forming machines
| BEARING TYPE: |
Cam followers filled, and bushings and slides plugged with MicroPoly solid profiles |
| CONDITIONS: |
Lubrication was not containable in machine, causing a very severe safety hazard as floor became slippery around the machine. |
| RESULTS: |
Eliminated safety hazard and housekeeping problem. Eliminated lubricating oil usage. |
CASE 11: Stamping press flywheel and drive shaft bearings
| BEARING TYPE: |
Cylindrical roller & tapered roller bearings – about 4” bore |
| CONDITIONS: |
Bearing life was unpredictable due to inconsistent lubrication. Bearings were difficult to reach, and the press had to be shut down for manual lubrication. Bearing speed approximately 300 RPM. |
| RESULTS: |
Five years bearing life achieved consistently. Manual lubrication was eliminated. |
CASE 12: Overhead conveyor – assembly plant
| BEARING TYPE: |
6” trolley wheels and guide rollers |
| CONDITIONS: |
Wheels and rollers failed prematurely and were difficult to maintain due to the need for manual lubrication. |
| RESULTS: |
Since installation in June 2000, there have been no failures and the manual labor required to maintain the wheels and rollers has been eliminated. |
CASE 13: Overhead conveyor – phosphate line
| BEARING TYPE: |
4” trolley wheels
|
| CONDITIONS: |
Wheels failed prematurely. The phosphate solution would get contaminated from the grease dripping into the solution. This caused downtime and high maintenance costs. |
| RESULTS: |
The wheel life was increased and the maintenance costs were reduced due to the elimination of grease contaminating the phosphate solution. |
CASE 14: Roll bearings
| BEARING TYPE: |
XLC3, single row ball bearing – 3” bore |
| CONDITIONS: |
This bearing is no longer available with seals. Bearing speed was slow, with a very heavy load. |
| RESULTS: |
All machines have been converted to MicroPoly filled bearings, with longer bearing life than when sealed bearings were used. |
CASE 15: Special Machine - pallet bearing
| BEARING TYPE: |
CYR 2-1/2S cam follower |
| CONDITIONS: |
Grease was washed out by constant coolant flow. Bearing life only 1 to 4 months. |
| RESULTS: |
Eliminated early bearing failures. Bearing life increased and is more consistent. |
CASE 16: Forging machine – auto loader
| BEARING TYPE: |
2-3/4” cam follower
|
| CONDITIONS: |
Not able to lubricate bearings. Bearing life 2 to 3 months. Speed very slow; heavily loaded. |
| RESULTS: |
Eliminated early bearing failures. Bearing life increased and is more consistent. |
CASE 17: Conveyor bearings
| BEARING TYPE: |
Mounted bearings (flange and pillow block) - about 1” bore |
| CONDITIONS: |
Inconsistent manual lubrication of bearings. Over lubrication frequently caused seals to pop out and grease to drip on floor. Bearing life was inconsistent. |
| RESULTS: |
Reduced manual maintenance, eliminated safety hazard and housekeeping problem, and also increased bearing life. |
CASE 18: Automation for car body carrier
|
MICROPOLY: |
MicroPoly Sprocket for #60 chain |
|
CONDITIONS: |
Automation was designed without chain lubrication, causing problems with chain wear and unacceptable chain life. |
|
RESULTS: |
Installed July 1999 and still running. |
CASE 19: Sheet metal processing automation
| MICROPOLY: |
MicroPoly Sprocket for double #40 chain |
| CONDITIONS: |
Conveyor chain was periodically manually lubricated with an oil sprayer. This caused the oil to drip, thus creating the need to contain the excess oil in pans. Because of the severe safety hazard, the steel pans had to be cleaned out before the equipment and the chain could be serviced. |
| RESULTS: |
MicroPoly Sprockets have eliminated the safety hazard and increased the chain life. |
CASE 20: 6” forging machine
| MICROPOLY: |
Slides utilizing MicroPoly plugs |
| CONDITIONS: |
Lubrication holes and grooves would clog, causing inadequate lubrication of the slide surfaces. This lead to premature and heavy wear resulting in quality problems and excessive downtime. The machines needed to be rebuilt every 9 months. |
| RESULTS: |
The incorporation of the MicroPoly plugs provided sufficient lubrication to reduce the wear condition, increasing the interval for machine rebuild to 28 months. |
CASE 21: Tool room grinder
| MICROPOLY: |
Table slides utilizing MicroPoly plugs |
| CONDITIONS: |
The lubricity of the polymer slide material was lost due to the coolant exposure. This caused the coefficient of friction to increase and excessive force was required to move the table slide. |
| RESULTS: |
The incorporation of the MicroPoly plugs permitted sufficient lubrication to reduce the coefficient of friction to a low level. The slide can now be moved easily by hand. |
CASE 22: Stamping presses
| MICROPOLY: |
Bronze bushings and gear faces utilizing MicroPoly plugs |
| CONDITIONS: |
Lubrication was pumped vertically to each of the wear components. Lubrication lines would clog and the high load zones were not sufficiently lubricated, causing the overhaul of each press every 7 years of usage. |
| RESULTS: |
Eliminated the need for lubrication and the associated manual labor. After 7 years the bushings and gear faces showed no wear and did not need to be replaced. |
CASE 23: Parts conveyor chain drive
| MICROPOLY: |
1” x 2” x 20’ conveyor chain lubrication block, #60 chain |
| CONDITIONS: |
UHMW guide material supporting the chain wore out prematurely. This resulted in inconsistent parts feeding problems. The chain would disengage from sprockets when worn down, leading to frequent guide replacement. |
| RESULTS: |
Eliminated inconsistent parts feeding problems and frequent guide replacement. After three years of use the blocks are still in service. |
CASE 24: Car assembly line - carrier
| MICROPOLY: |
1” x 2” x 4” lubrication block in spring loaded mechanism |
| CONDITIONS: |
Grease lubrication was extremely messy. The lubrication also created housekeeping and safety problems. This could potentially contaminate parts of the car during assembly and affect paint quality. |
| RESULTS: |
Eliminated contamination, housekeeping, and safety problems. |
CASE 25: Car assembly line – chain drive
| MICROPOLY: |
1” x 2” x 5’ conveyor chain lubrication block |
| CONDITIONS: |
Could not lubricate conveyor chain with liquid lubricant, because lubricant contaminated sheet metal prior to painting and affected the paint quality. |
| RESULTS: |
Extended chain life and solved lubrication problem, therefore eliminating contamination of the sheet metal. |
CASE 26: 4-slide wire forming machines
| MICROPOLY: |
Cam followers filled, and bushings and slides plugged with MicroPoly solid profiles |
| CONDITIONS: |
Lubrication was not containable in machine, causing a very severe safety hazard as floor became slippery around the machine |
| RESULTS: |
Eliminated safety hazard and housekeeping problem. Eliminated lubricating oil usage. |
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