The use of energy efficient bearing solutions in industry
CeramicSpeed develops and produces ceramic bearings, which have a much lower energy losses than conventional bearings. Energy loss is reduced by a combination of precision rollers and ceramic balls with very smooth surface. Bearings are included in all electric motors and rotary machines. The project examines the benefits of using ceramic bearings in rotating equipment and developed a tool for calculation of energy saving.
The project is developing models that take the results from the previous project on bearings and utilize these for all common types of rotating equipment such as ventilators, compressors, etc. including use of new bearing types and sizes than the conventional steel bearings. The models are built on the basis of tests on new equipment as well as equipment that have been in operation for longer periods. A long series of tests will be performed based on the methods developed in the previous project to determine bearing losses including methods that can be made on existing equipment in the industry. Based on performed tests a tool will be developed that can be used widely by bearing suppliers and manufacturers of rotating equipment. The tests will be performed in cooperation with a German testing institute and with one or more machine manufacturers. The project includes:
- feasibility study of the total potentials for motors and rotating equipment in the industry
- potential analysis so the project targeted solutions and documentation on the areas where there is the greatest potential in industry
- selection of machine and bearing types on the basis of potential analysis as a basis for carrying out tests and selection of companies to be included in the project work
- execution of tests and documentation
- development of tools for documenting energy savings
- knowledge transfer for machine manufacturers, industry, consultants, etc.
Electrical engines transform 60% of the electrical energy consumed in private households and commercial enterprises. In Denmark the annual energy loss in the electric motor bearings is estimated to be 263TJ. This project documents that the bearing losses in electric motors are reduced with 48% on average when replacing premium standard bearings with ceramic bearings (steel rings and silicon nitride balls). The theoretical energy saving potential is then 126TJ.
Measurements on discount quality bearings shows 58% energy saving potential suggesting that the average energy saving potential could be even greater since many applications are running with cheaper bearings.
The motors drives a multitude of different applications, but the main energy consumer is ventilation. Ex situ measurements on bearings experiencing loads equivalent to the ones in a ventilator shows that the energy saving potential is 43% when replacing the premium bearings in self-supporting ventilators with ceramic bearings.
During the project, certain load conditions showed 57% energy saving potential between premium bearings and ceramic bearings.
Key figures
Category
Participants
| Partner | Subsidy | Auto financing |
|---|---|---|
| CeramicSpeed A/S | ||
| Teknologisk Institut | ||
| AURA Rådgivning A/S |
