Advance Design Industries (ADI) in
Sheffield Village, Ohio has designed and built innovative custom machine
systems for industrial and defense applications for more than 50 years.
Their latest problem-solving design, a de-burring system that removes
burrs from hobbed gears, was constructed using a series of drive
platforms, a robotic with grinding tool attachment and brushing
stations. To accurately and repeatedly position the various stations, in
a multitude of pre-programmed locations, ADI required a linear motion
system that could endure the contaminated environment and heavy loads of
the application. To accomplish this, they turned to PBC Linear products
once again, due to their successful implementation of previous systems
designed together.
For the de-burring
system to succeed, ADI required a linear motion technology that could
perform under 50,000 lbs of load in a dirty, industrial machine-tool
work area. De-burring is the process of removing burrs, or excess
protruding material, from large gears (70-120’’ in diameter).
Eventually, these gears will be utilized as the driving mechanism for
applications such as crane turn tables and energy efficient wind
turbines.
The de-burring machine rotates the gear
through the robotic grinding station, then through each brushing station
for an assured, smooth end-product. Excess material not removed, could
result in noise, binding and installation problems. Three drive
platforms as well as the robot and brush stations, riding on PBC linear
bearing system, adjust to the locations for various sizes of geared
rings.
An immense load (50,000 lbs) and harsh environment restricted what
technology ADI could use for linear motion. Ball-bearing systems would
deteriorate with vibration and spall shafting under the heavy load.
Excess dirt, dust and particulate can collect in the ball cages,
resulting in stalling and catastrophic failure. The drive platforms,
though very important to adjust for different gear sizes, are seldom
used for day-to-day functions; thus requiring a linear system that needs
little lubrication, but still provides smooth and reliable performance
when needed.
For this application, ADI favored
plane bearing technology due to its ability to thrive in contaminated
environments and sustain even disbursement of forces versus the small
point of contact provided by ball-bearings. Additionally, the bearings
need to prevent stick-slip, a common problem to bearing systems which
are not routinely in motion. As a result of previous application
success, performance and cost efficiency, ADI decided to implement
Simplicity® bearings as the linear motion system for all stations of the
de-burring machine. Simplicity® self-lubricating linear plane bearings
require little to no upkeep maintenance, excel in harsh environments and
handle heavy load applications. This is due to the bearings’ design and
FrelonGold® liner. Simplicity® bearings can run for years under
constant or intermittent use. The low friction, self-lubricating system
requires no additional grease or oil (as long as application is within
design criteria). FrelonGold® has also been shown to handle up to 20x
the load of a traditional ball-bearing! The Simplicity® bearing wipes
all dirt, dust and grime clean off the shaft—providing a reliable,
smooth and long-lasting linear motion system.
Simplicity® bearing/shafting assemblies were installed into the drive
platforms, robot station and brushing station of the system. Testing was
conducted over a period of two months with the bearings performing
without failure. Now, ADI is looking into manufacturing additional gear
de-burring systems guided by Simplicity® technology.
