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Bearings for Heavy-Duty and Off-Road Vehicles: 2025 Guide

Bearings for Heavy-Duty and Off-Road Vehicles

Bearings are an indispensable part of almost every moving component from precision instruments to heavy-duty vehicles, bearings have a crucial role to play in the overall operation of such machines. Now, given the wide application and usage range of bearings, there are different bearings engineered for different types of operation based on load requirement, operating speed, alignment requirements, and more. When it comes to application in heavy-duty and off-road vehicles, bearings are crucial components that enable smooth and reliable movement of parts in harsh and high-load environments.

Some of the features of bearings used for heavy-duty and off-road vehicles include:

  • High Load Carrying Capacity: The primary function of these bearings is linked to carrying massive radial and axial loads. Bearings in these heavy-duty vehicles prevent metal-to-metal contact between the moving parts and manage weight during off-road manoeuvres.
  • Smooth Rotational Movement: Bearings equipped in heavy-duty or off-road vehicles enable wheels, axles, gears, shafts, and motors to rotate with minimal friction. Plus, these heavy-duty bearings are essential for high-efficiency movement even on rough terrain.
  • Shock Absorption: off-road vehicles face sudden impacts, vibrations, and uneven surfaces. Bearings in these places absorb and distribute these shocks to protect the vehicle’s mechanical systems.
  • Friction Reduction: Bearings like high-capacity cylindrical roller bearings or tapered roller bearings reduce wear and tear on high-speed or heavily loaded parts. This leads to lower energy loss, better fuel efficiency, and longer component life.
  • Misalignment Compensation: Given that heavy-duty and off-road vehicles work under stress and uneven loads, misalignment is common. Bearings meant for high load, especially spherical roller types, adjust to shaft or housing misalignments.

Challenges for Bearings in Heavy-Duty & Off-Road Environments

Bearings Challenges in Harsh Environments

Bearings in general, in any operating environment, work under stress; however, in environments of heavy load and stress, bearings constantly work under extremely harsh and demanding conditions. Some of the challenges for bearings in heavy-duty and off-road applications include:

  • Extreme Load Stress: The primary challenge for bearings deployed in heavy-duty & off-road environments is related to the load they cater to. The bearings must withstand very high radial and axial loads from heavy vehicles carrying tonnes of weight. Extreme weights can lead to fatigue, deformation, or failure of the bearing if it is not accurately designed.
  • Extreme Shock & Vibration: Another significant challenge for bearings used in heavy-duty and off-road vehicles is associated with uneven terrains, sudden impacts, and high-speed jolts, which may expose the bearings to constant shock and vibration. Extreme shock and vibration can lead to premature wear, cage fracture, misalignment, etc.
  • Contamination: Heavy-duty and off-road vehicles operate in environments that are full of abrasive particles like dirt, sand, mud, and water. These particular conditions, if they enter the bearings, can cause abrasive wear, corrosion, and lubricant breakdown.
  • Extreme Temperatures: Along with heavy weight, these bearings are also exposed to very high or very low temperatures, especially in engines, brake systems, or outdoor conditions. Extreme temperatures can create a significant challenge and can affect lubricant performance and cause material expansion/contraction.
  • Lubrication Failures:It is one of the most common challenges for bearings fitted in heavy-duty and off-road vehicles. Given these bearings work in remote or dirty environments, which makes regular lubrication difficult.

Types of Bearings Best Suited For Heavy-duty & Off-Road Vehicles

There are various bearings designed and precisely engineered to suit the requirements of heavy-duty and off-road vehicles; some of the most common ones are included below:

Tapered Roller Bearing

Tapered roller bearings are the preferred choice of bearings used in wheel hubs, differentials, and axle systems of off-road vehicles. Tapered roller bearings are good at handling radial and axial loads, and are ideal for carrying vehicle weight and cornering forces. Truck wheels and off-road utility vehicles are commonly equipped with tapered roller bearings.

Double Row Tapered Roller Bearing

Cylindrical Roller Bearing

Cylindrical roller bearings are used in transmission systems, motors, large shafts, and more. These bearings are preferred given their very high radial load carrying capacity while supporting high-speed rotation. Cylindrical roller bearings are commonly used in transmission systems of tractors, construction machinery, etc.

Single Row Cylindrical Roller Bearing

Deep Groove Ball Bearing

When it comes to alternators, electric motors, and fans in heavy-duty and off-road vehicles, deep groove ball bearings are the preferred choice. They are the go-to bearings due to cost-effectiveness, simplicity, and suitability for high speed.

Single Row Deep Groove

Spherical Roller Bearing

Spherical roller bearings are used in suspension systems, gearboxes, and rotating joints of heavy-duty vehicles. These bearings are self-aligning and resistant to misalignment, vibrations, and impact loads.

Spherical Roller Bearings

Needle Roller Bearing

Needle roller bearings in off-road vehicles are fitted in gearboxes, transfer cases, universal joints, etc. These bearings are compact in size, yet are very capable of handling high loads. Needle roller bearings are fitted in off-road vehicles’ driveshafts, gear mechanisms, etc.

Needle Roller Bearing Product

Selection Factors of Bearings for Heavy-Duty & Off-Road Vehicles

Bearings for Tough Vehicles Guide

There are numerous factors to consider before selecting a bearing meant for heavy-duty and off-road vehicles; some of them are mentioned below:

  • Load Type & Capacity: Before selecting the bearing, consider the load requirement i.e. light, medium & heavy. Also, consider the load type i.e. radial, axial or combined.
  • Operating Conditions: A bearing for heavy-duty application must also be chosen based on the temperature (high or low), speed (high or low speed requirements) & environmental factors (moisture, dust, etc).
  • Misalignment Tolerance: Bearings chosen for heavy-duty or off-road vehicles must be self-aligning. Choose bearing types that are self-aligning.
  • Lubrication Needs: Understand the environment before selecting a bearing, as some environments may limit access to regular maintenance. Other lubrication factors to consider include lubrication type, quantity, and compatibility.
  • Mounting & Dismounting: Consider the mounting and dismounting process of the bearing, as some may require special tools for installation and removal.

Maintenance Best Practices

  • Regular Lubrication: Regular lubrication of bearings used in heavy-duty and off-road vehicles helps reduce friction, heat, and wear. Plus, it is essential to use the correct lubricant, or the lubricant recommended by the manufacturer.
  • Keep Bearing Clean & Contaminant Free: Regularly cleaning bearings of dirt, water, and debris is the top cause of bearing damage. Note: Avoid pressure washing near exposed bearings unless protected.
  • Regular Inspection & Monitoring: Regular inspection and monitoring of bearings in off-road vehicles is crucial as it can prevent catastrophic failure. Checks for cracks, rust, noise, leakage, imbalance, misalignment, etc, must be regularly done.
  • Condition Monitoring: Condition monitoring tools like vibration analysis and temperature monitoring should be done regularly to detect potential issues early.
  • Load & Speed Monitoring: Overloading or overspeeding can lead to early failure of bearings used in heavy-duty & off-road vehicles. The best practice is to ensure load conditions stay within design limits, avoid impacts, and more.

Future Trends in Heavy-Duty Bearings

Heavy-duty bearings equipped in high-load and heavy-duty vehicles are developed with a focus on customised requirements, are AI-driven, are made of advanced materials, and more.

  • Smart Bearings with Sensors: Heavy-duty bearings are now being developed with IoT sensors that help monitor vibration, load, temperature, lubrication condition, and more.
  • Bearings Made of Advanced Materials: Bearings meant for heavy-duty and off-road vehicle applications are now being made of advanced materials like ceramic hybrids, case-hardened steels, special coatings, etc.

FAQ's

What is the strongest type of bearing?

The strongest type of bearing depends on the specific load conditions, though roller bearings & their types are generally known for their high load-carrying capacity.

Which bearing is suitable for heavy loads?

Cylindrical roller bearings, spherical roller bearings, and tapered roller bearings are some of the bearings suitable for heavy loads.

What is a heavy bearing?

Heavy bearing is referred to as a bearing designed for heavy load carrying capability.

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Press Release

NBC Bearings Cracks Down on Counterfeiters with Major Raids in Delhi and Madurai

NBC Bearings Cracks Down on Counterfeiters
NBC Bearings Cracks Down on Counterfeiters

Seizes fake bearings and machinery worth over ₹72 lakh in coordinated enforcement action

National Engineering Industries Ltd. (NEI), part of the CKA Birla Group and manufacturer of NBC Bearings, has intensified its anti-counterfeiting drive with five targeted raids in Karol Bagh (Delhi) and Madurai (Tamil Nadu). Conducted in June and July 2025 in collaboration with local authorities, the raids led to the busting of four counterfeiting units and the seizure of fake bearings, packaging materials, and a laser marking machine used to forge NBC branding. The total value of seized goods exceeds ₹72 lakh.

On June 19, 2025, NBC representatives and the Karol Bagh Police raided a manufacturing and packaging unit in Karol Bagh, Delhi, resulting in the arrest of Amit Kumar-Creative Auto, Sachin Gupta-BMG Auto, and Arun Kumar Kalsi-Aman Auto. An FIR (No. 757/2025 dated 23-05-2025) was filed.

A second raid on July 1, 2025, with support from Madurai Police, targeted a similar operation on North Veli Street. Two individuals, Ankit Gupta- Shivam Bearings vide FIR no.8/2025 and Ramesh Gupta-Roller & ball Bearing vide FIR no.9/2025 were registered in this case and arrested. Bearings, packaging and a laser engraving machine was seized.

These actions mark a strategic shift for NBC Bearings—from targeting counterfeit sellers to dismantling manufacturing networks at the source. The seizure of advanced marking equipment highlights the scale and sophistication of such operations.

Rajesh Premchandran, Chief Sales & Marketing Officer, NEI, stated: “Counterfeit bearings are a serious threat to vehicle safety and industry reliability. At NBC, we are committed to protecting our customers and brand integrity. These raids reinforce that commitment and send a strong message: we will not tolerate counterfeiting in any form.”

NBC urges customers to purchase products only from authorized dealers and to use the NBC Connect App – a free verification tool that confirms product authenticity within seconds.

NBC continues to invest in anti-counterfeiting initiatives to protect its customers, partners, and the industries it serves.

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The Role of 3D Printing in Modern Bearing Production

The manufacturing landscape is an ever-evolving space driven by advances in production technology, machine tools, information technology, materials, and products. One of the newest advancements in manufacturing is 3D printing and additive manufacturing. 3D printing is a way of making real, 3D objects from a digital design – by building them layer by layer using materials like plastic, metal, or resin. 3D printing and additive manufacturing refer to the same thing, a process where objects are made layer by layer. It is called additive manufacturing as it involves adding material layer by layer unlike traditional manufacturing (like cutting or drilling), which removes material.

3D Printing in Modern Bearing Production

How does it work?

  • Design: A 3D model of a bearing is created on a computer.
  • Print: The printer builds the bearing layer by layer using various materials.
  • Finish: Once printed the bearing may go through polish, heat treatment, etc.

How 3D Printing Is Used in Bearing Production?

3D printing is mainly used to make bearing parts or full bearings for special applications – not for mass production. The 3D models are created using software, further depending upon the bearing’s use material is chosen, post-selection the printer starts building the bearing layer by layer. After printing the bearing may require post-processing involving polishing, heat treatment, assembly, etc. The bearings manufactured are especially useful in research, development, or custom machines. 3D printing is used in bearing production to:

  • Design and test new ideas quickly
  • Create custom or rare parts
  • Make lightweight or complex shapes

The key uses of 3D printing in bearing production involves:

  • Customised Bearings: 3D printing is widely useful for designing bearings and their components for machines and tools with unique designs and shapes. 3D printing allows for designing one of a kind bearing design that fits the custom space.
  • Rapid Prototyping: Another reason behind the wide acceptance of 3D printing for bearing production is due to its ability to quickly create sample bearings to test new designs and sizes. It helps with designing a prototype bearing to be used and test fit before mass production.
  • Lightweight Structures: 3D printing models allow for the creation of hollow or lattice designs that reduce weight without losing strength. These bearings are widely used in racing applications, drones, aerospace, and more.
  • Educational & Demonstration Models: 3D printing is also used in the production of non-functional bearings meant for training, teaching, and exhibitions.
  • Production of Bearing Components: 3D printing or additive manufacturing is also preferred to manufacture specific bearing parts like retainers, cages, housing, and more.

Low Volume Production: 3D printing of bearings is a cost-effective option for producing a small number of bearings without the need for expensive moulds or tools.

Materials Used for 3D Printed Bearings

The choice of 3D printing materials depends on the type of bearing being produced and its usage – whether it is being used for prototyping, lightweight design, or actual performance testing. A 3D printing machine builds the bearing or its parts layer by layer using suitable materials. Some of the common materials used for 3D-printed bearings include:

  • Plastic/Polymer Materials: Plastic or polymers are commonly used materials in 3D-printed bearings. Bearings made from plastic or polymer are lightweight, corrosion-resistant, and perfect for limited-load applications.
  • Metal Powders: Metal powders including stainless steel, titanium, tool steel, aluminium, and more are used in manufacturing 3D printed bearings that are strong and durable, ideal for high-load applications.
  • Resins: Resins as materials are used in high-detail 3D printing technology. Bearings designed using resins are materials that are precisely engineered, are very high on details, and have smooth surfaces. 3D printing machines like SLA, DLP, and LCD often use this material.
  • Composites: Several materials are combined like materials reinforced with carbon fibre or glass fibre offering a high strength-to-weight ratio and improved wear resistance. These materials are preferred for lightweight structural parts in aerospace or robotic bearings.

Advantages of 3D Printing in Bearing Manufacturing

3D printing is bringing innovation and speed to how different types of bearings, like ball bearings and roller bearings, are developed and tested. While it’s not yet used for mass production, it offers several key advantages in the manufacturing process:

  • Customisation: 3D printing makes it easy to design bearings in non-standard shapes or sizes for specific machines or tools. Eg: 3D printed bearings are ideal for custom applications in robotics, aerospace, medical devices, and more.
  • Faster Prototyping: 3D printing allows the engineers to quickly create and test new designs for various types of bearings including ball bearings or roller bearings without waiting weeks for machining or moulding.
  • Cost Effective for Small Batches: 3D printing of bearings is more cost-effective for limited production when compared to traditional methods of production. There is no need for tooling or moulds. 
  • Lightweight Designs: 3D printing allows hollow or lattice structures inside bearings — useful for creating lightweight ball bearings in drones or satellites.

Challenges and Limitations

While 3D printing offers many benefits in the design and development of bearings, there are some practical limitations that prevent it from fully replacing traditional manufacturing. Some of them are listed below:

Limitation

Description

Material Limitation

Not all bearing materials are 3D printable, thus bearings lack load carrying capacity and durability. 

Slow for Mass Production

3D printing can be too slow and expensive for producing large quantities, but traditional manufacturing is still effective for large-scale manufacturing. 

Post-Processing Requirements

Printed parts often require additional steps like heat treatment, surface finishing, or assembly.

With advances in metal 3D printing, hybrid manufacturing, and material science, the future holds promise for stronger, high-precision printed bearings. As technology evolves, 3D printing could become a key player in producing functional bearings for specialised industries like aerospace, robotics, and medical devices. 3D printing is a powerful tool for innovation in bearing manufacturing, especially for design flexibility, rapid testing, and small-scale production – with exciting potential still ahead.

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Blog

How Bearings Improve Performance in Hydro & Solar Power Systems

Hydro vs Solar Power Systems

Most of us are aware that bearings are important components used in various mechanical setups, vehicles, household appliances, and more. However, bearings are also proving to be an integral part of new and modern products like electric vehicles (EV), drones, UAVs, robotic surgery systems, and more. Additionally, bearings are also playing a key role in hydro and solar power systems enabling smooth, efficient, and long-lasting operation of mechanical components.

Given the rising demand for electricity, the push towards sustainability, and the increased demand for cleaner sources of energy the demand for hydro and solar power is rising. According to Niti Aayog, there are 198 hydropower plants and 849 small hydropower plants in India. Also, there are 363 solar power projects producing a total of 107945.61 MW of electricity.

Source Wise Energy Generation

The energy generation from these renewable sources systems is influenced by various factors like rotors, blades, gearboxes, sealing systems, bearings, and more. Bearings are the overlooked components but are quite crucial for the smooth and reliable running of these setups.

Renewable energy systems are fitted with various types of bearings including ball bearings, tapered roller bearings, plain bearings, self-aligning bearings, slewing bearings, and more. These bearings are used to support the rotating parts, reduce friction, and ensure sufficient power transmission. When it comes to the solar energy system, bearings are widely utilised in solar trackers, gearboxes, actuators, pivot joints, and more, while in hydropower systems bearings are fitted in turbine shafts, generator rotor, flow control mechanisms, and more.

Source Percentage
Coal 74.58%
Hydro 6.17%
Nuclear 3.11%
Oil & Gas 2.05%
Small Hydro 0.24%
Solar 9.61%
Wind 3.91%
Bio Power 0.33%

Overview of Hydro and Solar Power Systems

Solar power as the name implies works by converting energy from the sun into power. Energy generated through the sun is of two types i.e. electricity and heat. Solar energy is a clean source of energy and has no harmful emissions, whereas hydropower generates energy from the flow of water which spins the turbine which is connected to a generator, the turbine’s motor further rotates the generator’s motor creating electricity.

Hydro vs Solar Power Systems

Hydropower in India currently accounts for 6-7 % of total energy generation. Both of the sources i.e. solar & hydro, are vast global resources and have existed for centuries, but in recent years the majority of nations across the world are finding new ways to adapt them to work and cater to the increasing energy needs. For years National Bearing Company (NBC) has been supplying precisely engineered bearing solutions for numerous hydro and solar power systems.

When it comes to comparing these energy sources, it’s hard to say that one is definitely better than the other. It really depends on factors like how much sunlight an area gets and whether there are large bodies of water nearby. So, what works best for one location might not be the right fit for another.

Bearings in Hydro Power Applications

Power or electricity is generated in hydropower plants when the flowing water turns hydroelectric turbines. These turbines use the kinetic energy of water to generate mechanical energy. These turbines work under constant stress due to the continuous flow of water, thus requiring regular maintenance. These turbines to rotate smoothly and reduce friction are fitted with bearings. Bearings in these hydropower setups are under continuous operation and work under challenging conditions, like underwater operation, exposure to debris or rocks, etc.

Bearings in Hydroelectric Power Systems

Types of Bearings Used in Hydro Power Application

  • Thrust Bearing: Thrust bearings are widely used in hydropower applications, particularly in turbine shafts. Given their high axial load capacity and long operational life, these bearings are preferred for supporting the weight of the turbine and generator rotors.
  • Self-Lubricating Bearing: Self-lubricating bearings are preferred for moving parts in wet environments. Specialities of these bearings are they are maintenance-free, wear & corrosion-resistant, and they work well under static loads. These bearings are used in guide vane pivots, spillways, dam gates, and more.
  • Guide Bearing: Guide bearing or radial bearing supports radial loads and allows for the shaft to stay aligned. Such bearings are used in turbine and generator shafts.
  • Spherical Roller Bearing: Spherical roller bearings are preferred for their ability to handle radial and axial loads. These bearings have high load capacity, and self-aligning capability, and work fine under heavy loads. This type of bearing is used in the shaft line system, generator rotor, and more.
  • Hydrodynamic Bearing: Also referred to as water-lubricated bearing, these bearings use water as a lubricant instead of oil or grease. Hydrodynamic bearings are commonly fixed in submerged shafts and turbines.

Bearings used in these setups are required to be extremely durable and precisely engineered as hydro turbines are constantly moving leading to increased friction, heat buildup, lubrication issues, and stress from external forces like wind, rain, snow, etc. Bearings in hydropower setups are extremely crucial components as the entire operation depends on their functioning. Bearings fitted in these systems are designed to handle high-pressure and heavy loads. Self-lubricating bearings, thrust bearings, spherical roller bearings, cylindrical roller bearings, etc are used in hydropower applications.

Bearings in Solar Power Applications

The increasing awareness about clean energy has led to an increased demand for solar power energy. Solar power setups are made of various components and to enable smooth movement of these components bearings are employed. Bearings are used in solar trackers, motors, gearboxes, and more and allow for the panels to follow the sun and maintain optimal energy generation throughout the day. Various types of bearings including slewing bearings, tapered roller bearings, plain bearings, deep groove ball bearings, and cylindrical roller bearings are used in solar power applications.

The bearings fitted in solar power setups are required to be highly reliable due to the risk of corrosion, exposure to dusty and high-temperature environments, and more. NBC bearings are precisely engineered for solar power applications and have several advantages including, UV resistance, long service life, insensitive to dirt and dust, quieter operation, and more.

Types of Bearings Used in Solar Power Application

  • Slewing Bearing: Slewing bearings are the most common type of bearing fitted in main routine joints in solar trackers. These bearings are designed to handle axial, radial, and moment loads and are very durable to handle outdoor environments.
  • Tapered Roller Bearing: Tracker drive, pivot mechanism, etc are equipped with tapered roller bearings. These bearings are preferred due to their ability to handle combined radial and axial loads.
  • Plain Bearing: To support simple pivot or sliding motion in structural joints, plain bearings are often used.
  • Cylindrical Roller Bearing: Cylindrical roller bearings are used to handle radial loads in gearboxes and support shafts. Such bearings are used in tracker drives, power transmission, and more.
  • Deep Groove Ball Bearing: Deep groove ball bearings are preferred for electric drives, gearbox assemblies, and more. Such bearings are good for high-speed performance, and quiet operation, and are compact.

Challenges in Renewable Energy Applications

Challenges in Renewable Energy Systems

Bearings in renewable energy applications face various challenges, including:

  • Harsh Environmental Conditions: Bearings used in renewable energy setups operate under harsh environmental conditions like exposure to water, humidity, dust, sand, UV radiation, extreme temperatures, and more which can result in corrosion, rust, seal failure, abrasion, wear, and more affecting the overall operation
  • High Loads & Intermittent Operations: Renewable energy setups are heavy and put intense weight on bearings used, i.e. turbine shafts, solar panels, etc. Additionally, these bearings often experience a lot of starting and stopping during operation due to the fluctuating energy inputs from sunlight or water flow.
  • Reliability & Longevity: Reliability & longevity of any bearing are influenced by maintenance, though in renewable energy setups bearings are often located in inaccessible or remote sites which makes periodic maintenance difficult resulting in premature failure. 
  • Lubrication Issues: This is also one of the key challenges in these renewable setups. Given the remote location and their exposure to harsh conditions, lubrication can quickly degrade which may lead to premature failure.

How to Select the Right Bearing?

Selecting the right bearing for renewable energy applications is crucial as it helps ensure long-term performance, reliability, and more. Some of the key factors to consider include:

Factor

What to Consider?

Load Type & Direction

Consider the load type, i.e. axial, radial, combined or variable loads.

Operational Speed

Analyse the speed requirement, opt for ball or roller bearing for high speed & sleeve bearings for low speed.

Environmental Exposure

Identify the operating environment & possible exposure like water, dust, UV rays, temperature changes, etc. 

Lubrication Method

Select bearings based on lubrication requirements, i.e. self lubricated, oil lubricated, water lubricated, etc. 

Conclusion

Bearings play a vital role in hydro and solar power systems, acting as essential components that boost the overall efficiency of operations. These bearings operate in tough conditions, so it’s crucial that they are of the highest quality. NBC bearings are accurately designed and recognised worldwide for their reliability and excellence. It’s also important to choose the right bearing for your specific application, you can reach out to an NBC application engineer to ensure you make the best selection for your renewable energy needs.

FAQ's

What type of bearing is used in a hydro turbine?

Thrust bearings or plain bearings are most commonly used in a hydro turbine.

What type of bearing is used in a power plant?

Hydrodynamic bearings are mostly used in power plants.

What is a turbine bearing?

Turbine bearings are bearings fitted in turbines of hydropower plants. Turbines are fitted with thrust or plain bearings.

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Blog

The Critical Role of Bearings in Drones and UAVs

The Rise of UAVs and Drones

We have always heard – bearings are a vital component of industrial machinery, motors, and engines, utilised to minimise friction and allow for smooth rotation. While this is true, bearings are far more important, and the application of these crucial components is just not limited to machines. In reality, bearings are essential to nearly every moving system, from heavy industrial machines to precision surgical robots. Their role goes beyond just reducing friction; they support motion, precision, reliability, and efficiency, making them a vital part of traditional and emerging technologies. Talking about emerging technologies, bearings are now widely being used in medical devices, renewable energy, robotics & automation, and more. One such emerging area where bearings are playing a role is drones and UAVs.

The Rise of UAVs and Drones

The Rise of UAVs and Drones

Drones and UAVs are being used extensively, from being used in the military to being used in industries like logistics, agriculture, surveillance, filmmaking, disaster management, and more. According to a report by Statista, the revenue in the drone market worldwide amounts to US$4.4bn in 2025. Now, these drones and UAVs, in order to function efficiently, require high-precision bearings that can withstand high rotational speed, rapid directional change, vibrations, and harsh conditions, increasing the demand for precision bearings.

Sector

Use of Drones

Agriculture

Utilised in crop monitoring, spraying & soil analysis.

Logistics

Aids with parcel drops & last-mile deliveries.

Defence & Surveillance

Utilised in tactical operations, patrolling, etc. 

Media & Filmmaking

Needed for cinematography, aerial photography, etc. 

Disaster Response

Aids supply drops, aerial assessment, etc. 

Role of Bearings in Drones & UAVs

Bearing has an important part to play in drones & UAV systems for proper and smooth working. Drone motors and control systems are generally equipped with bearings. Bearings have an important part to play in this system, including:

  • Smooth Motor Movement: The main function of a bearing is to enable effective power delivery. Drones & UAVs are typically equipped with brushless motors, and bearings are an integral part of these motors. Bearings assist the rotor to rotate smoothly, reducing vibration, and wobble.
  • Precision Movement: Drones and UAVs are fitted with control systems that manage the movements of these appliances. Bearings are an essential part of the control system, ensuring precise and responsive movement, allowing the drone to manoeuvre accurately.
  • Minimise Vibration & Noise: Precision-made bearings reduce vibration & friction-related noise resulting in quiet operation and help maintain the accuracy of its flight.
  • Durability: Drones operate at extreme high-speed and at harsh conditions. Bearings fitted in drones and UAVs are built to handle extreme rotation and dampen vibration, enhancing motor’s efficiency and reducing the chances of failure.

Types of Bearings Used in Drones and UAVs

Types of Bearings Used in Drones and UAVs
  • Ball Bearing: Ball bearing is most commonly utilised in drone’s & UAVs motors, propellers, and gimbals. Ball bearing plays an important part in supporting the axial and radial load facilitating smooth rotation of moving components. Motor in drones and UAVs spin at extremely high speed producing friction and heat, ball bearing minimises friction and heat and promotes smooth & efficient operation.
  • Roller Bearing: Roller bearings, such as tapered roller bearings and cylindrical roller bearings, are mostly utilised in drones, particularly drones designed for maximum heavy radial load capacity. Drones used in cargo delivery, spraying for agriculture, or military operations incorporate roller bearings owing to their maximum load capacity.
  • Ceramic Bearing: Ceramic bearings are preferred type for drones with high-performance motors, racing drones, and drones operating in harsh conditions. Ceramic bearings offer good resistance to heat, corrosion, and wear.
  • Thrust Bearing: Thrust bearings are used in drone & UAVs systems to support axial loads. Thrust bearing manages stability and premature wear of components.
  • Angular Contact Bearing: Angular contact bearing is used to handle both radial and axial loads. These bearings are designed to provide better load handling & stability. Angular contact bearings are used in high-speed and heavy lift drones.

Drone Components Where Bearings Are Used

Bearings are vital parts of drone systems and are employed in numerous parts, such as:

  • Drone Motors: Motors in drones are equipped with bearings, commonly ball bearings. Bearings in motors bear the drone rotor, reduce friction, and facilitate smooth rotation of components.
  • Rotors & Propellers: Bearings are installed in propeller assemblies to facilitate even and stable rotation of the propeller.
  • Camera Gimbals: Bearings are installed in camera gimbals, mainly miniature or precision bearings, allowing smooth movement of the camera.
  • Payload Mechanism: Drones designed to carry heavy loads are fitted with bearings to help in the controlled release or transport of goods.
  • Landing Gear: Bearings in landing gears are used to cater for loads during takeoff and landing.

Industry Applications of Bearings in Drones

Industry Applications of Bearings in Drones
  • Agriculture: Drones are now being used widely in the agriculture field, specifically for spraying, crop monitoring, field mapping, soil analysis, and more. Bearings are used in motor systems of these drones and built to resist dust and moisture.
  • Surveillance & Defence: Drones and UAVs are emerging as a key component of defence, serving a vital function in intelligence gathering, surveillance, reconnaissance, precision strikes and so forth. Bearings employed in these drones & UAVs are extremely robust and are made to function in harsh conditions.
  • Filmmaking & Media: Drones deployed in media & filmmaking are fitted with precision bearings to provide smooth, shake-free camera movement. Bearings employed here are designed to dampen operation noise.
  • Logistics & Delivery: Drone are now an integral part of the logistics and delivery industry. Bearings in these drones are designed to endure safe flight operation for accurate parcel drops.
  • Infrastructure: Drones used in detailed visual inspection of infractures are fitted with bearings responsible for stable flight around structures like bridges and towers.

Selection of the Right Bearings for Drone Application

  • Application: Choose bearing based on the drone type & operating conditions.
  • Load & Speed Requirements: Ascertained load & speed requirements before choosing a bearing as it must support high RPMs & handle axial or radial loads.
  • Material Selection: Bearing material must be chosen based on requirement, ex: ceramic bearings are lightweight, stainless bearings are corrosion resistant.
  • Precision & Low Friction: Bearing should be chosen based on precision requirements, high precision drones require high-precision bearings.
  • Shock & Vibration Resistance: Bearings must be chosen to absorb mechanical shocks from take-off, landing, and during operation.
Categories
Press Release

NBC Bearings reinforces sustainability leadership by publishing Environmental Product Declarations for its range of bearings

~ NBC becomes the first Indian bearing manufacturers to issue EPDs, strengthening its commitment to transparency and global ESG standards ~

Jaipur, 3rd June 2025 – National Engineering Industries Ltd. (NEI), manufacturer of the NBC brand of bearings and part of the The CKA Birla Group, an Indian multinational conglomerate with a multibillion-dollar revenue, has announced the successful publication of Environmental Product Declarations (EPDs) for eight different types of bearings.

An Environmental Product Declaration (EPD) is an independently verified and standardized document that transparently reports a product’s environmental impact throughout its life cycle—from raw material extraction to manufacturing, usage, and end-of-life disposal. NBC’s EPDs follow globally accepted protocols, including ISO 14025 and EN 15804, and are registered with the International EPD® System.

This initiative is a key milestone in NBC’s ongoing efforts to embed sustainability across the value chain and support global customers in meeting their ESG and Scope 3 reporting requirements. With these EPDs, NBC Bearings joins a select group of global bearing manufacturers to offer verified life cycle data for their products.

Rohit Saboo, President & CEO, NEI, said, “We believe that true sustainability begins with transparency. By publishing EPDs for our bearings, we are empowering our customers with credible data to make responsible choices and reduce their carbon footprint. This initiative not only strengthens NBC’s position as a responsible engineering partner but also prepares us to participate in green supply chains across the world.”

These declarations are not just tools for transparency — they also serve as a roadmap for internal product and process improvements, helping identify high-impact materials, reduce waste, optimize energy use, and support sustainable procurement by OEMs and industrial customers globally.

NBC Bearings’ sustainability roadmap includes adopting clean energy, improving manufacturing efficiency, supporting green transportation, and contributing to circular economy principles through initiatives like bearing remanufacturing.

About National Engineering Industries Ltd (NBC Bearings)

Founded in 1946, National Engineering Industries Ltd (NBC), is an integral part of the CKA Birla group (formerly the CK Birla Group) and manufacturer of the NBC brand of bearings. CKA Birla Group is today a multibillion-dollar diversified conglomerate with over 35,000 employees and 50+ manufacturing facilities across India and the world, with a presence in diverse sectors including technology, automotive, home and building and healthcare. NBC is India’s leading manufacturer and exporter of bearings with manufacturing capacity of 250 Mn bearings annually in over 3100+ variants for application across automotive, railways, aerospace and industrial segments to serve customers in more than 30 countries. It also serves the Indian aftermarket through a countrywide network of over 550 authorized stockiest and thousands of retailers.

Headquartered in Jaipur, NBC is the only bearing manufacturer in the world to win the prestigious Deming Grand Prize (2015). With an employee strength of over 3,000 and five manufacturing plants in Jaipur (2), Bagru (Rajasthan), Newai (Rajasthan) and Vadodara (Gujarat), NBC is equipped with global manufacturing and process technology and has one of the best R&D centers in India. Apart from being technologically advanced, the company practices methods of sustainability by using alternate sources of energy and increasing the efficiency of the manufacturing process by leveraging on the power of digitization.

In 2020, National Engineering Industries Ltd, acquired Kinex bearings in Europe through its subsidiary NBC Global Ag, to enhance, diversify and provide best-in-class products to its existing and potential customers. In 2022, NBC Global Ag opened its Global Technology Centre in Germany to support innovation and provide support to NBC’s global growth.

In 2024, NBC Bearings has ventured into the aerospace segment, leveraging its precision engineering expertise to support India’s growing ambitions in aviation and space technologies.

For details, visit: https://nbcbearings.com/

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The Role of High-Speed Bearings in Powersports and High-Performance Engines

Role of High-Speed Bearings in Powersports

Powersports refers to motorised vehicles used for motorised vehicles used for recreation or competition. These vehicles are fitted with high-performance engines as they need to handle tough terrains and extreme conditions. Though these big and high-performance engines play a key role, a lot of supporting systems and components work together to bring out the full potential. A key component that plays a vital role is the high-speed bearing. These bearings are specifically designed to work under high-speed conditions.

These bearings are crucial for the engine’s performance, ensuring smooth rotation even at high speeds. They’re specially crafted to handle the tough demands of powersports applications, allowing for seamless rotation at high RPMs while also withstanding extreme stress and heat.

Spinning Car Wheel

Standard bearings are not the recommended/used in high-performance engines or powersports engines to several reasons including:

  • Increased Friction: Using a standard bearing in high-performance engines can lead to excessive friction & potential seizure as these engines produce more head and friction than standard engines.
  • Material Limitation: Standard bearings are not made of strong material or are heat resistant as high-performance bearings. Thus, it can lead to premature wear and failure.
  • Lubrication Issues: Standard bearings may not be able to handle lubrication requirements of a performance engine and it can lead to friction, wear, and failure.
  • Low Performance: Standard bearings are not designed in a way to bear the extreme operation stress. They may wear out quickly or fail resulting in decreased performance and reduced power output.

Specially made speed bearings are installed in performance engines to provide the strength accuracy and longevity necessary for seamless operation. Using a standard bearing in these engines can definitely be a recipe for disaster.

Benefits of Using High-Speed Bearings in Racing & Powersports

When it comes to racing and powersports all we tend to imagine is extreme speed, roaring engines, adrenaline-pumping speed, and machines pushed to their absolute limits. Though this is all true, a crucial role is also played by components fitted including the precision-engineered bearings. These bearings are unsung heroes that have an impact on performance, reliability, and efficiency.

The key benefits of using high-speed bearings in racing & powersports includes:

Benefits of Using High-Speed Bearings
  • Support Extreme RPMs: High-speed bearings are specifically designed to handle ultra-high speed without failing. These bearings are usually fitted in engines, gearboxes, and other components spinning at 10,000+ RPMs.
  • Heat Resistance: High-speed bearings are made from advanced materials and coatings tolerate higher operating temperatures. These bearings also include advanced cooling features or made from materials that dissipate heat faster. 
  • Reduced Friction: High-speed bearings are crafted from low-friction materials that minimise energy loss, allowing for more power to be transferred to the wheel. This ultimately leads to improved performance.
  • Better Stability: High-speed bearings maintain tight tolerance at extreme speed leading to smoother operation, better handling, and less vibration.
  • Lightweight Design: Ceramic or hybrid materials are commonly used in high-speed bearings. Ceramic or hybrid made bearings provide the bearing the strength it requires to cater extreme conditions without excess weight.

Types of High-Speed Bearing

Various types of bearings are designed to handle the intense demands of high performance engines.

Ball Bearings

High-speed ball bearings are known for their ability to provide low-friction rotation, even at very high speeds. Ball bearings are generally fitted in gearboxes, electric starters, turbos, crankshafts and various other components in racing and powersports engines.

Single Row Deep Groove

Roller Bearings

Roller bearings, such as needle roller bearings and tapered roller bearings, are widely utilised in powersports engines. These bearings manage heavy loads and absorb vibrations effectively.

Single Row Cylindrical Roller Bearing

Thrust Bearings

Thrust bearings are prominently used in powersports engines, especially in clutches and crankshafts. These bearings are manufactured in a way to absorb axial forces and ensure the crankshaft stays properly aligned.

Thrust Ball Bearings

Ceramic Hybrid Bearings

Ceramic bearings are most widely used in powersports engines. These bearings are preferred as they are extremely lightweight and have heat resistant properties. Ceramic bearings are fitted in turbos, wheel hubs, and other high-speed rotating parts.

Hybrid bearings

Selection of Right High-Speed Bearings

Finding the right type of bearing for powersports and racing engines is important as a mismatch can cause faster wear, lower output and failure. A high-speed bearing must match the engine’s load, speed, environment, and lubrication system. There are several factors to consider when it comes to selecting the right bearing for high-performance engine including:

  • Operating Speed: The bearing for racing and powersports engines must be chosen based on the speed rating of the bearing. Choosing a high-speed rated bearing ensures smooth operation at extreme RPMs without overheating or vibrations.
  • Load: Before selecting a bearing for a high-performance engine the load requirement on the engine must be considered. Selection basis the load requirement ensures bearing handle load without failing.
  • Material: The material of high-speed bearing determines its strength, heat resistance, and wear properties. Bearings made of ceramic and hybrid materials are usually preferred for high-speed bearings.
  • Environmental Exposure: Exposure to environmental factors like dirt, mud, sand, water should also be considered before selecting a high-speed bearing. If there’s exposure to dust, dirt, mud, sand, etc a sealed, corrosion-resistant, or coated high-speed bearings should be preferred.

Installation of High-Speed Bearings

Installation of High-Speed Bearings

Installation of high-speed bearings must be done with accuracy to allow a good fit, alignment, and avoid premature failure. The key to installation is having the right tools and following the manufacturer’s recommendations. There are a number of ways the bearings can be fitted. Different techniques of installation depends on the type of bearing and installation location such as press fit installation, thermal expansion installation, slip fit installation, among others.

  • Preparation: This is the first step in the installation and involves cleaning the work area including bearing housings, shafts, and surrounding surfaces.
  • Inspection: The second step involves inspecting the fitment areas and checking the shaft and housing to ensure exact fit within manufacturer tolerances.
  • Installation: Post cleaning and inspecting the area the high-speed bearing can be precisely installed. The bearing can be installed through several techniques including press fit installation, thermal expansion installation, etc.
  • Lubrication & Coating: Post fitment lubrication should be applied before assembly. High-speed bearing grease or manufacturer recommended lubricant should be used.
  • Alignment: The step involves checking the bearing’s seating and alignment, misaligned bearings can lead to uneven loading and heat buildup.
  • Post-installation Run: During the post-installation run listen for any unusual sounds, check for oil pressure and leaks.

The Role of Lubrication in High-Speed Bearings

Lubrication is crucial for high-speed bearings, it helps prevent wear, reduce friction, and dissipate heat. Periodically lubricating high-speed bearing also contributes to performance by ensuring smooth operation and maintains bearing’s integrity especially in high-speed application. Some of the benefits of lubrication includes:

Role of Lubrication

Impact

Reduced Friction

Periodic lubrication or lubrication as per manufacturer guidance minimises metal to metal contact & reduces wear.

Heat Dissipation

Adequately lubricated high-speed bearing prevents overheating & bearing failure.

Corrosion Protection

Applying lube coats the surface & prevents oxidation leading to enhanced durability in harsh conditions.

Protection During Startup

Lubrication protects against dry friction during engine start reducing early wear.

Support Load Capacity

Properly lubricated bearings helps distribute engine loads evenly & handle dynamic loads.

Lubricants for racing & powersports engines must be chosen based on compatibility with the engine type, as it is important for optimising engine performance and longevity in racing. Synthetic lubricants, racing specific lubricants, or manufacturer recommended lubricant should ideally be used.

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Optimize V-Belt Performance: Maintenance and Lifespan Tips

Maintain Tension & Alignment

V-belt is a crucial component of machinery used to transmit power between different parts of the machine. These flexible elements are usually made of rubber or synthetic materials like neoprene or polyurethane. V-belt is a trapezoidal shape that ensures a secure fit into the shaft’s sleeves. These belts are designed by compressing various fibrous tensile cords for strength and longevity.

Maintain Tension & Alignment

V-belts, due to their trapezoidal cross-sectional shape, provide a better grip on the pulley than flat belts. The V-shaped wedges into the pulley groove lead to better traction and reduced slippage. These mechanical belts are widely used in industrial machinery, automotive engines, agriculture equipment, and more.

The Role of V-Belts in Machinery

Optimize V-Belt Performance

The efficiency of any machinery doesn’t just depend on the big visible parts like motors or engines but it also depends on smaller components like bearings, bushings, pulleys, v-belts, and more. One such important component of these machines is the V-belt.

  • Power Transmission: These belts are crucial for transmitting power from one rotating component of the machinery to another. In conveyor systems v-belt connects the motor with a drive pulley which further moves the conveyor belt.
  • Maintain Tension & Alignment: V-belts also play a role in maintaining constant tension and alignment with the pulleys which helps prevent slippage and ensure smooth power transfer.
  • Shock Absorption: These flexible belts help damp vibrations and absorb shocks caused due to sudden jerks or uneven loads. In agricultural machinery, v-belts play a key role in reducing jerks and protecting the drive system.
  • Maintains Efficiency: V-belts help maintain efficiency by minimising slippage and reducing energy loss.

Common Causes of V-Belt Failure

Various factors may lead to premature failure of these mechanical belts including incorrect tension, misalignment of pulleys, environmental factors and more. Some of the most common causes of v-belt premature failure

Common Causes of V-Belt Failures
  • Improper Tensioning: Improper tensioning of the v-belt, i.e. too tight tensioning can strain the bearings and the belt, while too loose tension can lead to slippage & heat buildup resulting in quick wearout or breaking of the belt.
  • Misaligned Pulleys: Unaligned pulleys can cause the belt to twist and wear unevenly leading to increased vibration, noise, and premature failure.
  • Excessive Heat: The V-belt may get worn out quickly due to excessive heat causing the belt material to weaken and degrade weakening the belt structure and resulting in belt failure.
  • Wrong Belt Type: V-belts are not one-size-fits-all and one size is not suited for all application types. Using the wrong belt type can reduce efficiency and lifetime.
  • Other Factors: Exposure to oils, grease, chemicals, and others can degrade the belt’s rubber and can even cause the rubber to slip resulting in premature failure.

V-belt is a widely used mechanical component, from applications in big mechanical systems like conveyors, compressors, crushers, and pumps these are also used in fans, mixers, screens, and more. However, selecting the right V-belt is absolutely critical for both performance and reliability.

Types of V-Belts

There are various types of v-belts designed for different applications. Some of the common types of v-belts include:

  • Standard or Classical V-Belt: This type of v-belt is also referred to as classical, standard or conventional belts. Standard v-belt is used in a wide range of general-purpose machinery like pumps, compressors, etc. The dimensions of standard v-belts are designated as Y, Z, A, B, C, D, and E.
  • Wedge V-Belt: Wedge v-belt is designed for high-speed and high-torque transmission. They can operate 1.5 to 2 times the load of classical v-belts. Wedge v-belt is commonly fitted in crushers, mixers, industrial gearboxes, and more.
  • Narrow V-Belt: Narrow v-belt as the name implies has a narrower profile but transmits more power than classical belts. Narrow v belts are ideal for compact & high load systems including heavy-duty fans, HVAC systems, industrial drives, etc.
types of vbelt
  • Double or Hexagonal V-Belt: This type of v-belt is shaped like a hexagon and is designed to transmit power from both sides of the belt. A double v-belt can drive multiple pulleys in opposite directions. Textile machinery and agriculture equipment are equipped with this type of belt.
  • Banded V-Belts: Also known as joined v-belts multiple v-belts joined together. This type of v-belt is used in high-power or heavy-duty applications like stone crushers, large fans, and more.
  • Cogged V-Belt: Cogged v-belts are similar to classical belts but they have cogs or notches at the bottom side. Smaller pulleys, automotive, and woodworking machines are usually equipped with cogged v-belts.
  • Agricultural V-Belts: Agricultural belts are wrapped belts designed for more extreme abrasion from dust, sand, grains, and more. This type of belt is made of durable polyurethane blends to cater to harsh working environments.

Factors to Consider While Selecting V-Belts

Now, when it comes to longevity & durability several factors play a key role in enhancing efficiency and avoiding premature failure. Also, finding the right fit guarantees performance, durability, and safety. Some of the key factors to consider include.

Factors What to Consider
Load Requirements Power to be transmitted, i.e. heavier tabs require stronger belts.
Speed in RPM For higher speed, belts that support higher speed are required. Like narrow or wedge belts.
Centre Distance The distance b/w the pulleys affects belt length & tension settings
Operating Environment Belts made of higher grade must be chosen if there is exposure to dust, oil, moisture, etc. Ex: agricultural v-belt.
Space V-belts must be chosen based on application space, if space is limited narrow V-belts are preferred.
Temperature Choose belts based on operating temperature, if operating temperature is more choose belts made to support such temperature.

V-Belt Installation Techniques

Proper installation of a v-belt is essential for ensuring long belt life, proper tension, and safe operation. The installation of v-belts involves the steps mentioned below:

Step 1 – Check Pulleys: The first step in the installation is to check the pulleys thoroughly. The process involves identifying signs of damage and detecting worn-out parts. A damaged or worn-out pulley component may reduce v-belt life, cause slippage of the belt, reduce power transfer, and lead to vibrations.

Step 2 – Check Alignment: Check the alignment using a straight edge or laser alignment tool. Misalignment can lead to premature wear.

V-Belt Installation Techniques

Step 3 – Loosen Tension Mechanism: Loosen the mounting bolts or tensioner to allow belt fitting.

Step 4 – Fit the V-Belt: Place the belt into the pulley groove without twisting or stretching.

Step 5 – Apply Correct Tension: Use a belt tension gauge or follow the manufacturer’s guidelines for correct tension and ensuring safety.

Step 6 – Tighten & Recheck: Secure the bolts and tensioners and re-check the alignment and tension.

Step 7: Run a Test Cycle: Turn the power on and run it briefly. Check for unusual sounds, vibrations, and belt movements.

Step 8: Monitor After Installation: Recheck the belt tension after a few hours of operation, the belt may require tightening as it often stretches slightly.

Routine Maintenance Tips to Extend V-Belt Life

Periodic maintenance of v-belts is key to keeping machinery efficient, reducing downtime, and extending belt life. The maintenance procedure involves

  • Visual Inspection: Visual inspection can be done weekly or as per the manufacturer’s guidelines. The process involves inspecting for cracks, fraying, glazing, etc.
  • Check Belt Tension: Belt tension can be checked every 2 weeks or as per the manufacturer guidelines by using a tension gauge or deflection method.
  • Check For Alignment: Alignment can be checked monthly using a straight edge or laser.
  • Clean the Drive Area: The drive area must be cleaned regularly including removing dust, oil, debris, and chemical buildup.
  • Listen to Noise: Check for unusual sounds during operation as it may indicate slippage or misalignment.
  • Check For Vibration: Vibrations during operations can be checked at monthly intervals, excessive vibration may indicate a loose belt or misalignment of components.
  • Replace: If there are signs of wear, cracks or damage it is recommended to replace the belt.

Common Causes of V-Belt Failure

V-belt failure can result from several factors, improper tension and misalignment are the most frequent causes of V-belt failure. Some other causes of v-belt failure include:

  • Improper Tension
  • Pulley Misalignment
  • Worn Pulleys
  • Wrong Belt Size
  • Contamination
  • Overheating
  • Aged/Cracked Belts

When to Replace a V-Belt?

Replacing a v-belt is essential for maintaining the smooth, safe, and efficient operation of the machinery. V-belt should be generally replaced every 1 to 3 years or as per the manufacturer’s guideline or when signs of wear and damage like cracks, missing chunks, or squealing are present. A few factors that determine if a V-belt needs replacement include:

  • Age: V-belts should be replaced every few years, especially if there’s heavy usage or extreme temperatures.
  • Visual Inspection: If there are signs of damage, cracks, or excessive wear.
  • Squealing Noise: A squealing or chirping noise could also indicate that the belt needs replacement.
  • Manufacturer’s Recommendations: The belt should also be replaced according to the interval recommended by the manufacturer.
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Wind Turbine Bearings: Enhancing Efficiency in Renewable Energy

Bearing Technologies for Wind Turbines

Bearings are an indispensable part of almost all industrial machinery, household appliances, automobiles, construction equipment, and nearly everything – that has a moving part. From the smallest applications in fidget spinners to utilisation in wind turbines, bearings are everywhere.

Wind power is expanding globally due to increasing environmental concerns, technological advancements, government policies, cost-effectiveness, and more. Wind power is generated by wind turbines, which are gigantic machines equipped with a rotor hub. These turbines can weigh over 200 tons and are fitted with bearings to support the rotating shaft and allow the turbine to operate smoothly. Several types of bearings are used in wind turbines including, spherical roller bearings, tapered roller bearings, cylindrical roller bearings, deep groove ball bearings, and more.

Wind Turbine Bearings

India’s wind energy sector accounts for 10.5% of total power generation, additionally, India aims to generate 50% of the electricity from green sources by 2030. The growth and expansion are highly dependent on the wind energy sector and necessitate the need for high-quality bearings that can sustain high loads, dynamic loads, and more.

Role of Bearings in Wind Turbine Efficiency

Role of Bearings in Wind Turbine Efficiency

Wind turbines are equipped with various bearings used in each section including the pitch and yaw location, main shaft location, and gearbox. These bearings are responsible for the efficiency, reliability, and lifespan of wind turbines. Bearings play a crucial role in ensuring smooth power transmission and supporting the rotating components. The impact of bearings on wind turbine efficiency includes:

  • Reduce Friction: The primary role of bearing in wind turbines is to reduce friction between the moving parts, leading to reduced energy loss and improved overall efficiency.
  • Load Support: Bearings in wind turbines play a crucial role in supporting wind turbines as they operate under fluctuating loads due to speed variations. Bearings play an essential role in distributing the load evenly resulting in stable operation.
  • Support Rotation: Bearings are fitted in the rotor and gearbox and ensure smooth rotation and efficient power transmission. High-quality bearings are critical for optimum turbine efficiency and lifespan.

Types of Bearings Used In Wind Turbines

Several types of bearings are fitted into wind turbines to perform different functions. Here is a rundown of some of the most common bearings within wind turbines:

Cylindrical Roller Bearing

Such bearings are widely preferred for gearboxes and generators. Cylindrical roller bearings are designed to handle high-radial loads generated by the turbine’s gearbox and generator making it ideal for demanding conditions.

cylindrical roller bearing brass

Spherical roller bearings

Spherical roller bearings are usually found in the main shaft of the turbine. These bearings are designed to handle high-radial and axial loads at low to medium speeds.

Spherical roller thrust bearings

Tapered Roller Bearing

Tapered roller bearings are fitted in wind turbines to handle tilting movements. These bearings are usually custom-designed and are commonly used in gearboxes to handle high vibration levels.

Taper Roller Bearing

Deep Groove Ball Bearings

Commonly used in generators and electric motors to handle medium to high radial and axial load, deep groove ball bearings hold weight in loads in both directions.

Single Row Deep Groove

Bearing Technologies for Wind Turbines

Bearing Technologies for Wind Turbines

Wind energy is emerging as a significant source of clean electricity. Wind turbines are fitted with various components that allow for effective energy generation, one such crucial component is the bearing system. The bearings fitted in wind turbines operate under extreme conditions including:

  • High Loads (rotor weight, dynamic load due to wind speed variations)
  • Harsh Environmental Conditions (temperature variations – deserts, arctic regions)
  • Maintenance Challenges (remote locations and size of wind turbines)

However, the wind turbine sector continues to expand necessitating the need for further improvements in the bearing technology.

Technologies Used in Wind Turbines

  • Coating: Bearing technologies like black oxide coating help prevent components from corrosion and other environmental damages, thus enhancing lifespan.
  • Monitoring Tool: Allows for monitoring and predicting issues before complete failure impacting operation. Monitoring technology reduces the risk of damages, increases turbine uptime, and allows for planned maintenance.
  • Lubrication: Bearing technologies like self-lubricating bearings and lubricants resistant to corrosion and wear limit friction and increase the overall life of bearings.

Maintenance of Wind Turbine Bearings

Maintenance of Wind Turbine Bearings
  • Lubrication Management: Lubrication plays a key role in the maintenance of wind turbine bearings. Greasing at periodic intervals and using high-quality lubricants formulated for extreme temperatures minimises friction and wear.
  • Inspection: Bearings must be checked for damages, cracks, and scoring during routine maintenance. Additionally, temperature and vibration monitoring may be performed to check for misalignment, overheating issues, etc.
  • Predictive Maintenance: Tools like advanced monitoring systems help predict bearing damage or failure based on vibration patterns, wind speed, and temperature trends. Predictive maintenance techniques eliminate unexpected breakdowns of wind turbines.
  • Replacement: The bearings in wind turbines must be replaced on their expected lifespan or when there’s a sign of wear or damage. Additionally, proper installation with specialised tools must be done to avoid misalignment and premature failure.

FAQ's

What are the bearings used in wind turbines?

Several types of bearings are used in wind turbines including cylindrical roller bearings, tapered roller bearings, deep groove ball bearings, etc.

What 2 types of bearings are in a turbine engine?

Spherical roller bearings and cylindrical roller bearings are most commonly used in turbine engines.

How long do wind turbine bearings last?

The lifespan of turbine bearings depends on various factors including operational environment and maintenance. Usually wind turbine bearings last 20 years.

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Self-Lubricating Bearings: A Maintenance-Free Solution

Self-Lubricating Bearings

Self-lubricating bearings, also referred to as maintenance-free bearings lubricate on their own while operating. The bearings are impregnated with lubricants within the sliding layer or pores and as the bearing operates lubrication is released through the pores in the sliding layer.

Self-lubricating bearings are preferred over traditional bearings when lubrication is difficult or costly.

Additionally, these bearings offer several benefits including:

  • Eliminating periodic lubrication reduces maintenance effort and downtime.
  • Longer bearing life and less wear as a result of regular lubrication.
  • Designed for extreme operational conditions where external lubrication is impractical (extremely high or low temperature)
Self-Lubricating Bearings

How Self-Lubricating Bearings Work ?

Self-lubricating bearings continuously supply lubrication while the bearings operate to reduce friction between the moving parts. They are designed to release lubrication gradually during operations. The working of self-lubricating bearings include:

  • Storage: Self-lubricating bearings usually contain lubrication within their structure. Bearings made out of polymer, and porous metal contain lubricants within the structures, while bearings made out of metal contain lubricants in the tiny pores.
  • Release: When the bearing is in motion, the heat and pressure causes the lubricants to mitigate to the surface, creating a lubricating film and reducing friction and wear.
  • Reabsorption: Post-bearing operation, the lubrication gets reabsorbed into the bearing material, avoiding wastage and extending service life.
  • Continuous Process: The process of releasing and reabsorption is a continuous process ensuring a long-term, maintenance-free operation.

A common misconception about self-lubricating bearing is that it does not require additional lubrication throughout the life or they are lubed for life. However, the lubrication eventually runs out, the lubrication is used and needs to be replaced. The bearings are lubed for a long time, not for a lifetime.

Self-Lubricating Technology in Plain Bearings & Bushings

The word self-lubricating is mainly linked with bushing and plain bearings as they are designed to function without the need for any additional or external lubrication. In both areas of application, self-lubrication enhances durability, reduces maintenance needs, and improves performance. Self-lubricating plain bearings and bushings are widely used in automotive components, industrial machinery, medical devices, aerospace, and more.

  • Plain Bearings: These bearings are designed from oil-impregnated metals, PTFE, graphite-lined surfaces, and more. These bearings are known to reduce friction and wear without the need for external lubrication. conveyor belts, precision instruments, robotic arms, hydraulic systems, etc are fitted with self-lubricating plain bearings.
Plain Bearings
  • Bushings: Bushings are small tube-shaped bearings designed to help parts move smoothly. Bushings are usually made from materials like oil-impregnated bronze or PTFE, which release lubrication as they rotate.

Types of Self-Lubricating Bearings

Self-lubricating bearings are made out of different materials and designs depending upon the application and operating condition.

  • Metal-based Bearings: Metal-based bearings are the most commonly used self-lubricating bearings. These bearings are made out of bronze and designed with interconnected pores which store and release lubrication through capillary action during operation. Electric motors, industrial machines, and automotive parts are usually fitted with metal-based self-lubricating bearings.
  • Polymer-based Bearings: Polytetrafluoroethylene (PTFE), nylon, and other materials are used to make polymer-based bearings. Continuous low-friction operation is provided by the solid lubricants embedded in the material. Food processing industries, medical devices, etc all make extensive use of polymer-based bearings.
Polymer-based Bearings
Carbon-graphite Bearings
  • Carbon-graphite Bearings: These self-lubricating bearings are made out of carbon and graphite mixture. Carbon-graphite bearing is ideal for high-temperature & chemical resistant applications. These types of bearings are used in pumps, steam turbines, and chemical processing equipment.
  • Sintered-metal Bearings: Sintered-metal bearings are based on powder-metallurgy technology. It is one of the sliding bearings with high porosity (20-25% in volume), impregnated in a lubricant oil. Sintered metal bearings are suitable for high production rates and are designed to precision tolerances. These bearings are widely fitted in small motors, machine tools, aircrafts, automotives, construction equipment, etc.
Sintered-metal Bearings2

Bimetallic Bearings: A bimetallic bearing is an oil free lubricating bearing. The bearing is based on a steel backing, and the surface is sintered with led-tin bronze alloy.The steel backing in such bearings provide strength and rigidity. Such bearings are widely preferred for high load capacity, have good chemical resistance, and can sustain a wide range of temperatures.

Bimetallic Bearings

Solid Oil Bearing: Solid oil bearings are filled with a solid, porous resin that is impregnated with lubricating oil. As the bearing rotates the lubricant is released through capillaries to ensure its smooth running. This type of bearing is used where there is high centrifugal force or vibration.

Benefits of Using Self-Lubricating Bearings

  • Lower Maintenance Requirement: The key advantage of using self-lubricating bearings is that they do not require any additional oiling device or grease resulting in lower maintenance cost and reduced machine downtime.
  • Cost-Efficient: Using self-lubricating bearings reduces the need for labour costs, and eliminates the need for a lubrication system resulting in reducing overall operational cost.
  • Suitable for Harsh Environment: Self-lubricating bearings are designed to work in extreme temperatures, underwater, and other extreme conditions where traditional lubrication is impractical.
  • Extensive Lifespan: It’s a fact that bearings last longer if they are lubricated well. Self-lubricating bearings operate under continuous lubrication leading to minimal wear and reduced friction resulting in extensive bearing lifespan.
  • Clean Operation: Self-lubricating bearings are designed to avoid lubricant leakage thus making them ideal for food processing, medical devices, etc.
  • Smooth Operation: The continuous lubrication mechanism of self-lubricating bearings helps improve the overall operation of equipment or machines equipped with such bearings by reducing vibration and noise.

Applications of Self-Lubricating Bearings

Applications of Self-Lubricating Bearings
  • Automobile Industry: Self-lubricating bearings are commonly used in the automotive industry specifically in suspension systems, wiper motors, power windows, sunroof, etc. Self-lubricating bearings in automobiles ensure reduced maintenance and longer service life.
  • Aerospace & Defence: Self-lubricating bearings are designed to work in extreme conditions and, therefore, are preferred in aircraft’s landing gear, doors, and control systems.
  • Textile & Printing Machines: The bearings are designed to be dust and lint-resistant thus avoiding clogging and failure. In the textile and printing industry with continuous production lines where stopping for lubrication is impractical, self-lubricating bearings are preferred.
  • Industrial Machinery: Self-lubricating bearings are designed for high loads, harsh environments, and continuous operation without frequent maintenance, thus making it a preferred bearing for conveyors, pumps, and gearboxes where frequent lubrication is difficult.

Self-Lubricating Bearings vs. Traditional Bearings

  • Requirement for Lubrication: While traditional bearings need to be lubricated on a regular basis, self-lubricating bearings have lubrication built in and don’t require periodic lubrication.
  • Maintenance: Regular maintenance including lubrication, cleaning, and inspection is required for traditional bearings, whereas self-lubricating bearings have low maintenance requirements thus reducing machinery downtime.
  • Durability: The durability of bearings is heavily impacted by lubrication. Therefore in traditional bearings, the risk of premature failure is higher if they are not adequately lubricated whereas self-lubricating bearings are constantly lubricated which lowers wear and friction leading to increased durability.
  • Operating Conditions: Self-lubricating bearings are designed to work in extreme temperatures, wet environments, etc while traditional bearings to work in extreme conditions require frequent lubrication and maintenance.
  • Load Handling: Traditional bearings are designed to handle extreme loads effectively while self-lubricating bearings have lower load handling capacity.
  • Friction: Since self-lubricating bearings are under continuous lubrication, there’s low friction and reduced energy consumption, whereas traditional bearings can have higher friction if not properly lubricated.

FAQ's

What are lubricant-free bearings?

Other names for self-lubricating bearings include greaseless lubricant-free and maintenance-free bearings.

Do self-lubricating bearings last long?

The operating load, temperature, and bearing application environment all have an impact on a self-lubricating bearing’s lifespan.