Dust and particles can create serious problems for overhead conveyors used across industrial and logistics operations. When dust settles on conventional metal ball bearings, it can lead to deposits, increased friction and sluggish movement. In severe cases, this can result in equipment failure and costly downtime.
igus has introduced a new hybrid ball bearing from its xiros series designed to address this challenge. The bearing combines stainless steel with high performance plastic and can operate without lubrication. This helps make it more resistant to dirt while reducing maintenance requirements.
Overhead conveyor systems are widely used to move goods and workpieces between production and storage areas while making efficient use of available space. As manufacturers and logistics companies look to improve efficiency, reducing downtime has become increasingly important.
"Design engineers are currently endeavouring to make these systems more efficient as users are increasingly less accepting of downtime and breakdowns. Even short interruptions can cause high costs and delays," says Marcus Semsroth, Head of Business Unit xiros Polymer Ball Bearings at igus.
According to Semsroth, replacing conventional ball bearings used in conveyor trolleys can be one way to improve system reliability. The new hybrid bearing is designed to provide smoother operation while reducing maintenance.
Designed for dusty environments
Most overhead conveyors use standard metal ball bearings. These bearings are generally degreased and filled with low friction oil to reduce friction during operation. However, the oil can escape through the seals and attract dust and other particles.
This can be particularly challenging in dusty working environments, including textile manufacturing. As particles collect around the bearing, deposits can build up and affect its movement. Over time, this can increase the risk of failure.
The new igus hybrid bearing is designed to work without lubrication. It uses xirodur B180, a high performance plastic that allows low friction dry operation. This reduces the bearing's sensitivity to dirt and removes the need for regular lubrication.
The outer race is also designed to run with low friction on aluminium profiles. Conventional steel bearings can require an additional plastic outer component for such applications, making the overall solution more complex and expensive.
Stainless steel and plastic combination
The bearing uses a combination of materials to balance load capacity with low friction operation. Its inner race, which experiences the highest surface pressure, is made from stainless steel. The load balls are also made from stainless steel, using a different alloy.
The cage is made from iglidur J3, a high performance polymer with additives that improve strength and sliding properties.
This hybrid construction gives the new bearing a load capacity of up to 39kg. While conventional metal ball bearings can support higher loads of around 80kg to 100kg, igus says the new bearing can meet the requirements of a wide range of applications in industry and logistics.
Potential applications include furniture manufacturing and packaging systems, where reliable movement and low maintenance can help improve overall efficiency.
The new ball bearings are available in three variants with inner diameters of 8mm, 10mm and 12mm. A version with a spherical outer race is also available, allowing smooth operation in aluminium profiles.
