Bearings, which are key to the rotational movement of heavy machinery such as cranes and excavators, are expensive and have long delivery times when replaced. Regeneration is a cost-effective, fast and environmentally friendly alternative that can save 40-70% of the cost of a new bearing and reduce delivery times by up to 80%. FA.RE.MEC s.r.l., based in Fontaneto d’Agogna, Italy, has advanced its regeneration technology with state-of-the-art laser measurement equipment and control systems to provide a full range of bearing remanufacturing services.
The regeneration process begins with a detailed assessment of the bearing’s condition. Bearings removed before severe wear are ideal candidates. FA.RE.MEC performs a thorough inspection, creating a detailed report to determine the level of regeneration:
- Level 1: Bearings are disassembled, checked for damage from improper storage, cleaned of oxidation, checked for dimensions and clearances, lubricated and packaged.
- Level 2: For moderately used bearings, the components are cleaned, lightly ground and inspected. If necessary, spacers, cages or seals are replaced, then clearances are checked, lubricated and packed.
- Level 3: Bearings that have reached the end of their theoretical service life or have abnormal clearances are subjected to a deep machining process, including raceway grinding, replacement of rollers, spacers or seals, and new induction hardening if necessary. Clearances and torques are measured, lubricated, packaged and, if desired, painted.
- Level 4: For severely damaged bearings, major components, such as the inner or outer ring, are replaced. This level incorporates the processes of level 3 and addresses problems such as gear tooth damage.
The assessment includes cleaning, inspection and disassembly of the bearing to analyse rings, rollers, spacers and seals. State-of-the-art tools are used, such as ultrasonic spectrometers to measure hardening depth and laser equipment for dimensional accuracy. If the bearing design does not match the loads, FA.RE.MEC’s technical team offers corrective solutions using SolidWorks for 3D modelling and FEA analysis to optimise clearances, preload and torque.
Regeneration reduces downtime, costs and environmental impact by lowering CO2 emissions and energy consumption compared to manufacturing new bearings. FA.RE.MEC’s expertise ensures that remanufactured bearings meet original performance standards, making regeneration an effective solution for extending service life.