A woodworking manufacturer used a
commercial wood sander for fast sanding of large furniture. However,
their sanding table would only successfully function for about a week
before failing. This would lead to a costly cycle of replacing damaged
parts and awaiting the next shut down. The manufacturer decided to take
action and approached PBC Linear for a solution. After examining the
internal components, PBC Linear engineers recommended swapping out the
continually failing rolling element bearings with a customized,
Simplicity® plane bearing assembly.
The wood sander station sat on a 180 lbs
steel base and used high speed oscillating motion (1735 RPM) for a
short, 4mm stroke. The oscillating mechanism is operated by two cam
assemblies running with a roller bearing in between. As the system runs
in short, reciprocating motion, the sanding mechanism is operated. This
wood sander is under constant use by two labor shifts (1st and 2nd), 16
hours a day for six days a week until it breaks down.
For the roller bearing to function
properly, precise alignment was crucial. The slightest misalignment
resulted in grinding between the cam and roller bearing. High friction
and heavy shock loads caused fretting on the system. In fact, shop
employees commented the roller bearing would glow red from heat created
by friction where the cam system made contact. Even when running under
lubrication, misalignment, high temperatures (110°F) and grinding would
persist and the system was unable to last a full week.
When PBC Linear stepped in, they
immediately recognized the problem as a great application for their
Simplicity® plane bearing technology. Simplicity® plane bearing products
handle up to 20x the load of a traditional rolling element bearing. The
proven technology of their proprietary Frelon liner supports even
disbursement of forces; while rolling element bearings provided limited
point of contact and cannot effectively disburse heavy loads. Primarily
utilized for linear applications, Simplicity® products also excel in
rotary and oscillating tasks. It is also ideal for dirty workshop
environments, gliding through wood chips, dirt and grime without binding
or additional maintenance.
For this particular application, PBC Linear
designed an optimized bearing assembly that would rock along with the
motion of the cam system—completely eliminating misalignment issues.
Using an internal, periodic lubrication system to facilitate smooth
oscillating motion for long-term operation, PBC Linear was able to
extend the life of the system from one week to over a year of smooth,
non-stop and maintenance-free performance.
After the custom Simplicity® assembly was
installed, the wood sander realized immediate increase in life-time
performance. The manufacturer also noted significant cost savings as a
result of life improvement. Weekly replacement parts for the previous
internal design amounted to $300.00, with $15,000.00 in annual cost
savings! Overall, the wood manufacturer was more than pleased with the
new Simplicity® bearing assembly, as it provided enhanced system
integration, quieter operation and overall cost saving for the wood
sander.
