Premesy | Schaeffler medias

Precise bearing preload from installation to operation – awarded with the WIND FUTURE AWARD 2021

When setting the rotor bearing preload in wind turbines for large bearings, a few micrometers make all the difference. Even small variations could lead to increased bearing wear and, as a result, to bearing failure. This puts pressure on the manufacturer (OEM) to determine the precise preload values needed. The bearing preload is often set with the support of manual measurements for verification of the correct preload values. Manual measurements and the fact that the measurement of fits and bearing seats can be difficult mean increased sources of error and therefore can potentially affect the bearing service life. For this reason we developed Premesy. This innovative preload measurement system records axial displacements in rolling bearings and, for the first time ever, converts them to the corresponding bearing preload accurately and precisely – even when in operation. In addition, the documented measurement results serve the OEM as quality verification.

Wind Future AWARD 2021

Premesy was awarded with the Wind Future Award 2021 in the category “Smart Technology Innovation of the Year”. Schaeffler received the award at the ASEAN Wind Energy, one of the largest onshore and offshore wind energy events in Southeast Asia.

General Advantages
Technical Advantages
Functions
Applications
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General Reasons for Using Schaeffler Premesy

Lower levelized cost of electricity (LCOE) through avoidance of failures
Maximum rotor bearing service life
Improved competitiveness

Technical Advantages

Optimized and recorded bearing preload
Distance measurement with extremely high precision (< 5 µm)
Stationary and rotating application possible during installation
Online visualization of the installation process
Monitoring of the bearing preload during operation
High robustness (IP 68 sensor) for suitability in harsh conditions

Functions

Why is a precise bearing preload so important?

The answer is obvious: Because it allows you to maximize the bearing service life, lower costs, and avoid turbine failures.

The bearing preload is one of the most important parameters in bearing systems. If the preload is too high, the nominal service life goes down drastically. In extreme cases, the bearing can even overheat. On the other hand, if the preload is too low, the uniform kinematic rolling behavior is disrupted and premature failure can result. An optimal preload, however, guarantees reliable functioning.

Installation preparations – double-row taper roller bearing for a wind turbine

How Does Premesy Work?

The optimal preload is calculated using the finite element method (FEM), especially for large bearings. Under a preload, the rolling contacts of the bearing change while the surrounding structure is elastically deformed. This leads to displacement of the bearing rings relative to each other, which can be determined in advance with the help of an FE calculation.
This displacement is measured precisely with Premesy.

Frequently Asked Questions

For which bearings is Premesy suitable?
Premesy is suitable for all preloaded bearings. In general, Premesy is used in relatively large bearings due to the sensor size.
Does the solution only work with Schaeffler bearings?
No. Through adaptation of the FE calculation, Premesy can work with products from other vendors too. Please feel free to contact us for further information.
When will the preload measurement system be available?
Premesy is already being used in pilots, and we look forward to receiving your inquiries. The product will be available on the market in the first quarter of 2022.
For which applications is Premesy suitable?
In general, applications with preloaded bearings. Application areas include, for example, wind turbines, ship propulsion systems, and output shafts on large gearboxes.

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Precise bearing preload for adjusted bearing arrangements
- Preload measuring system instead of manual measurements
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