The switch to igutex polymer bearings for long standing customer and agricultural equipment manufacturer, Sumo UK, has allowed the company to produce longer lasting, durable machinery and save on the cost of standard metal bearings that require lubrication.
igus manufactures most lubrication-free plain bearings using plastic injection moulding. However, for extreme heavy-duty applications, such as tillage equipment and cranes with high surface pressures, sometimes a bearing is needed with a higher load capacity.
Finding bearings that are cost effective, tough enough to take on the most heavy-duty loads and run without any lubrication is no mean feat. igus has managed to do this with the igutex bearing range, designed to withstand the pressure of demanding industries such as agriculture and construction. For applications such as chassis mounts of cranes with surface pressures of more than 80MPa, the material structure does not offer sufficient mechanical stability, so igutex is manufactured in a two-stage winding process.
To do this, the winding machine first produces an inner layer of filament fabric with integrated solid lubricants. The microscopically small lubricant particles are successively released during operation and enable dry running with low friction coefficients. The second winding then creates a protective outer shell made of a particularly hard-wearing glass fibre fabric to achieve a maximum surface pressure of up to 200MPa. This makes the polymer bearings robust enough to work with low wear and fail-safe in ship-toshore (STS) cranes.
Renowned manufacturer of agricultural cultivation equipment, Sumo UK, knows that engineering is fundamental to success and there is no room for error. Producing equipment that often weighs over ten tonnes requires technical solutions that can take high loads frequently and with ease. A long-standing customer, Sumo UK was first introduced to igus plain bearings in 2017 and they have been installed in some of the heaviest equipment with no complaints.
However, Sumo UK wanted to go a step further and assess how igutex compares to other options in high load applications where greased metal bearings are usually fitted. No stone was left unturned as factors such as load, wear resistance, serviceability and cost were all incorporated into the final decision.
As a result of the assessments carried out by Sumo UK, conclusions were made that for a majority of applications, igutex TX1 and TX3 would be the best materials. The bearings are primarily used in the articulation geometry on folding hinge points, running on mild steel connection pins. The igutex TX1 and TX3 materials both have excellent running characteristics in oscillating motion – exactly what is needed in the company’s applications.
Providing lasting solutions
As a leading motion plastics company, igus has a constant focus on adding value for machine builders through improving all types of motion. One of the underlying strategic drivers is to be able to deliver sustainable solutions that have minimal impact on the environment, which has been happening for years, long before it became fashionable to do so.
These core principles are present in all igus products, including the range of igutex bearings. These high load, dry running bearings are a composite material engineered with fibres and resins which are treated with high temperatures and pressures to create an exceptionally hard-wearing material. Not only can this range accommodate huge loads, but it also has a very wide window of operating temperatures ranging from -60°C up to +120°C.
Combined, these qualities allow igutex bearings to be used in a variety of industrial environments at a reasonable price, reducing cost for customers as well as eliminating maintenance and lubrication requirements. The range of industries in which igutex can benefit applications extends to shipto-shore (STS) cranes, as well as rubber tired gantry (RTG) and rail-mounted gantry (RMG) cranes, operating all year round in the harshest conditions – including dirt, dust, salty air, heat and cold.
Some components respond to this extreme load with premature wear, often causing system failure. This is time consuming and costly – a big threat as handling capacities increase and competition strengthens. To relieve the burden on crane operators and ports, igus presented the igutex series as an alternative to problematic classic steel bearings at TOC Europe 2024, where issues such as corrosion, rapid wear and lack of lubrication are often discussed.
As with all igus products, the igutex bearings do not require any lubrication which presents an immense cost advantage. Every year, billions of pounds are spent on lubrication in industries across the world. In addition, there are extortionate maintenance costs and yet there are always failures and roadblocks due to insufficient lubrication.
The use of lubrication-free plain bearing technology therefore reduces maintenance costs, conserves personnel resources in times of a shortage of skilled workers and increases the service life of machines and therefore has a direct impact on productivity.
Tried and tested quality solutions
A strong relationship has formed between igus and many customers like Sumo UK over the years, with a consistent priority on quality and reliability.
The testing carried out on all igus products is thorough. With around 15,000 tests carried out a year, all products undergo rigorous testing, with the added transparency of allowing customers to see the products for themselves before they decide to invest. In summary, igus uses plastic technology to solve engineering problems in the toughest environments, something clearly achieved with the tilling equipment at Sumo UK.
The data supports the benefits of this product range and the fact that the wound polymer bearings are more wear-resistant than steel bearings has been proven by igus in their in-house, 4,000 square metre test laboratory. On a test rig, steel bearings with a diameter and length of 40mm each were loaded with 80MPa. They pivoted 50,000 times by 50 degrees – at a speed of 30 cycles per minute.
The result; the bearings suffered such massive shaft wear that the engineers had to stop the test after 10,000 cycles. In that same time, the bronze bearing failed due to wear on the bearing itself. On the other hand, the igutex bearing survived the 50,000 cycles with minimal signs of wear. The benefits of lubrication free products are being recognised more and more by manufacturers and operators around the world.
The company Tan Cang Gantry Joint Stock Company (TCGT) from Vietnam, has noticed these benefits and are equipping RTG cranes with lubricationfree and maintenance-free high-load bearings in collaboration with igus. This bearing range is not just for new systems, but also for existing ones, and the switch from metal bearings to polymer variants is quick and simple.
This is because igus can manufacture the bearings, which usually have a diameter of 100mm or more, with the same dimensions. To further simplify the process, application consultants are available onsite to assist with changeovers and make the transition a valuable step in the right direction for industries looking to improve and modernise their operations.
For more stories similar to this, visit our Innovation channel
