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How to sustain your farm’s profitability in the long term

As a farmer, you are under more pressure to produce than ever before. With a constantly growing global population to feed, it is all-important to maximise yield. However, if demands are to be met in the future, you also need to take care of the environment to ensure that your main production input, your soils, stay in a good condition to produce. Here is a selection of tips and best practices for the new age of sustainable farming.

Demands are growing: What can be done?

We will need to produce more food in the next 50 years than we did in the past 10,000 years combined. This ominous prediction from the Food and Agriculture Organization (FAO) shows the enormous size of the challenge facing farmers today. Against this background, it is crucial for you to maximise yield, while ensuring you look after your farm to ensure its long-term productivity. This comes down to taking a forward-looking and strategic approach to your farm – and that is where sustainable agriculture becomes an essential practice.

Fuel efficiency – a win-win for farmers

As public awareness concerning environmental issues rises, the EU has committed to reducing greenhouse gas emissions by at least 40% by 2030 compared to levels in 1990. Agriculture plays a key role in this, and such targets and regulations are driving technological advances.

For example, new farming machinery, such as tractors and combine harvesters, are now built with variable-speed gearboxes. These allow a greater degree of adaptability to the present soil and weather conditions. No longer do you have to find a compromise between gears, but instead you can easily alter your speed to reduce RPM. Shifting to a higher gear, whilst lowering speed shows impressive results in terms of fuel efficiency – reducing fuel consumption and therefore also costs. Other techniques for maximising fuel efficiency include correct tyre inflation, using front wheel drive, and replacing fuel and air filters at the right moment, which can immediately increase engine power output by 3.5%.

Controlled traffic farming – keeping sustainability on track

Soil preservation is vital to the longevity of arable land. In addition to conventional soil conservation methods, such as crop rotation and no-till farming, controlled traffic farming (CTF) provides you with new opportunities to ensure your farm’s sustainability. CTF reduces soil compaction as farming machines only drive on permanent tracks (or ‘tramlines’) and avoid areas where crops grow. The concept relies on high-precision automatic steering technology, such as real-time kinematic (RTK) navigation. This delivers multiple benefits – both environmental and economical. For example, studies have shown that CTF protects life in the soil, leading to increased biological activity. Because the soil’s heath is better preserved, you can see a significant rise in crop quality and yield. In addition, research indicates that CTF systems could help reduce fuel consumption by up to 25–50%, depending on the type of soil.

Precision farming – the future of agriculture

Thanks to precision farming technology, you could soon have additional support for your sustainability efforts. Through a combination of yield mapping, crop sensors, and variable-rate technology, you can improve productivity and sustainability at all stages of the crop growth lifecycle. Increasing volumes of data collected in the field can provide you with timely recommendations and support for decision making, meaning you can make a decision based on facts and not have to rely on gut feeling. You can also predict possible shortages for the crop – before crop damage occurs.

While this might seem like a distant vision, precision farming is already gathering pace. According to CEMA (the European association for agricultural machinery), as much as 70–80% of new farm equipment sold today contains some form of precision farming component.

Pragmatic approach – long-lasting equipment

If you are not yet ready to invest in precision farming technology or CTF system, there are simpler ways to contribute to sustainability. For instance, by equipping your machinery with reliable components that have a longer service life, you not only reduce maintenance efforts, but also minimise waste and improve productivity.

As one example, you could switch to more robust bearings. This can potentially increase service life by up to three times compared to conventional components, cutting the environmental impact of manufacturing and disposal by up to two-thirds. In addition, proper maintenance of your machinery can prevent oil leakages, boost fuel efficiency, and keep your machines up and running with limited use of grease. Using quality, well-maintained components can improve fuel efficiency by 5–15%.

There are many more ways to increase sustainability that are not covered in this article – the possibilities are virtually limitless. However, by adopting just a few new practices and technologies, you can increase yield and profits while doing your bit for the environment. So, what do you think should be done to make farming more sustainable?

This article has been made possible by Kramp and SKF.

#agriculture #farming #agricultural machinery #sustainability #precision farming

Protect yourself against the top 3 causes of bearing failure

With tight margins in the agricultural sector, farmers are constantly on the lookout for high-quality, long-lasting components. Any downtime can have a knock-on effect, putting your harvest, yield, and profits at risk. To keep machinery up and running, it is vital to take good care of the bearings. Here are the top three causes of bearing failure – and how you can avoid them.

#1 – Contaminants and corrosion Operating conditions in the agricultural industry can be very demanding and vary significantly. It is crucial to protect critical components against all kinds of contamination. For example, especially when harvesting in warm and dry environments, there is a risk that dust and vegetable fibres could enter bearings and negatively impact performance. And during the tilling or sowing process, bearings could be susceptible to contamination in the form of mud, dust, moisture, and rocks. Furthermore, pesticides, herbicides, fertilizers, and even liquids from the crops themselves, can lead to corrosion and pose a threat to the bearing’s lifespan – especially for exposed bearing positions such as on the feeder house of a combine harvester. As the oil film between steel surfaces in a bearing is around twenty times thinner than a single strand of human hair, even the tiniest particle of vegetable matter or dust can potentially cause damage to the bearing. To prevent this, you should always choose bearings with appropriate sealing systems. There is no one-size-fits-all solution: Depending on type, position, and application, bearings should be equipped with either an internal seal, external seal, or both.

#2 – Insufficient lubrication Lubrication is critical in preventing steel-on-steel contact between the bearing raceway and the rolling elements. Adequate lubrication therefore keeps machinery working as it should do. However, there are two different approaches you can take. One philosophy is to regularly relubricate bearings to extend the service life. This also provides a good opportunity to inspect other aspects of the machine. However, relubrication takes time and can lead to significantly higher costs in the long term. And by applying too much grease, you are at risk of polluting the soil or rupturing the seal – the latter of which puts the bearing’s lifespan at stake. For this reason, many OEMs and farmers are turning to what are known as maintenance-free bearings. While these solutions are not possible for all bearing positions, they can bring considerable benefits. In addition to saving time and reducing costs, relubrication-free bearings can improve reliability and performance. For example, there are cases where such solutions have helped achieve up to 25% faster tillage: from the standard high speed of 8–9 mph to 10–12 mph.

#3 – Improper storage and installation Installation errors and improper storage are actually more common than you might think. Some estimates indicate that around one sixth of all bearings are already damaged in some way before they are even used. A number of elements in bearings, particularly rubber seals, have a limited shelf life. It is therefore highly advisable to manage inventory effectively and take a ‘first in, first out’ approach. In addition, using the correct procedures and tools to mount bearings is highly important. While many bearing positions in agricultural machinery can tolerate a certain amount of misalignment, installation errors will drastically reduce the lifespan of a bearing. An effective way to reduce this risk is with self-aligning bearings. These solutions often require less frequent maintenance and can reduce the noise and vibration generated by machinery.

As bearings are one of the most critical elements in agricultural machinery, considerable research and testing is being conducted to develop more effective solutions. Simulations and test tracks are used to gather information. But unlike other industries, agriculture still requires extensive field testing to replicate the diverse operating conditions and environments that the bearings will be exposed to. Sourcing is a further point to consider when it comes to critical components like bearings. Counterfeit bearings are a serious issue in many industries, including agriculture. If you accidentally purchase fake components and install them in your machinery, they can have a profound impact on reliability. You should therefore always purchase components from a trusted and reliable supplier.

This article has been made possible by Kramp and SKF.

5 maintenance tips to help you reduce unexpected downtime

When maintaining agricultural machinery, there is no room for compromise. Every machine has to function reliably all year round. If a bearing fails or a belt tears, the resulting downtime can threaten your productivity and profits as a farmer. Here are five simple maintenance tips that can help you reduce downtime.

#1 – Read the manuals

This sounds like a no-brainer, but let’s be honest, when do you read the manual for a technical component? Probably when it fails. Consulting the handbook before operation and following the instructions can significantly decrease the risk of machine failure. Which parts of a universal shaft have to be cleaned and how often? Which components should be replaced and in which timeframes? What is the ideal amount of lubrication for a particular bearing? And which particular lubricant should actually be used? Many farmers rely on their experience when it comes to these type of questions. However with the huge number of highly specialised components available today, experience alone isn’t enough. A quick way to obtain the answers is to consult professional dealers.

#2 – Rethink cleaning

Cleaning is something that seems so simple many farmers just apply practices they have learnt over the years. But using a high-pressure cleaner on a bearing is an example of where you can actually do more harm than good. Lubricants are washed away, and the moisture leads to corrosion. Both of these can lead to failures – probably when you least expect them. The ideal cleaning procedures are explained in the operation manual. However, you should keep in mind that as well as cleaning components machinery should always be kept in a safe location, protected from dust, moisture and vermin.

#3 – Install a central lubrication system

Whether you operate a fertiliser spreader or a combine harvester, you deal with a variety of components that require lubrication. More and more farmers are switching from manual, individual lubrication with up to 300 grease fittings, to a central system with a single grease tank. This type of system is initially more expensive, but it pays off in the long run: Statistics provided by SKF indicate that automatic lubrication systems can increase productivity, halve the costs of replacement parts, and reduce man-hours spent on repairs by over 50 percent.

There are also low-maintenance components available today that decrease the required amount of effort even further, such as lifetime-lubricated bearings.

#4 – Use mounting and dismounting tools

Agricultural machinery often fails prematurely because the components have not been assembled correctly. When mounting a bearing, it is important to ensure it does not become contaminated by substances such as dust, soil, or water, as this will have a negative impact on the bearing’s service life. To reduce this risk, it is good practice to give bearings a full clean before use. In addition, there are assembly sleeves available that guarantee easy and reliable mounting, as well as tools for dismounting. Using these tools might take a bit longer than just separating shafts and bearings with a hammer – but you won’t damage the components before you have even used them.

#5 – Seize the moment

Sudden machine breakdowns during the middle of crucial periods, such as harvest, can lead to significant losses. To help reduce the risk of this happening, maintenance and repair tasks should be planned proactively. With regular routine maintenance and additional checks, you can reduce unexpected downtime and costly repairs. An effective maintenance plan should include regular oil changes, routine internal and external inspections, and keeping an adequate inventory of spare parts. When implemented successfully, this can reduce costs by 25 percent according to a study by the University of Nebraska.

Reliable partners for improved productivity

Overall, there are a lot of advantages to gain by trying to be as proactive as possible. The tips above can help reduce the risk of machine breakdowns; but what if a failure occurs anyway? Then farmers can always turn to a trusted supplier who can provide advice or consult their spare parts dealer to quickly obtain replacement or alternative parts.

This article has been made possible by Kramp and SKF.

Challenges in the field

How to tackle the top issues in modern agriculture

Farming has always been a tough job. With so many tasks to be completed within short timeframes, it requires a strong work ethic and technology that farmers can rely on when they need it most. Here are some of the top challenges in agriculture – and how to overcome them.

Time is of the essence

Today’s farmers face pressure from multiple sides. Unexpected machine downtime, when combined with unpredictable weather and fluctuating crop prices, can have a huge impact on overall yield. Political decisions can also pose a challenge: surveys show that 30% of farmers expect new government mandates and regulations to have the biggest impact on their business. With targets to meet and little room for delays, reliability is all important.

However, as machines are subjected to intensive use during key periods like the harvest season, component failures are practically unavoidable. To minimise losses in time and productivity, farmers need to ensure that key components such as bearings are easy to install and replace. They also require a dependable components supplier that can deliver spare parts quickly to reduce downtime.

Component quality is key

One of the most complex challenges for farmers is cost pressure. As the value of crops is prone to sudden change, it is virtually impossible to predict the selling price at the start of the season. For this reason, farmers need to maximise their yield, while eliminating unexpected or unnecessary costs wherever they can.

Using high-quality parts is one way to do this. For example, tests have shown that some bearing solutions specifically developed for the agriculture industry can increase farm productivity by up to 150%* thanks to a reduction in bearing failures. Additionally, such components require less frequent lubrication, which helps farmers save time and cut costs, while reducing their environmental impact.

Eye in the sky

A recent trend that could make life easier for farmers is precision agriculture. One aspect of this is the use of satellite imagery to provide insights into a field’s condition, which can improve land management, productivity, and efficiency. Some experts estimate that this method could even reduce input costs by more than 20%. Similarly,drones are being used to support crop monitoring, giving farmers a better view of problems that they might otherwise miss, such as diseased crops or dry areas in a field.

Reliable partners for reliable products

While high-tech developments like drones and satellite imagery may take some time to become widespread, farmers can already tackle many challenges simply by using high-quality components for their machines. These products help boost machine reliability, enhance productivity, and reduce maintenance costs.

Choosing the right supplier for these parts plays a crucial role too. A trusted partner can provide farmers with expert guidance on components and maintenance. In a survey by Case IH, nearly 25% of respondents indicated that equipment dealers would be one of the top advisors influencing their decision making. With support from suppliers and guaranteed availability of parts, farmers can sow the seeds for a successful future.

In our next blog post, in September, we will take a deeper look at how to minimize machinery downtime with high-quality components and maintenance tips.

This article has been made possible by Kramp and SKF.

*This figure is rounded off and based on SKF testing estimates. Particular savings and results may vary.

Tidal energy? Think windmills under the sea

The next wave in sustainable energy could, quite literally, be waves. More specifically, tidal streams - sea currents created by the movement of the tides.

In some areas, the strength of these currents is intensified when water is forced to flow through a narrow channel or around headlands. Such is the case off the coast of Scotland, where the Inner Sound of the Pentland Firth has some of the world’s fastest tidal streams.

In these powerful waters, the MyGen project is the world’s largest planned tidal stream sustainable energy project to date. Here, ANDRITZ HYDRO Hammerfest, based in Glasgow (UK), is supplying three of the four turbines that harness the power of the sea. The turbines have a capacity of 1.5 megawatts each, and a rotational speed of 14 revolutions per minute. The plan is to have 270 turbines operating in 2020, at a full capacity of 398 MW.

The Pentland Firth is one of the most challenging maritime environments on earth – making operating and maintaining tidal stream turbines equally challenging. Careful engineering, manufacturing and assembly of turbines is essential. Components must be designed to withstand harsh conditions for a service life lasting 25 years, with maintenance intervals of five years. That has led to the development of state-of-the-art technologies customized to these applications.

Read more about how ANDRITZ HYDRO is utilizing the latest technologies to harness an ocean of power: http://evolution.skf.com/an-ocean-of-power/

Augmented Reality - Engineering access at your fingertips

Imagine having access to an SKF application engineer or service technician on-demand, in real-time. If you happen to operate a paper mill located a short drive from an SKF Solution Factory, it’s not a problem. But what if you are based in a rural area, hundreds or even thousands of kilometres from your nearest SKF engineer. Soon, that won’t be a problem.

The answer lies in Augmented, or “Mixed” Reality and SKF is already developing use of this technology, by using hardware such as the Microsoft Hololens. Not what you might expect from a traditional bearing company, right? But it’s time to change those expectations. SKF is one of the most digitally advanced industrial companies around.

Whilst Virtual Reality or “VR” glasses have become a consumer top-seller, their limitation for industrial applications is that they simply enable the user access to a digital model, without taking the user’s real-time surroundings into account.

With Augmented Reality, the environment you see before you (for example, a paper mill machine hall) is combined with a digital model that allows any user, anywhere in the world, to overlay technical data, instructions and real-time machine performance. When your head moves to the left, to look at a different machine, so the digital overlay also adjusts – showing you the data you need. But that’s not all. It also shares what you see with SKF’s engineer, hundreds or even thousands of kilometers away.

Imagine the possibilities that this creates. An SKF engineer sitting in Gothenburg, Sweden, can conduct a bearing condition check at a paper mill in Johannesburg, South Africa without leaving her desk. All that’s needed is for the local machine operator in Johannesburg to put on a pair of Augmented Reality glasses, connect via Skype and simply walk through the machine hall. SKF’s engineer in Gothenburg, using a connected tablet, sees exactly what the machine operator sees – in real-time.

As the machine operator approaches the dryer section, live bearing performance data, overlaid on the “real-life” image that both the operator and SKF engineer see, shows an adjustment needs to be made in order to avoid an unplanned and costly failure. At the press of a button, SKF’s engineer in Gothenburg overlays instructions for adjusting the lubrication of the bearing in the roller via the operator’s glasses – talking him through every step.

It might sound like something that’s years and years away from being reality. But it’s not. It’s only around the corner.

SKF’s machine health team in Sweden are hard at work developing exactly this type of solution. By combining SKF’s rotating equipment performance expertise (bearings, seals, lubrication systems and condition monitoring sensors) with the technical capabilities of Augmented Reality, the possibilities are endless.

And what’s more, so are the potential benefits for machine operators and OEM’s.

Want to stay up to date on the latest developments? Stay tuned by keeping up to date via our social media channels:

https://www.facebook.com/SKFGroup/

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6 essential tips to get your tractor through the winter

The winter period. A special time of the year, especially for your machinery. Cold conditions demand special care of your tractor, whether you use it on a daily basis, or just few times a year. Here are the 6 essential tips to help your tractor through the winter months.

Tip 1: Oil

Even if you use it every day or once in a while, your tractor needs goods care. Perhaps an empty battery won’t be the problem, but cold conditions can affect oil. It gets thicker and stiffer, making it harder for the engine to turn over and start. If you have a tough winter, consider using oil designed specifically for winter usage.

Tip 2: Moisture

In the winter, period the amount of moisture in the air can create problems. Moisture can get into an engine compartment and cause shorts, or the failure to spark. So, be sure to check your engine compartment regularly.

Tip 3: Battery and fuel

If you don’t use your machine on a daily basis, the battery can let you down. You can prevent battery drain by flipping the switch and disconnecting the battery from the rest of the electrical system. It might be wise to order a spare one, especially if yours is getting old. Fuel issues can also pop up, especially if it sits weeks between uses. The easiest solution is to just start your tractor up every few days and allow it to run for some time.

Tip 4: Fluids

If you are storing your tractor, it is important to check the fluids. Hydraulic fluid is particularly important to check, as it can draw in moisture during storage due to condensation.

Tip 5: Filters

Filter maintenance helps prevent clogged air filters in the spring time. It’s best to do a thorough filter cleaning or a replacement prior to storage. But, this can be done in the winter as well.

Tip 6: Maintenance

The last and most important tip: schedule your maintenance. The winter time is the ideal period to give your tractor a solid check-up by your dealer. He is the expert, he has the right tools and knowledge and he will make sure your machine is set to go once the season starts. Good maintenance saves you money. To give an example: research from SKF states that 16% of broken bearings can be traced back to incorrect installation of the product without the required tools. Approximately 36% of the bearings fail prematurely, due to incorrect lubricant selection and failure to apply the required lubrication conditions.

So, there it is. Our 6 essential tips. Did we leave out important maintenance tips? Please share them in the comments section below. And don’t forget to join your fellow agriculture professionals! Follow us now and get the latest articles straight to your inbox.

This article has been made possible by Kramp and SKF with information from www.tractorbynet.com

For more information, please go to www.skf.com and www.kramp.com

Big turbines, big challenges

In a new, 33-gigawatt offshore wind energy project in the United Kingdom, turbines have rotor blades roughly the size of a football field, along with a hub and blade weight of close to 220 tons. Turbine sizes are growing right along with the world’s appetite for greater sustainable energy generation. Yet, while turbines are getting bigger and heavier, the drivetrains that power them must become lighter and more compact in order to reduce the total cost of the machinery and installation.

SKF offers a wide range of rotor bearings for turbine drivetrains, in sizes up to and including the 8-MW offshore category. All are focused on providing a high level of performance in keeping with the turbine layout, and are designed to deliver exceptional reliability along with the lowest possible operating cost.

Bearing solutions innovated by SKF include spherical roller bearings for geared turbines, rigid bearings for geared turbines, Nautilus bearings for geared turbines, and Nautilus bearings for direct drives. We have also developed related housing, seal and lubrication solutions.

As turbine designers, manufacturers and operators seek ever-higher energy-generation capabilities, they will rely on our engineering to further develop bearing upgrades, inclusive new seals for oil lubrication and lubrication systems.

Learn more about our partnership with the wind industry here.

Going circular: The next industrial revolution?

The benefits of recycling, reusing and remanufacturing have been promoted for years. But today, the practice has evolved from one of environmental responsibility to a model for the future of industry and world economies. It’s called the “circular economy” and is viewed by many as the next industrial revolution.

The circular economy aims to almost eliminate waste by using products, parts and raw materials for as long as possible. Proponents see the model as having tremendous global advantages, offering a solution to population growth, dwindling natural resources and climate change.

Researchers and scientists view it as an absolute necessity, as elements, including gold, silver and tungsten could be exhausted in the next 50 years. Other resources, such as crude oil, are getting harder and more expensive, to extract. Commodity prices are increasingly volatile and environmental degradation is impacting the food supply.

Bringing the circular economy to reality will require the reorganization of how the world produces and consumes. Changes will include designing products to last longer, and in a way that allows raw materials and components to be stripped out when the product has reach the end of its service life. Using renewable resources, reusing and recycling excess resources, and buying and selling services instead of products would also be standard procedure.

Leading business and industrial leaders are already buying in. French automaker Renault, fashion retailer H&M, and telecommunications giant Vodafone have introduced “circularity” into their business models. Other companies are sure to follow. Could your organization benefit?

www.skf.com

Let’s Talk – Future Materials

Why does industry need new materials? And is there anything wrong with the ones used today? The materials (such as steel) widely used today often perform very well; in most instances they do the job more than adequately.

Even so, many companies today are taking a more sustainable approach to the materials they use. Often this is due to either a strategic shift internally, consumer demand externally, or legislation forcing the issue.

To put it simply: most companies (and their customers) want fewer emissions. The choice of materials used in industry is a key component of this conversation.

One way to achieve fewer emissions is to burn less fuel. One way to burn less fuel is to reduce weight. One way to reduce weight, is to look at alternative materials.

This is where future materials come in, and where the story gets interesting.

The development of any new material is a complex business. Not only does the material need to first have the desired properties (e.g. strength, durability or thermal performance), but it also needs to prove itself commercially: is it easy to fabricate, or manufacture at scale? How hard is it to replace, and how fast is it to produce?

The reality is, if it can’t meet production and manufacturing requirements, it won’t be widely used – or perhaps used at all. On top of this, matching the mechanical properties of steel is easier said than done.

Many believe it’s not a matter of replacing steel, so much as reinventing it. Iron is such that it can be combined with nearly anything in the periodic table to produce something new. This means an almost infinite number of new grades of steel can be explored.

New alternatives for steel will undoubtedly be discovered in the future. The real question is; what will it take for people (or companies) to use them? For everyone involved, this is the key challenge.

Polymers (plastics) may not be a viable alternative to steel yet, but 3D printing is already disrupting industry. It’s perfect for rapid prototyping because it’s fast and accessible. The process of taking an idea, designing it, printing it, and immediately using it has never been easier.

However, polymers simply can’t compete with many of steel’s key properties. As such a combination of materials will likely continue to be the optimum solution for most applications.

If a future material can perform within high stress areas such as shafts, bearings and gears—places where steel remains a key component, due to its inherent properties—then it is likely a range of innovative new prototypes and solutions would start to emerge.

Watch the full discussion on future materials here:

Within industry, steel remains one of the most commonly used materials in the world today – around 1.7 billion tonnes are produced annually. On average, for every tonne of steel produced, 1.7 tonnes of CO2 are produced. Better grades of steel will help reduce that number. The reuse of scrap will also help. But the development of new future materials may take industry a big step forward, toward reducing emissions.

Let’s Talk Future Materials aims to help spark conversation around this topic.

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Meet the Panel – Let’s Talk Future Materials

Were excited to announce the experts who will discuss the topic of future materials for the manufacturing industry. Together they draw on their collective expertise, knowledge and experience to offer different perspectives on what we can expect in the future.

Filmed at Cambridge University in the UK, it’s a future-focused discussion about where we are headed, what we’ll need to think about to get there, and what challenges we will face.

A Technical Specialist on steels with over 30 years of experience working in Rolls-Royce, Martin is a Fellow of the IOM3, has co-authored a number of research papers, and is a member of the BSI Aerospace Steels Committee. Rawson is married with two daughters and enjoys outdoor activities including scuba diving.

“I’m not sure if people really appreciate what a thermal barrier coating does in a gas turbine engine. It essentially the gas temperature would actually melt the material that is used for the turbine blade, it’s that hot. So what the thermal barrier coating does is it actually protects, literally like a blanket, the metal of the blade from the gas temperature.”

A metallurgist and Tata Steel Professor of Metallurgy in the Department of Materials Science & Metallurgy at the University of Cambridge – Bhadeshia obtained his PhD in 1980 at Cambridge, and has been a part of the academic staff ever since. He is the author of several books and more than 500 published papers (in the field of metallurgy) and heads up the SKF University Technology Centre; a cooperation between SKF and the University of Cambridge to conduct research in the field of physical metallurgy of bearing steels.

“When industry has a need, for example, there’s an engine program for 20 years ahead for which there isn’t a material, then there is extremely good collaboration between industry and universities with any amount of resources that are necessary to reach a certain level of technology readiness, but when something is invented at universities out of the “blue sky”, in order to convince industry that they should use something, is far more difficult.”

A new faculty member in the Department of Applied Physical Sciences at the University of North Carolina (UNC), his group focusses on the design, synthesis and processing of high-performance polymers for structural and functional applications. UNC is Dingemans’ alma mater – he received his PhD with the Samulski-DeSimone polymer group in the mid-90s. Dingemans recently left the Faculty of Aerospace Engineering at the TU-Delft in The Netherlands where he was a professor within the Department of Aerospace Structures and Materials. When not in the lab, Theo can be seen on the track. OK, not so much these days, but he still holds various local Dutch records (Zeeland) in several sprint and hurdle events. He also won gold, silver and bronze medals at national championships.

“If you look at polymers and composites, I think they will eat away at certain steel applications. You try to come up with materials that can provide the safety, that will be processable. In the short term, 5 years, you’ll see these polymers, these 3D printed capabilities coming out and adding a lot of creativity to designers.”

Steve Lane is the manager of the Metallic Materials and Ceramics department at SKF’s Engineering and Research Centre in the Netherlands. He has been with SKF since 1979 and has held a number of positions in Group Technology Development in Nieuwegein, including: manager of heat treatment development at the SKF Manufacturing Development Centre in Gothenburg, and also manager of the Global Metallurgy & Chemistry laboratories. Prior to moving to the Netherlands, Steve worked as a metallurgist at a car manufacturer and was educated in metallurgy at Birmingham Polytechnic in the UK.

“We’re currently using something like 1.7 billion tonnes of steel worldwide and that will grow to 2.8 billion in 2050, so steel is growing. The emissions and the energy usage in producing steel must be brought down to lower levels. At present to produce a one tonne amount of steel, it emits 1.8 tonnes of C02. These are issues that need to be addressed.”

You can watch the film when it goes live on Tuesday the 22nd of November. Subscribe to our YouTube channel to make sure you catch it.

Hello, Aldo!

SKF retiree Aldo Demaria spent 40 years with the company, working at the SKF facility in Airasca, Italy. On a recent trip to Sweden with his son, Fabrizio, Aldo fulfilled a lifelong dream of visiting the SKF headquarters in Gothenburg. While there, he offered a look back at his career – and inspiration to today’s employees – in this interview with SKF CEO Alrik Danielsson.

Aldo Demaria (center), son Fabrizio (right) and SKF Group CEO Alrik Danielsson (left) enjoy a visit at SKF Headquarters in Gothenburg, Sweden.

Welcome to Gothenburg, Aldo! How are you enjoying Sweden?

It has been a very exciting trip – and there were many surprising and emotional moments throughout our stay. In Stockholm, we visited the Royal Residence, the Vasa Museum, Djurgarden Park, and Gamlastan. Our time in Gothenburg included the Aero Museum, the Slottsskogen park, and the Volvo Museum and Visitor Center. The city of Gothenburg is very nice and we appreciated the politeness, warmth, and genuine welcome of the Swedish people.

How was your visit to SKF Headquarters?

It was the most emotional moment of the trip!

Tell us about your career at SKF.

In 1964, when I was 14 years old, my parents enrolled me in technical school. After receiving my Professional Diploma in 1967, I joined the RIV-SKF production plant in Airasca. My first job was a workman in the testing area. I tested bearing components and final assembly throughout production phases. I did this work until 1984, when I became an operator working on process tolerances. From 1999 until my retirement in 2005, I was responsible for Channel Quality HBU 2 and HBU 3.

What were some of your favorite memories of working for SKF?

I had many special moments working for SKF. One of the best was in 2005, when I was asked to travel to Shanghai to support the Chinese SKF team in setting up the new HBU 2 channel. I made two trips and was impressed with the Chinese team who were very skilled and collaborative.

What changes have you seen during your 40 years at the Airasca plant?

I saw many changes! Production processes changed significantly as great attention was paid to product quality. Work methods improved as the latest technologies were implemented, and new employee teams were developed to continually improve the processes. I also saw great changes in creating a safe work environment.

What words of wisdom can you provide to our current and future employees?

I would encourage all employees to be passionate about their work, and motivated to have a self-driven attitude of collaboration. Passion, motivation and team spirit will be essential in order to meet the future challenges SKF will face in a world that is highly competitive.

#SKF #SKF History

Winds of Progress: Design process for SKF wind turbine bearing combines traditional methods with new calculation tools.

Our engineers are always looking for ways to help customers enhance machine performance, reliability and cost effectiveness. Sometimes, we realize that less can be more, and that maximization doesn’t always equal optimization. This was exactly the case in the wind turbine industry, where spherical roller bearings are used in the rotor main shaft.

Bearings typically utilized in wind turbines are not specific to this application. Instead they are designed for a wide variety of industrial machines. Our analysis revealed that the bearings used had parameters for speed, load and temperature that generally exceeded what was needed for a wind turbine application. With the goal of refining the design to meet the specific requirements for a wind turbine, our engineers implemented an innovative analysis and simulation process to determine what could be eliminated, and what could be optimized.

Analyzing conditions: Identifying specific needs

Our design team contrasted the typical wind turbine main shaft against conditions found among diverse industrial applications. They found that wind turbine bearings require:

• Maximum speed up to only about 20 rpm (compared with other applications requiring speeds up to 600 rpm)

• Bearing temperatures starting from ‐40°C up to 80°C (lower than other machines)

• High and variable loads, with relatively high axial component

These differences justified a dedicated bearing design to meet the specific conditions in wind turbines. Our designers set out to eliminate features that were not needed in wind turbine applications, while improving the design of critical components.

The design process: Doing old things in a new way

Our designers applied a novel engineering methodology to designing a new bearing. This involved enhancing well-established rolling bearing design methods with modern calculation tools. The focus was on the goal of tailoring the internal geometry to meet the precise needs of wind turbine operations.

Optimizing the internal geometry was accomplished through a 4-step process.

1. Generate a coherent geometry

The SKF bearing design generator was used to define a geometrically coherent spherical roller bearing that would meet the needed boundary dimensions and base input variables.

2. Analyze/simulate with application inputs

The bearing design was analyzed using the SKF SimPro application engineering software suite. Design engineers also utilized the SKF BEAST, a multibody simulation tools that serves as a virtual test rig. SKF BEAST enables engineers to study the dynamic behavior of all bearing components, such as the forces and motions of the cage, as well as skidding, skew and the tilt behavior of rolling elements.

3. Apply unique SKF design criteria to qualify candidates

The bearing design was evaluated through specific SKF design criteria to assure robustness. This involved screening for bearing component fatigue loading conditions, kinematics, static load limits, risk for fretting, load ratings and other factors.

4. Optimize for user value

The SKF process generated thousands of feasible designs for bearing optimization. A Pareto analysis was used to separate those with the greatest potential for meeting specific wind turbine application needs in the area of load capacity, mass and life.

The result: An industry first

Through our design process, a new spherical roller bearing was created designed explicitly for wind turbine main shafts. Part of the Explorer class of high-performance bearings, the new design can significantly improve turbine reliability and bearing life, while reducing levelized cost of energy (LCOE).

To learn more, visit: skf.com/wind

The energy potential of our waters

The energy thirst

We humans need energy. We need it to power our homes and our businesses. We need it to cook our food and help provide us with shelter and warmth. There’s no disputing we need it, and our energy thirst is on the increase. In fact, energy demand globally could be up to 35% higher by 2040*.

Meeting the energy demand

Right now we meet the energy demand in a variety of ways. These are mainly a combination of: Fossil (oil, coal, natural gas), Renewable (solar, wind, geothermal, hydropower) or Nuclear. In most countries traditional fossil fuels dominate, yet alternative energy sources—such as wind and tidal energy—are steadily making ground. One main reason we’ve yet to see widespread adoption is cost. Specifically, reducing the cost per unit (KWhr) to be at a level where it is competitive. Only then would we see a tipping point, and a more dramatic shift away from traditional energy sources.

Reducing the cost – where to focus

The greatest cost reduction opportunity relates to the environments these machines often operate in. The ocean is especially challenging – it’s unpredictable at best; a tempest at worst. In the ocean machines and devices face a continually shifting slurry of salt, sand and marine life. As such reliability, availability and maintainability are key considerations, but also a huge challenge. Industry success will be largely dependent on improving in these areas.

Reducing the cost – how to get there

First is ensuring reliability is designed in at the prototype stage – to help ensure future availability and power generation targets are met. Second is defining a maintenance strategy early on, one that addresses the challenges of the harsh (and often inaccessible) environments. Thirdly, using the right tools, products and services – and applying learnings to optimize during the operation phase. These three combined can help boost profitability, and also meet the end goal of being more competitive (with traditional energy sources).

The hydropower opportunity

Ocean energy is perhaps the most under-utilized renewable resource we have; though some go so far as to say that harnessing it is more difficult than putting a man on the moon. It’s clear that capturing the power of the ocean (in a cost-effective and competitive way) is full of challenges, but it’s equally clear that the potential is great.

Where we’re helping

We’re involved in helping explore ocean energy potential by providing expertise, products and services. To read more into some of these projects, visit the links below. If you want to talk to us more about how we can help with ocean energy, contact [email protected]

Scotrenewables SR2000 floating tidal turbine Read about the project You can see more of the launching of the Scotrenewables SR2000 floating tidal turbine from the renowed shipyard of Harland and Wolff in Belfast in this video.

River turbine projects – The RivGen Power System Read about the project

Tidal lagoon Project – Swansea bay Read about the project Read about Swansea bay

*According to Exxon Mobil report

We went all the way to the bottom to find our solution

It might sound utterly worrying to hear that we believe we can find solutions at the bottom of the ocean. Well, we went down there, battled a challenge and found a solution. And the solution became rather great – if we do say so ourselves.

It started when Statoil came to us and needed help to find solutions to prolong their gas extraction plant Åsgard, off the Norway coastline, to both maximize the use of their gas wells and to minimize CO2 emissions. Statoil understands the importance of being at the forefront of technology for cost cutting and environmental reasons.

During a five year period, Statoil and SKF worked together and created a system for controlling and monitoring the world’s first subsea gas compressors by means of magnetic bearings. Traditionally, gas compression takes place on platforms or onshore, quite a distance from the source. But, the result of this new underwater system manages to extract gas as close to the source as possible, making it more energy efficient – using some 40 per cent less power than a traditional topside solution.

The compressor was equipped with magnetic bearings. Since magnetic bearings are frictionless and spin without making contact – they eliminate the need for seals, gearboxes and lubricating oil, leading to smaller and lighter compressor modules and infrastructure. Thanks to the system being unmanned and operated remotely, it removes the need for constant supervision.

SKF’s magnetic bearing technology was a key enabler in turning this subsea system into reality. Magnetic bearings have many benefits – energy efficiency being one of them. We at SKF like efficient use of energy, and talking about it. So please, come visit us at our booth, at the ONS summit in Stavanger, Norway (booth 960) – starting on August 29th 2016.

When? August 29 - Sept. 1

Where? Stavanger Forum

Stavanger, Norway Booth 960, Hall 9

Read more about SKF’s magnetic bearing technology here.

Let’s Talk Smart Robotics - The transformation of Maintenance & Engineering

Smart robotics are no longer science fiction – they have become reality.

Today, robots are leading the move from traditional best-practice manufacturing to automated manufacturing, independent of the human touch but rich on maintenance intelligence, real-time data usage and cost-efficiency.

Countries such as South Korea, Germany and China, currently in the forefront of adoption of intelligent robots, are experiencing tremendous growth and as more companies begin to use robots in the workplace – many have begun to weigh the risks.

While companies using robotics, will be focused on improving operations efficiency, increase productivity and safety – the majority of workers will feel threatened and challenged in adapting to these new automated realities.

The key themes for workers to be concerned about are:

While robotics so far primarily has had negative impact on blue-collar employment; the coming wave of innovation and increased adoption of sensors will threaten engineers and other white-collar workers as well.

Some highly-skilled workers will succeed greatly in this new environment. However, a large party can also be displaced into lower paying jobs or unemployment, as decreased competence levels will be required to manage or handle robots in daily work.

At one hand, the education system is lagging behind in preparing us for the automated work of the future. On the other, engineers who already have been active within the industry for several years, will be asked to get further educated to be able to act in this automated reality.

The key reasons to be optimistic:

Even though robots may displace some kinds of jobs, historically robots have proven to create more jobs.

As always, industries and workers will adapt to this new reality by inventing entirely new types of jobs and by taking more advantage of the unique human capabilities.

To a high-extend, robots are expected to work next to human beings. That way, companies will benefit from the cognitive capability of human beings while letting robots do all the heavy lifting that is unsafe for humans to do.

Watch the full #LetsTalkSmartRobotics film and get all the insights here:

About Let’s Talk Let’s Talk is SKF’s knowledge-sharing symposium that promotes the sharing of free knowledge. It gathers inspiring thinkers together and lets them discuss important global topics. Topics that are interesting for us at SKF to be connected to because of how they relate to industry and manufacturing today.

Limas – Staying Ahead of Customers' Needs

The story of the family-owned company that designs, manufactures and sells machines for food production.

The machines they create are tailored towards the peeling and processing of potatoes and root crops.

Several of their machines have been redesigned, due to new customer demands. This resulted in solutions that are ahead of the current hygiene standards in food production.

This came as no surprise to us at SKF; Limas has a history of need-based innovation.

For example, in 1993 they recognised that not all countries have good access to water and energy – so they established a peeling solution that operated without the need for water.

Now 95% of their production is exported, validating the opportunity they saw in developing energy and water efficient machines.

Interestingly, the water-efficient solution also gave a better quality result – and created a machine with a longer operating life.

Limas and SKF have had a long relationship where both parties identify problem areas and together come up with solutions. Their approach values enduring quality, mixed with a healthy dose of innovation – both of which are close to our hearts.

Read more about Limas: http://www.limas.se

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