Mine Expo 2012 is this week, so for those of you that didn’t make it out to Vegas here are some products that can help increase your bottom line.

Conquest XP: ContiTech Engineered Products

ConquestXP™ primary crusher belt has the power to keep your bottom line on its shoulders. Backed by the power of Fortress™ Technology, an innovation in rubber compounding and reinforcement technology, ConquestXP™ is built to excel in impact and puncture resistance. Including one-ply 330, one-ply 440, two-ply 660 and two-ply 880, and available with ContiTech Engineered Products compounds like Defender®, Stacker®, Survivor® and Global X®, this belt is ready for anything you can throw at it. When good just isn’t good enough, start a Conquest.

Retro Rolls: PPI- Precision Pulley and Idler

PPI Retro Rolls allow you to use our proven idler rolls in other manufacturers frames. You get the durability and low maintenance that PPI is known for without having to replace existing frames. Available in CEMA B, C, D, and E Series Rolls. A solution for reduced inventory, labor and downtime.

Belt Cleaners and Plows: Flexco

Belt cleaning is necessary to optimize the performance of your conveyor system. Clean belts will last about 150% longer and require 50% less maintenance, helping to reduce costs and downtime for repairs or maintenance for the entire system.

Mine Duty Extra (MDX) Conveyor Pulleys: Dodge

Drum Pulleys: Standard, stock mine duty drum pulley assemblies that fit CEMA dimensions and exceed the CEMA application standards by two to five times depending upon pulley size. One piece integral hubs that eliminate welded hub heat affected zones (HAZ). HE (High Endurance) 14-degree taper bushings with the lowest bellows installation stress of any taper bushing shaft mounting system for two hub pulley applications. Full 360-degree fillet welding of internal center discs.

Wing Pulleys: Extremely heavy, strong mine duty wing pulley assemblies that fit CEMA dimensions and exceed the CEMA application standards by 2 to 5 times depending upon pulley size. One piece integral hubs that eliminate welded hub heat affected zones (HAZ). HE (High Endurance) 14-degree taper bushings with the lowest installation bellows stress of any taper bushing shaft mounting system for 2 hub pulley applications. Rugged wing-on-drum construction incorporating 2″ x 3/4″ thick contact bars, 3/8″ thick wings and 3/8″ thick spacers.

Quarry Duty Motors: Toshiba

Toshiba’s definite purpose XT, totally enclosed fan cooled, high efficiency, Quarry Duty motor series has a proven track record of exceeding the extreme demands in the cement and aggregate industries. Our Quarry Duty motors utilize a totally enclosed fan cooled design and provide exceptional high torque, oversized superior-grade roller bearings, and shafts built with high strength 4142 steel. The roller bearings on the motor’s drive-end allow for heavy radial loads normally associated with belt-driven applications.

Completed Line-up – Hawk Pd is now available in all the popular pitches – 5mm, 8mm, 14mm and 20mm – adding to the universal appeal of this premium product.

Compounding / Reinforcement Integration – Hawk Pd is an exceptional example of a molded, high-performance rubber composite, giving end-users the latest drive belt technology from ContiTech.

MRO Replacement – Hawk Pd can be a superior MRO retrofit to many existing drives, giving the end-user potentially longer life without changing drive hardware.

Properly installing large bore roller bearings is essential in achieving the maximum life of a mounted bearing. It’s estimated that the second most common cause of failure of large bore bearings is improper mounting techniques. Failure can come in the form of shaft-attachment loss, excess vibration and elevated bearing temperatures. Following proper mounting techniques will ensure that the bearing is mounted correctly, and that the maximum life of the bearing will be realized.

There are many different methods of mounting large bore bearings. Common methods include manual assembly, heat shrink, jackscrews, oil injection and hydraulics. The most common is the manual method, which incorporates the use of a hammer and drift, or spanner wrench.
The manual approach involves a bearing, plus a sleeve, nut and washer. The adapter sleeve would be slid over the shaft, and the bearing over the adapter sleeve. The nut would be screwed onto the adapter sleeve, which then forces the bearing up the tapered OD of the sleeve. In turn, the movement of the bearing up the tapered OD of the sleeve would reduce the clearance in the bearing. This provides a press fit to the shaft.
Shim stock is used during this mounting process to measure the amount of radial clearance removed from the bearing. The shim stock is inserted between the roller and outer ring to determine the clearance reduction. When applying this method, the user tightens the nut, checks the clearance reduction, continues to tighten the nut, and measures the clearance reduction until the proper amount of clearance has been removed.
This method has always been suspect, as human error influences the measured values. It’s also very time-consuming, requires extreme physical effort, involves potential safety hazards, and in the end, leads to a questionably mounted bearing.
A solution to this problem is to use hydraulics to mount the bearing. The use of hydraulics dramatically decreases mounting time, eliminates much of the manual effort required, reduces the potential for injuries and ensures a proper press fit between the shaft, adapter and bearing. When mounting a bearing using hydraulics, the standard nut is temporarily replaced with a hydraulic nut.
The hydraulic nut consists of two pieces: the nut and a piston. In this scenario the hydraulic nut is screwed onto the tapered adapter sleeve. Fluid is then pumped into the nut, which causes the piston to extend. The piston comes into contact with the bearing inner ring and pushes it up the tapered adapter sleeve to the starting position. The starting position is considered the point at which the clearance between the shaft, adapter sleeve and bearing bore has been reduced to zero, and the bearing is snug to the shaft.
The next step is to place a measuring device onto the bearing inner ring or face of the piston to measure axial displacement. The measuring device can be as simple as a magnetic-base indicator or a displacement gauge. Continuing to supply hydraulic pressure to the nut will further displace the piston until the final position is obtained. At this point, the hydraulic nut would be removed and replaced by the standard nut.
The hydraulic nut supplier and bearing manufacturer supply the starting position pressure and required final displacement values. Applying hydraulic pressure to set the bearing (and measure axial movement of the bearing to remove the required clearance) replaces the use of shim stock. This provides for a consistently and properly mounted bearing.
Dismounting the bearing can also be a very tedious and time-consuming process, especially if the bearing was mounted without a predetermined method to dismount the bearing. There are several methods of removing bearings, including a manual method, the use of oil injection or a hydraulic dismount nut.
Manually dismounting the bearing usually consists of torching the bearing from the shaft, which destroys the bearing and can damage the shaft. This is also a time-consuming and costly method, especially if the bearing had not failed, but just needed to be re-positioned.
The use of oil injection requires that the shaft, or a special adapter sleeve, contain a hydraulic port plus blind circumferential grooves, which allows hydraulic fluid to be pumped in between the bearing ID and the shaft or adapter OD. While this method will not cause damage to the bearing or the shaft, the hydraulic oil that filled the grooves spills out when the bearing suddenly becomes dismounted. The biggest disadvantage to this method, however, is the high cost of the specially machined adapter sleeve or shaft.
Recognizing the benefits of incorporating hydraulics to mount and dismount bearings, mounted-bearing manufacturers are now supplying products that include pre-assembled hydraulic mount and dismount nuts. Unlike conventional hydraulic nuts, which are separated from the bearings after assembly, the hydraulic nuts used in these new products are an integral part of the bearing assembly and stay with the bearing for the entirety of its life.
The use of the hydraulic dismount nut will remove the bearing from the shaft quickly and easily, without damage to either. Basically, a hydraulic dismount nut functions in the same manner as a hydraulic mount nut. Hydraulic fluid is supplied through the nut and to the piston, which causes the piston to extend and come into contact with the inner ring. Increasing the hydraulic pressure will force the bearing down the tapered adapter sleeve until the bearing is dismounted.
Correctly mounting large bore roller bearings is a critical step to achieving optimum bearing performance and maximum bearing life. By selecting a bearing with a hydraulic system already built in the product, you will reduce mounting and dismounting time, eliminate bearing and shaft damage, and most importantly, end up with a properly mounted bearing.
Greg Hewitt is a Dodge Roller Bearing Development Engineer with Baldor Electric Company. For more information, visit www.baldor.com.
This article is from the Plant Engineering Magazine link to it by clicking here.

On September 11, 2012, Binkelman Corporation participated in the United Way Week of Caring. Companies all over our community stepped up to make a difference by participating in a variety of community projects. Binkelman chose to re-create a US Map on the playground of neighborhood Keyser Elementary, servicing K-8 grades. Our employees spent a wonderful morning and afternoon creating this lasting, fun, educational piece for the students at Keyser. The enthusiasm shown from the students, teachers and administration was heartwarming and appreciated. Thank you to all the volunteers for the hard work put forth today.

Introducing Baldor Electric Company’s new manufacturing plant in Shelby, North Carolina. With a significant investment from Dodge, this 259,000 square foot facility, which began producing DC motors in June of 2012, is the new home for Dodge’s DMI DC product line and will serve as the global center of excellence for DC motor production.