TFL bearing solution saves $67,500 per year on the Screw Compressor
screw compressor
Critical Role in Production: The heart of this compressor is its main rotor assembly (male and female rotors). The high-speed male rotor meshes with the female rotor to efficiently compress intake gas, initiating the entire gas purification and delivery process. The stability and efficiency of this assembly directly dictate final product purity, output volume, and operational costs.
Industry Challenges: As semiconductor manufacturing demands ever-higher gas purity and global energy costs continue to rise, the client faces a dual challenge: ensuring 7×24 operational reliability while continuously improving energy efficiency. Any unplanned downtime can halt the entire production line, leading to significant financial losses.
Key Facts
The standard angular contact ball bearings previously used were failing prematurely under the compressor's demanding operating conditions, leading to three critical issues:
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Pain Point 1: Premature Wear from High Axial Thrust
- Failure Mechanism: This force concentrated on the male rotor's end bearing, causing excessive localized stress on the raceway and accelerating material fatigue. This led to a premature increase in the bearing's axial play.
- Consequences: The rotor began to exhibit slight axial movement, disrupting the optimal meshing gap with the female rotor. This resulted in a noticeable drop in compression efficiency, higher energy consumption, and, in severe cases, risked rotor-to-housing contact.
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Pain Point 2: Cage Failure Caused by Lubricant Degradation
- Failure Mechanism: Acidic byproducts from the degraded oil would gradually corrode the standard metal cage or cause the polymer cage to become brittle. Under high centrifugal forces, the weakened cage would fracture.
- Consequences: Cage fragments would enter the raceway, causing the bearing to seize instantly. This would trip the drive motor, leading to an abrupt and catastrophic shutdown that severely impacted production.
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Pain Point 3: Raceway Damage from VFD-Induced Skidding
- Failure Mechanism: During periods of light load or rapid speed changes, the rolling elements would transition from pure rolling to a state of microslippage (skidding) against the raceway, creating microscopic "scuff" marks on the surface.
- Consequences: These scuff marks became stress concentration points, disrupting the protective oil film and eventually developing into surface spalling. This resulted in abnormal vibration levels and a drastically shortened bearing life.
The TFL Solution
TFL's engineering team developed a customized solution based on the 7215 BEP bearing, designated as TFL 7215 BEP-C3S1.
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Bearing Type: 7215 BEP (Single-row angular contact ball bearing, 40° contact angle, optimized internal design, polyamide cage)
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Optimized Raceway Geometry & Tighter Axial Clearance:
- Down-to-Earth Description: We fine-tuned the shape of the inner and outer ring raceways to create a larger, more uniform contact area between the balls and the raceway. Think of it like using a wider tire to better distribute pressure, effectively handling the high axial thrust. We also manufactured the bearings to a more precise and narrow axial clearance range.
- Appropriate Process: Utilized high-purity bearing steel (GCr15) with a mature heat treatment process to enhance the toughness and fatigue resistance of the rings.
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Upgraded, Chemically-Resistant Polymer Cage:
- Down-to-Earth Description: We replaced the standard glass-fiber reinforced polyamide (PA66) cage with an advanced engineering polymer (PEEK-based material) known for its superior chemical and thermal stability. This material is far more resistant to chemical attack from aged lubricants and does not become brittle at high temperatures.
- Appropriate Process: Employed proven injection molding techniques and optimized the cage pocket design for smoother guidance and lower friction at high speeds.
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Special Black Oxide Coating on Raceways:
- Down-to-Earth Description: We applied a micro-porous black oxide layer to the raceway surfaces. This coating acts like a sponge, retaining lubricant more effectively. It provides an extra layer of boundary lubrication during startups, shutdowns, or low-load conditions, preventing direct metal-to-metal contact and skidding damage.
- Appropriate Process: A standard, cost-effective chemical conversion coating process known for improving run-in performance and oil adhesion in critical applications.
Product Features
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Handles High Axial Loads: The 40° contact angle is engineered specifically to manage heavy thrust forces.
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Stable at High Speeds: The lightweight, high-strength polymer cage reduces centrifugal forces for smooth operation.
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Resists Wear and Skidding: The special raceway coating improves lubrication under tough VFD conditions.
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Longer Service Life: The combination of optimized geometry and high-purity steel significantly increases fatigue life.
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Universal Fit: Designed as a drop-in replacement, requiring no modifications to the shaft or housing.
Application effects
Before: The maintenance team would receive vibration alarms from the compressor after just 8-10 months of operation. They lived with the constant worry of an impending failure, forcing them to schedule costly, disruptive maintenance shutdowns. Each bearing replacement was a race against time to minimize the impact on customer gas supply.
Now: After installing the TFL custom bearings, the situation has completely changed. The optimized raceway flawlessly manages the axial thrust, keeping the rotor perfectly stable. The robust cage has eliminated the risk of seizure from oil degradation, and the surface coating has conquered the VFD-induced wear. The new bearings have been running smoothly for over 24 months, with vibration levels still in the “excellent” range. The maintenance team has confidently extended the major overhaul interval from 1 year to 2.5 years, making production planning far more reliable.
Cost-Savings Breakdown
| REDUCED SPARE PART COSTS | $12,000 |
| ELIMINATED DOWNTIME LOSSES | $48,000 |
| ENERGY & QUALITY GAINS | $7,500 |
| TOTAL ANNUAL SAVINGS | $67,500 |
About TFL BEARINGS
Why is TFL BEARINGS frequently chosen as the specified bearing brand bymajor international companies?
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