PLAIN BEARING TECHNOLOGY

The ZOLLERN Group

The ZOLLERN Group is an international company with
over 3000 employees. Our fields of activity include
drive systems (automation, gears and winches), plain
bearing technology, mechanical engineering components,
foundry technology and steel profiles.

CONTENTS

Applications 4/5
Combustion engines and piston-type machines 6
Plain bearing shells 7
Bushings 8
Turbocharger bearings and thrust bearings 9
Industrial and plant engineering 10
Energy conversion machineries
Tilting pad and thick-walled bearings 11
Housing and pedestal plain bearings 12
Special configurations/bearing metal linings and repairs 13
Hydraulic components
Sliding elements 14
Special industrial engineering
Hydrostatic bearing systems and components 15
Research and development
Application engineering 16
Quality and environmental management 17
 PLAIN BEARING TECHNOLOGY

2 3

OSTERODE BRAUNSCHWEIG HERBERTINGEN CATAGUASES, BR LES MUREAUX, F

ZOLLERN plain bearings

keeping everything in motion
Throughout the world ZOLLERN stands for high-
quality plain bearings. The international com-
petition demands innovation, delivery reliability, The requirement profiles of the plain bearings in
product quality and excellent customer service. modern machine designs are as many as they
Variegated designs of special plain bearings are varied. It is not only the design principle of a
and multilayer compound castings adapt to the machine but also its size and anticipated operating
specific market demands. A glance at our product conditions which have a decisive effect on the
range reveals that ZOLLERN produces suitable design of the plain bearings used and their
plain bearings for every application whether for combinations of materials. A technically efficient,
the purpose of generating, converting and convey- economically viable plain bearing system must
ing energy in diesel and gas engines, gearboxes, therefore be specially adapted to the requirement
turbines and turbo-machines or in other industrial profile of the machine. A consequence of the
applications. development of engines and machines to produce
higher and higher outputs is that the plain bearings
must accommodate increasingly high static and
dynamic loadings while, at the same time, still
achieving prolonged durability in service. That is
why the worlds leading manufacturers of engines
and machines place their trust in our products and
their quality.
 COMBUSTION ENGINES AND
PISTON-TYPE MACHINES

1 Plain bearing shell

2 Bushing

3 Turbocharger bearing

4 Thrust bearings

1 2 3 4

Plain bearing shells Bushings

Thin-walled split radial plain bearings for two- One-piece radial plain bearings for the piston
stroke crosshead and four-stroke trunk pins of four-stroke trunk piston internal com-
piston internal combustion engines and for bustion engines and crossheads, camshafts
other piston-type machines. Generally used as and control shafts, intermediate bearings,
main bearings, conrod bearings and crosshead rocker arms and items of ancillary equipment
bearings, and as bearings for camshafts and such as pumps also as combined radial/
control shafts. thrust bearings.

Thin- and thick-walled, split, combined radial/ Turbocharger bearings

thrust bearings (flange bearings) as main bea- One-piece thick-walled radial plain bearings
rings for all kinds of piston-type machines and with particular bore profiles for very high circum-
as bearings for camshafts and control shafts. ferential speeds and one-piece thrust bearing
rings with special profiling for extreme axial
thrust also as combined radial/thrust bearings.

Thrust bearings
Thin- and thick-walled thrust bearing rings in
split and non split design, and combined axial-/
radial bearings (flange bearings) for crankshafts,
camshafts and control shafts.
 INDUSTRIAL AND PLANT ENGINEERING

4 5
1 Tilting pad and thick-walled bearings

2 Housing and pedestal plain bearings

3 Sliding elements

4 Hydrostatic bearing systems

1 2 3 4

Energy conversion machineries Hydraulic components

Tilting pad and thick-walled bearings Sliding elements
Radial/thrust bearings as tilting pad bearings for Valve plates and holding down devices for axial
applications with high circumferential speeds or piston pumps and motors subject to high load-
thrust loadings, or as thick-walled plain bear- ings, with high precision geometry and plane
ings with high inherent stability and special parallelism, as ready-to-install elements or
bore profiles. Principal applications are turbines, semi-finished products.
gearboxes, turbo-compressors, fans, vertical
generators, electrical machines, turbochargers. Special industrial application
Hydrostatic bearing systems
Plain bearings type Z Radial, thrust and combined hydrostatic bearings
Z-bearings are high performance bearings com- for spindle units, guides and thread gears as
plying with the applicable ISO standard and well as bearings for test rigs and special pur-
designed on the modular principle. The broad poses, with a variety of regulating systems;
application spectrum for the different types of compound bearing materials for applications
bearings (pedestal, flange-mounted and centre in special purpose machines.
flange bearings) covers electrical machines,
fans, turbines and test rigs
 COMBUSTION ENGINES AND
PISTON-TYPE MACHINES

Our production processes are aligned to the

specific requirements of plain bearings for large
diesel engines, e.g. crush height measuring,
fineboring for large diameters or the electro-
plating processes, which are worldwide leading. ZOLLERN BHW customer service is available at
all times. Whether to examine and evaluate a
Our employees in R&D, production and quality plain bearing or merely to provide expert infor-
draw their know-how and expertise from years mation on plain bearing technology or tribology.
of experience in the field of plain bearing tech-
nology for combustion engines and general ZOLLERN BHWs test rig technology is unique.
industrial engineering. Thanks to the so-called two-pulse concept,
combined with high stress loading frequencies,
prolonged operating times can be represented
in short-term tests (screening).

Environmental awareness is taken into account

by, among other things, a unique metal recycling
facility with an adjoining quality control.
 4

6 7
1 Bearing shell consisting of steel/lead-bronze/electroplated layer, diameter 250 mm

2 Bearing shell consisting of steel/aluminium alloy, diameter 280 mm

3 Deburring of a large size bearing, diameter 940 mm

4 MAN B&W 12K98ME-C

two-stroke diesel engine with main, conrod and crosshead bearings made by

1 2 3

Plain bearing shells made in exchangeable halves. When arbitrarily

designed for internal combustion engines and assembled, the pair of bearing shells always
other piston-type machines, but also proven fits in such a way that, when installed, the seat
in other areas of general industrial machines, complies with the specified prestress level
e.g. gearboxes and roll stands if required, compensation for housing distor-
with a ratio of wall thickness to diameter less tion by adapted wall thickness progression
than 0.06 to support the optimum bearing function, so
bimetal plain bearings in materials consisting that the inner diameter complies with a geo-
of steel/white metal or steel/aluminium, metric shape which favours the formation
trimetal plain bearings made of steel/bronze of a uniform lubricating film
or steel/aluminium with an additional lining tested with special crush height measuring
with steel supporting shells and bearing metal machines, which we produce also for our
coatings of between 0.5 and 3 mm and linings customers. The crush height is the charac-
of between 0.01 and 0.04 mm teristic required to achieve the necessary
type of material selected to meet the require- prestress in installed condition
ments of the stress loading profile
 4

1 Piston pin bushing made of steel/lead-bronze, diameter 190 mm

2 Camshaft bushing made of steel/lead-bronze, diameter 210 mm

3 Guide bushing for a piston rod made of bronze/white metal, diameter 80 mm

4 Crankshaft of a piston-type compressor

1 2 3

Bushings with special external shape

for universal applications in engine and machine for piston pin bushings
manufacturing, in thin- or thick-walled designs with specially shaped grooves
available in various combinations of materials for oscillating movement
and dimensions from 50 to 800 mm with precise concentricity of outer
made of steel/lead-bronze or steel/white metal and inner diameters
by the compound centrifugal casting method with defined eccentricity of outer
made of steel/lead-bronze or steel/aluminium and inner diameters
bimetal strip with welded joint, with electroplated with cylindrical bore or
lining as an option multi-lobe sliding profile
with precisely turned or ground outer diameter with special supporting cradle for
(between centres or centreless) crosshead bushings without lift
 4

8 9
1 Turbocharger radial/thrust bearing with multi-lobe profile

2 Radial turbocharger bearing

3 Crankshaft thrust washer

4 Wrtsil W6L46
four-stroke diesel engine with main- and conrod bearings,
piston pin and camshaft bushings

1 2 3

Turbocharger bearings Thrust bearings

radial bearings for high circumferential for the axial guidance of crankshafts
speeds with 2-, 3- or 4-lobe profile and camshafts
thrust bearings with customized taper ready-to-install thrust rings and combined
land profile for highest specific load radial/thrust bearings (flange bearings)
also as combined radial/thrust bearings split and non split thrust rings
in fixed or floating execution solid bronze or aluminium or multi-layer
predominantly made of bearing metals materials with special linings
on a bronze base thin- or thick-walled flange bearings
on request with additional sliding layer materials and structure as for engine
radial bearings
 INDUSTRIAL AND PLANT ENGINEERING

Industrial bearings such as cylindrical radial plain

bearings or multi-lobe or tilting pad bearings
have long been traditional products of ZOLLERN
BHW. The former factory in Herzberg founded in
1950 under the name of GMH started designing The staff in the design and research and devel-
and producing so-called multi-lobe bearings at opment departments are continuing the com-
an early stage. panys successful tradition in the field of plain
bearing innovations and providing the customer
The first tilting pad bearings were developed in with support appropriate to the latest state of
the 1970s (when the firm was trading under the art.
the name of Glyco). ZOLLERN is also recognized
as a leading manufacturer of hydrostatic plain The special designs of the respective hydrody-
bearings. The development of the bearing clear- namic and hydrostatic plain bearings also under-
ance compensating system and its pressurising lie the fact that we have our own dedicated
characteristics dates back to the early 1980s. range of machines.

Our environmental awareness is reflected by,

among other things, a unique metal recycling
facility with adjoining quality control.
 4

ENERGY CONVERSION
MACHINERIES

10 11
1 Thick-walled radial/thrust bearings

2 Combined tilting pad bearing

3 Radial and axial tilting pad plain bearings

4 Steam turbine with radial tilting pad plain bearings with hydrostatic lift

1 2 3

Thick-walled radial and radial/ Radial and thrust tilting pad plain
thrust plain bearings bearings
split plain bearings for general industrial for use at very high circumferential speeds or
applications, e.g. gearboxes, turbines and axial loadings and general use in machines
electrical machines such as turbines, turbo gearboxes, turbo com-
thick-walled configuration ensures high pressors, fans and vertical generators
thermal stability dimensions and designs to ZOLLERN BHW
available in standard and non-standard sizes standard or customers specifications
standard configuration in a combination of configured for one or both directions of rotation
steel/white metal and diameters up to 1600 with hydrostatic starting aid if required
mm; non-standard versions in steel/bronze in with temperature or vibration measuring
diameters up to 800 mm, with or without sensors if required
additional lining
processed to ready-to-install condition:
scraping-in is generally not necessary
with bore profiles matched to the requirement
profile; cylindrical bore, 2-, 3- or 4-lobe profile,
offset halves
with hydrostatic starting aid if required
with temperature or vibration measuring
sensors if required
 ENERGY CONVERSION MACHINERIES

1 Pedestal plain bearing

2 Vertical bearing

3 Centre flange bearing ZM on a generator

1 2 3

Plain bearings type Z mum dissipation of heat. The spherical bearing

ZOLLERN Z-bearings comprise a series of high shell support was chosen so that the forces
performance plain bearings complying with DIN generated are evenly directed into the lower
standards 31690, 31693 and 31694 for a wide part of the housing. The housings are therefore
range of applications (electrical machines, fans, capable of accommodating extreme stresses.
turbines and test rigs). The modular principle They are also supplied in insulated versions in
was consistently applied to the different types order to prevent creeping currents.
(pedestal, flange and centre flange bearings),
permitting different modules from the system If required, additional equipment can be ordered
to be combined at any time. with the bearing, such as oil supply systems and
monitoring instruments. If desired, all parts can
The finned Z-bearing housings, which are made also be supplied with inspection certificates
of nodular cast iron GGG 40, provide the opti- (DNV, LRS, GL etc.).
 ENERGY CONVERSION MACHINERIES

12 13
1 Radial tilting pad made of copper-chrome

2 Radial tilting pad bearing

3 Thrust bearing pad

1 2 3

Special configurations Bearing metal linings and repairs

pads made of the compound material steel/ as sliding elements for hydraulic machines,
white metal (St/Z-BHW 36); in special cases, power transmission and other applications;
steel/lead-bronze made of compound casting as steel/white metal,
tilting pad thrust bearings with or without steel/bronze or steel/bronze/white metal
levelling pieces as ready-to-install compound casting sliding
thrust and radial tilting pads can also be elements or prefabricated steel blanks with
supplied as complete sets or as spare parts bearing metal coating
we will also calculate the dimensions, number coated by custom designed casting and
of pads and oil flow requirements for your application procedures
plain bearing design ultrasonic bonding check and dye-penetration
test for non porosity
supply of high quality white metals for repair
purposes or linings

Typical applications: Planetary gear bolts,

hydraulic cylinders for axial piston pumps and
spherical plain bearings such as spherical
shells for diesel engines
 4

HYDRAULIC COMPONENTS

1 Valve plate

2 Holding-down device

3 Control disc

4 Cross section of a Parker axial piston pump

1 2 3

Sliding elements
valve plates and holding-down devices for axial
piston pumps and motors
made of the compound material steel/Z-BHW 46
for high loadings, pulsating and vibrating stresses
outstanding wear resistance, even under excep-
tional operating conditions, such as cavitation,
oil corrosion and lack of lubrication
as ready-to-install parts and semi-finished
products
with dimensionally accurate geometry and plane
parallelism due to double-sided grinding and
lapping and by monitoring the dimensional
accuracy with high precision, computer aided
measuring instruments
 4

SPECIAL INDUSTRIAL
ENGINEERING

14 15
1 Hydrostatic radial/thrust bearing (rotary table bearing)

2 Hydrostatic screw-type drive

3 Grinding spindle unit

4 Gearwheel profiling machine with hydrostatic plain bearing system

1 2 3

Hydrostatic bearing systems no stick-slip effects and outstanding protection

and components against crashes
compact design, thanks to the ZOLLERN bearing
for machine tools clearance compensating system
for industrial engineering circumferential speeds in the bearing up to 65 m/s
for testing and measuring systems thermal stability resulting from heat dissipation
by way of cooled lubricating oil
hydrostatic systems and components ensure available as complete systems and individual
the utmost manufacturing precision and the components
highly efficient damping of vibrations from made of compound materials steel/lead/bronze,
production processes steel/white metal, steel/aluminium and special
wear resistance ensures consistent materials optimized for the intended purpose
processing precision
 RESEARCH AND DEVELOPMENT
APPLICATION ENGINEERING

1 Radial tilting pad bearing with controlled lubrication and hydrostatic system

2 Exploded view of Fig.1

3 Test rig for engine bearings

1 2 3

The plain bearing nothing new since Test rig trials serve to verify the proposed solution.
Leonardo da Vinci? ZOLLERN BHW possesses one of the largest and
While the principle remains unchanged, tools most modern plain bearing test rigs in the world,
and materials, by contrast, are new and ultra- which permits all types of stress loadings to be
modern. High precision computing methods, simulated. Even specific preliminary development
such as FEM and EHD, deliver data for design is possible involving the actual bearing housing.
work based on the 3D-CAD method and, in
conjunction with competent application know- Increasing demands on the efficiency of the bear-
how, give rise to the optimum solutions to ings in modern engines and machines are our
problems whether in respect of prototypes, incitation to develop new plain bearing materials
individual components or mass produced parts. and designs. High stress loading capacities, pro-
Whether it be the design of a bearing for a new longed durability and the protection of the shaft
machine or engine associated, needless to say, in the event of damage are just as essential devel-
with the appropriate choice of material, or an opment objectives as economical and reliable pro-
increase in the output of an existing machine, a duction methods.
tailor-made configuration always takes pride of
place. Hydrostatic, hydrodynamic or elasto-
hydrodynamic, the specific application decides
on the appropriate technology.
 3

QUALITY AND
ENVIRONMENTAL
MANAGEMENT
16 17
1 Surface measuring of a bearing shell

2 Micrograph of a lead-bronze/electroplated layer specimen

3 Certification in accordance with DIN EN ISO 9001:2000

1 2

Customer satisfaction takes top priority Our standards of care for employees and the
quality and environmental protection are environment are equally as high as our stand-
our demand ards of quality. In this context, we do not
For the production of high quality products and only implement our guidelines on innovative
effective process orientation in any company, the ways and means of protecting the environment
introduction of a quality management system and our staff, but also regularly monitor and
(QMS) is an indispensable prerequisite. For this evaluate the effects of our activities on man
reason, ZOLLERN introduced DIN EN ISO 9001 and the local surroundings. Environmentally
certification for the optimum integration of quality conscious behaviour is a duty for everyone
and environmental protection, with the result that at ZOLLERN.
the successful implementation of compliance
with the standard is consistently checked by an
independent certification company. Well trained
responsible employees are essential for high
quality workmanship and the continuous, success-
ful striving for progress. ZOLLERN meets exacting
customers requirements and quality standards
through the use of modern methods, procedures
and production units.
ZOLLERN plants

Braunschweig plant Plain Bearing Technology Soest plant Foundry Technology

Postfach 32 13 Overweg 15
ZOLLERN BHW Gleitlager D-38022 Braunschweig ZOLLERN D-59494 Soest
GmbH & Co. KG Tel. +49 53 12 60 50 Aluminium- Tel. +49 2921 7896-0
Fax +49 53 12 60 53 00 Feinguss Soest Fax +49 2921 7896-17
eMail [email protected] GmbH & Co. KG eMail www.zollern-afs.de
[email protected]

Osterode plant Plain Bearing Technology Portugal plant Foundry Technology

Rolandsweg 16 20 Rua Jorge Ferreirinha, 1095
ZOLLERN BHW Gleitlager D-37520 Osterode am Harz ZOLLERN & Apartado 1027
GmbH & Co. KG Tel. +49 55 22 31 27 0 Comandita P-4470-314 Vermoim MAIA
Fax +49 55 22 31 27 99 Tel. +351 22 94 14 68 1
eMail [email protected] Fax +351 22 94 14 69 5
eMail [email protected]

Brazil plant Plain Bearing Technology Sweden plant P. O. Box 233

Av. Manoel Incio Peixoto, 2147 SE-73224 Arboga
ZOLLERN BR-36771-000 Cataguases MG ZOLLERN Tel. +46 58 91 60 35
Transmissoes Mecanicas Tel. +55 32 34 29 53 02 Norden AB Fax +46 58 91 20 02
LTDA Fax +55 32 34 29 53 26 eMail [email protected]
eMail [email protected] www.zollern.se

France plant Plain Bearing Technology USA plant 283 Lockhaven Drive Suite 204
62, Rue Pierre Curie Houston TX 77073
ZOLLERN TLC SAS B.P.No 1055 ZOLLERN USA
F-78131 Les Mureaux CEDEX North America L.P. Tel. +1 71 36 73 79 02
Tel. +33 1 34 74 39 00 Fax +1 71 36 73 79 50
Fax +33 1 34 74 28 52 eMail [email protected]
eMail [email protected]

Herbertingen plant Transmission Technology Plain Bearing Romania plant 0317235 Pecica FN
Automation Technology Ferma 20
ZOLLERN GmbH & Co. KG Tel. +49 75 86 95 95 86 Tel. +49 75 86 95 95 20 S.C. Zollern S.R.L. Arad - Romania
Fax +49 75 86 95 95 85 Fax +49 75 86 95 97 15
Heustrae 1 eMail [email protected] eMail [email protected]
D-88518 Herbertingen Gears and Winches
Tel. +49 75 86 95 95 47
Fax +49 75 86 95 95 75
eMail [email protected]

Dorsten plant Transmission Technology

Gears
Sales offices
ZOLLERN Dorstener Httenstrae 1
Antriebstechnik D-46284 Dorsten
GmbH & Co. KG Tel. +49 23 62 67 0 France Great Britain Italy
Fax +49 23 62 67 40 3 ZOLLERN S..r.l Zollern UK Limited ZOLLERN Italiana S.r.L.
eMail [email protected] 13, Rue Allwies Castle Hill Via della Ciocca, 9
F-57200 Sarreguemines Kenilworth I-21026 Gavirate (VA)
Tel. +33 3 87 95 35 14 GB-CV8 1NB Tel. +39 03 32 46 20 59
China plant Transmission Technology Fax +33 3 87 95 35 21 Tel. +44 19 26 51 54 20 Fax +39 03 32 46 20 67
No. 79, 11th Avenue eMail [email protected] Fax +44 19 26 85 34 11 eMail [email protected]
ZOLLERN (Tianjin) TEDA 300 457 Tianjin www.zollern.fr eMail [email protected] www.zollern.it
Machinery Co., LTD. Peoples Republic of CHINA www.zollern.co.uk
Tel. +86 22 25 32 38 11
Fax +86 22 25 32 38 10
eMail [email protected]
Netherlands Russia
ZOLLERN Nederland B.V. ZOLLERN Ltd.
Aulendorf plant Mechanical Engineering Components Postbus 134 115114, Russia, Moscow
Postfach 12 65 NL-5150 AC DRUNEN Derbenevskaja nab., 11, A
ZOLLERN D-88322 Aulendorf Tel. +31 41 63 22 92 0 Sector 2, Office 66
Maschinenbauelemente Tel. +49 75 25 94 81 30 Fax +31 41 63 20 93 6
GmbH & Co. KG Fax +49 75 25 94 81 00 eMail [email protected]
eMail [email protected] www.zollern.nl

Laucherthal plant Steel Profiles Foundry Technology

Postfach 12 20 Postfach 12 20
ZOLLERN GmbH & Co. KG D-72481 Sigmaringen D-72481 Sigmaringen
Tel. +49 75 71 70 24 6 Tel. +49 75 71 70 44 0
Fax +49 75 71 70 27 5 Fax +49 75 71 70 60 1
eMail [email protected] eMail [email protected]
 CONTACT

18 19
ZOLLERN Plain Bearing Technology

ZOLLERN BHW Gleitlager

GmbH & Co. KG
Postfach 32 13
D-38022 Braunschweig
Tel. +49 53 12 60 50
Fax +49 53 12 60 53 00
eMail [email protected]
www.zollern.com
 www.revoLUZion.de
Errors and Omissions excepted.

ZOLLERN BHW Gleitlager

GmbH & Co. KG

Postfach 32 13
Z529 10.2011

D-38022 Braunschweig
Tel. +49 53 12 60 50
Fax +49 53 12 60 53 00
eMail [email protected]
www.zollern.com