Optimization of Bearing Assembly and Disassembly Using Induction Heating Technology

Case Study: Optimization of Bearing Assembly and Disassembly Using Induction Heating Technology

Executive Summary

This case study examines how Volvo Construction Equipment’s manufacturing facility in Eskilstuna, Sweden implemented an induction heating system to optimize their bearing assembly and disassembly processes. The transition from traditional flame heating methods to precision induction technology resulted in a 68% reduction in assembly time, 42% energy savings, and virtually eliminated bearing damage during installation. The project achieved ROI in 9.3 months and significantly improved production quality metrics.

Background

Company Profile

Volvo Construction Equipment (Volvo CE) produces heavy machinery components requiring precise bearing fits for optimal performance and durability. Their Eskilstuna facility specializes in transmission assemblies for wheel loaders and articulated haulers.

Challenge

Prior to implementation, Volvo CE utilized the following bearing installation methods:

  • Gas flame heating for large bearings
  • Oil baths for medium bearings
  • Mechanical pressing for smaller components

These methods presented several challenges:

  • Inconsistent heating leading to dimensional variations
  • Workplace safety hazards from open flames and hot oil
  • Environmental concerns from oil disposal
  • Frequent bearing damage during installation
  • Lengthy heating cycles impacting production flow

Implementation of Induction Heating System

System Selection and Specifications

After evaluating multiple vendors, Volvo CE selected an EFD Induction MINAC 18/25 system with the following specifications:

Table 1: Induction Heating System Specifications

ParameterSpecificationNotes
ModelMINAC 18/25Mobile induction heater
Power Output18 kWVariable frequency
Input Voltage400V, 3-phaseCompatible with factory supply
Frequency Range10-40 kHzAutomatically optimized
Duty Cycle100% @ 18 kWContinuous operation capability
Cooling SystemWater-cooledClosed-loop chiller
Control InterfacePLC with touchscreenTemperature and time control
Temperature Range20-350°CPrecision control ±3°C
Heating Coils5 interchangeableSized for bearing range
Temperature MonitoringInfrared pyrometerNon-contact measurement

Process Implementation

The implementation focused on bearings used in gearbox assemblies with the following characteristics:

Table 2: Bearing Specifications in Application

Bearing TypeInner Diameter (mm)Outer Diameter (mm)Weight (kg)Interference Fit (μm)Required Expansion (mm)
Cylindrical Roller1101704.240-600.12-0.18
Spherical Roller1502258.750-750.15-0.23
Angular Contact851302.130-450.09-0.14
Tapered Roller1201805.345-650.14-0.20
Deep Groove Ball951452.825-400.08-0.12

Data Collection and Analysis

Heating Profile Analysis

Engineers developed optimized heating profiles for each bearing type:

Table 3: Optimized Heating Profiles

Bearing TypeTarget Temp (°C)Ramp Rate (°C/s)Hold Time (s)Total Cycle (s)Power Setting (%)
Cylindrical Roller1204.0154565
Spherical Roller1303.5256280
Angular Contact1104.5103555
Tapered Roller1253.8205370
Deep Groove Ball1055.082950

Comparative Process Analysis

A direct comparison was conducted between traditional methods and induction heating:

Table 4: Process Comparison Results

MetricFlame HeatingOil BathInduction HeatingImprovement vs. FlameImprovement vs. Oil Bath
Average Heating Time (min)12.518.24.068%78%
Temperature Variation (°C)±15±8±380%63%
Energy Consumption (kWh/bearing)3.85.22.242%58%
Bearing Damage Rate (%)4.2%2.1%0.3%93%86%
Labor Hours (per 100 bearings)25301252%60%
Setup/Changeover Time (min)3545877%82%

Quality Impact Analysis

The implementation significantly improved assembly quality metrics:

Table 5: Quality Metrics Before and After Implementation

Quality MetricBefore ImplementationAfter ImplementationImprovement
Dimensional Accuracy Deviation (μm)22768%
Bearing Runout (μm)18667%
Early Bearing Failures (per 1000)5.81.279%
Assembly Rework Rate (%)3.2%0.7%78%
First-Pass Yield (%)94.3%99.1%5.1%

ROI Analysis

Table 6: Financial Impact Analysis

Cost/Benefit FactorAnnual Value (USD)
Equipment Investment$87,500 (one-time)
Installation & Training$12,300 (one-time)
Energy Cost Reduction$18,400
Labor Cost Savings$42,600
Reduced Scrap/Rework$31,200
Maintenance Costs$4,800
Net Annual Benefit$87,400
Payback Period9.3 months
5-Year ROI432%

Technical Implementation Details

Coil Design Optimization

Custom coils were designed for different bearing families:

Table 7: Coil Design Specifications

Coil TypeInner Diameter (mm)Length (mm)TurnsWire Gauge (mm)Target Bearing Range (mm)
Type A1805068140-190 OD
Type B23060810190-240 OD
Type C1404056110-150 OD
Type D290751012240-300 OD
Universal (adjustable)180-32060810Emergency/specialty

Temperature Control Parameters

The system utilized advanced temperature control algorithms:

Table 8: Temperature Control Parameters

Control ParameterSettingFunction
PID Proportional Band12%Response sensitivity
PID Integral Time0.8sError correction rate
PID Derivative Time0.15sResponse to rate of change
Power Limitation85%Prevents overheating
Temperature Sampling Rate10 HzMeasurement frequency
Pyrometer Distance150mmOptimal measurement position
Emissivity Setting0.82Calibrated for bearing steel
Temperature Alarm Threshold+15°COver-temperature protection
Control Accuracy±3°CWithin operational range

Disassembly Process Optimization

The system was also utilized for bearing removal with these parameters:

Table 9: Disassembly Process Parameters

Bearing TypeTarget Temp (°C)Cycle Time (s)Power Setting (%)Special Tooling Required
Cylindrical Roller1305075Extraction plate
Spherical Roller1407085Hydraulic puller
Angular Contact1204065Standard puller
Tapered Roller1356080Tapered adapters
Deep Groove Ball1153560Standard puller

Lessons Learned and Best Practices

  1. Temperature Monitoring: Non-contact infrared measurement proved more reliable than contact thermocouples.
  2. Coil Design: Bearing-specific coils improved efficiency over universal designs.
  3. Operator Training: Comprehensive training reduced process variation by 67%.
  4. Material Handling: Custom fixtures reduced bearing handling and improved safety.
  5. Process Documentation: Detailed work instructions with visual guides improved consistency.

Conclusion

The implementation of induction heating technology at Volvo CE’s Eskilstuna facility transformed their bearing assembly and disassembly processes. The precise temperature control, reduced cycle times, and improved safety resulted in significant quality improvements and cost savings. The technology has since been deployed across multiple Volvo CE facilities globally, with similar positive outcomes.

The data clearly demonstrates that induction heating technology offers superior performance for bearing installation and removal compared to traditional methods, with quantifiable improvements in process control, energy efficiency, and product quality.

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