Subdued sales growth in automotive industry - which accounts for 48 per cent of bearings demand in India - is taking a toll on suppliers including bearing makers. However, industrial segment is offering some solace to the bearing industry. To tide over this tough time, manufacturers are focusing on more technology intensive product to meet the growing requirements of durable, smart and cost-efficient bearings, says Rakesh Rao.

 

Bearings - which are widely used to enable rotational or linear movement - fulfil several important functions including reducing friction, efficient transmission of power and ensuring alignment between rotating parts. Quality bearings help in enabling machineries to run efficiently for a longer duration.

 

Bearings of various types are extensively used for industrial and automobile applications. Globally, ball bearing has higher market share owing to the development of new product portfolio that enhances power saving, lubricating abilities and reliability of products. For example, SKF India launched UC range ball bearings in January 2019 with the enhanced set screw locking system that provides 16 per cent better holding power (compared to conventional products) and the rugged integral seal with flinger delivers effective protection in a highly contaminated environment.

 

The Indian bearing market is estimated at Rs 95 billion accounting for less than 5 per cent of global bearing demand. Manufacturers in India cater to about 60 per cent of domestic bearing needs with the remaining met through imports. While there are large numbers of players present in the industry, the competitive intensity is moderate as top 5 players constitute about 80 per cent of the market share, according to PA Wealth Advisors.

 

Indian bearing market is dominated by multinational companies like SKF, Schaeffler, Timken, NTN, etc who bring their global expertise to serve local customers. Sharing Timken experience in this respect, Sanjay Koul, Chairman & Managing Director, Timken India Ltd, says, “Timken has been producing bearings for more than hundred years and we bring peace of mind to our customers. Timken brings the vast experience using high end technology for overcoming friction and delivering unparalleled reliability for our end users. Timken is often consulted when OEMs design their products and Timken suggests the engineering applications that mandate bearings. We have been delivering solutions to the industry for last 100 years so that we can add value to the products on which these are used.” Timken engineers bearings for a variety of industrial applications, from small motors to huge gear boxes for wind turbines.

 

He adds, “Every day, Timken company associates are working to solve our customers’ most difficult frication management challenges. Producing high end technology savvy products which cater to the growing needs of the bearing and power transmission industry is our mantra for growth.”

 

On a slow drive

Being extensively used in engineering sector, the demand for bearings is directly linked to the performance of automotive and other industries. The present subdued market sentiment in India is having an impact on bearing markets. “Globally, we have started to see a bit of softening of the auto sector. Currently, industrial demand remains fine and we see strong demand in the wind sector,” informs Sanjay Koul.

In India, continuous slide in automotive sales for the few months is taking a toll on suppliers including bearing makers. However, industrial segment is offering some solace. Harsha Kadam, Managing Director and President Industrial  Business of Schaeffler India, highlights, “Indian automotive industry continues to witness unprecedented slowdown across all segments. Auto OEMs are cutting down production significantly which is affecting the whole industry, including us. However, the good thing is that due to our strong presence in the industrial segment which has been performing fairly well, we have been able to mitigate the impact of market slowdown to some extent.”

 

The current business scenario is volatile and disruptive and hence, in order to continue their growth journey, bearing makers are working closely with their customers who are looking for the right product and solutions suiting their requirements. “The market need has shifted from providing only products to the customer to being able to provide a complete system solution. The products need to be more feature rich and solutions driven. There is a greater demand for bearings with reduced size, cost and greater performance efficiency, which is also generating huge prospects for manufacturers. Integration of additional functionalities within the bearing through integration of surrounding components and sensors is gradually gaining popularity among various industry application. The need of the hour is for manufacturers to keep pace with the changing industry demands and invest in modern technology to deliver on innovation and customised products and fully grasp the growth opportunities the industry has to offer,” explains Kadam.

 

Making the right choice 

Bearing plays a vital role in smooth performance of rotating parts. Hence, right selection of bearing units is important for efficient functioning of rotating machinery. “Selecting the right bearing with the right inspection code will determine the life and reliability of the application. The selection of a bearing is a science and that is where Timken brings in the expertise. Depending upon the application, our engineering would select and recommend the right type of bearing so that the customer finds engineering excellence out of it,” points out Koul.

 

Moving parts in automobiles and industries often have to fulfil extreme demands in terms of load carrying capacity, harsh environment and extended durability. Bearings are high-precision parts that allow equipment to move at different speed levels by efficiently transporting notable loads. “Bearings must offer high precision and durability, as well as the possibility of working at high speeds with minimal noise and vibration. Rolling and plain bearings play a central role here, since bearing damage causes the total failure of technical systems in most cases,” opines Harsha Kadam.

 

Bearings play a significant role in machineries and depending on the application, appropriate selection of material and design is critical. Hence, Kadam belives that one must consider all critical factors such as load, rotating speed, intended use, bearing life etc before choosing 

the appropriate bearing. Choosing right bearing for each application involves knowledge of each type of bearings and in depth understanding of their behaviour under given application environment.

 

Various calculation tools are used to evaluate the bearings even before physical products are manufactured. Harsha Kadam elaborates, “As such, manufacturing processes are being redefined and higher degree of automation is being adopted to deliver uniform higher quality and eliminate human errors and lower the cost of production. Considering the criticality and importance, Schaeffler has developed high-quality rolling bearings with the X-life seal of quality, which contributes to achieving a high level of efficiency, cost-effectiveness and productive use of resources.” 

 

In their quest to serve industries better, bearing suppliers work as partner with customers for selection of right bearings for their applications. Ramnath Shenoy, Executive Director, NTN Bearings India Pvt Ltd, explains, “Over the years, the expectation level from our customer has been increasing. They are now looking for more than just a bearing supplier. Our engineering team in India works closely with the actual user of the product, identifying the root causes and offer a range of solutions from new technology products, auto-lubrication solutions, maintenance tools and more.” 

 

IoT transforming the industry

According to Sanjay Koul, industrial IoT (IIoT) is going to be a game changer. “The amount of data which gets created while our bearings are in application can predict so many things which can help the industry to function better. Just imagine an aircraft which is flying from Delhi to Dubai and gets stranded at Dubai as the maintenance folks found that the bearing is having a noise. With the power of IoT same things can be predicted in a manner that machines do not have to undergo sudden breakdowns,” he adds.

 

Customers are increasingly looking for durable, smart and cost-efficient bearings, hence the demand for more technology intensive product is growing. “Data analytics and Internet of Things (IoT) have a positive impact on businesses and bearing companies are specifically working to infuse technology drivers into products enabling them to provide data that can add value to their customers,” opines Harsha Kadam.

For example, Schaeffler offers Industry 4.0 solutions that are customised to suit the respective applications in drive technology, logistics or machine tool digitalization. Kadam elucidates, “Our systems and components are installed in machines at exactly the points where the most important data are generated. We continuously sense and monitor the data in terms of noises, vibration, temperature, etc. The information that is provided by these sensors are narrated to the owners of the function so that corrective action can be taken. Apart from prediction it helps in distinguishing the lifespan of the bearing that reduces the downtime for a manufacturing unit.”

 

Companies are using wireless condition-based monitoring system for bearings to measure variables such as vibration levels and temperatures for spotting anomalies at an early stage, reducing the need for unplanned downtime and stoppages. Ramnath Shenoy explains, “NTN is using IIoT for continuous condition monitoring of equipment in certain applications like wind turbine, automotive hub bearing and in-wheel motors in EV (electric vehicle). These advanced sensor technologies help in predicting condition of the bearing product when in use, leading to more advanced failure prediction and replacement before damage.”

 

Eco-friendly products 

The current trend in the industry is to move towards bearing assemblies (the housing and bearing delivered as a single unit) rather than sourcing individual component. Bearing assemblies allow the end-user to reduce overall costs, consolidate suppliers and streamline in-house production. For example, CCTY Bearing produces a number of bearing assemblies that include tie rods and rod end linkages 

for suspension systems in construction equipment.

 

Regulatory requirements of emission rules and improved safety norms demands for reduced vehicle weight and lower friction technology. Rising requirement to reduce the carbon dioxide (CO2) footprint from aviation sector is pressurising industry to develop advanced products. To meet this market requirement, bearing makers are developing several lightweight products (some even 50 per cent lighter than conventional steel bearing).

 

Koul says, “Around the world the focus is on the environment - be it lighter vehicles or electrical vehicles that are more fuel efficient and reduce emissions. We work closely with many industries on solutions designed to protect our planet. From custom drives that make solar panels more efficient and reliable to durable bearings that extend the lives of wind turbines, our products are helping to reduce fossil fuel usage and emissions around the globe.”

 

On the roll 

At present, the automotive industry - which accounts for 48 per cent of bearings demand in India (which is quite high compared to the global level of about 37 per cent) - is in topsy-turvy due to low sales. With the government pushing for emission free drive, the demand for electric vehicles – which require far less number of bearings - is likely to gain momentum. While rise in vehicle electrification will lead to fall in bearing demand, it is likely to witness growth in value (as EV will need specialised bearings).   

 

Industrial sector is expected to remain steady and, as the growth returns, the demand for bearings from all markets will grow at a robust pace. Meanwhile, bearing manufacturers, on their part, are gearing up to meet the customer’s demand by developing products that can work in harsh and more diverse environment.

 

Types of bearings 

Numerous industrial and automobile manufacturers use varied kinds of bearings considering size, load capacity, shape, material, lubrication, principle of operation, and so on. Some of them are:

Courtesy: PA Wealth Advisors

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Industrial IoT (IIoT) is going to be a game changer. The amount of data which gets created while our bearings are in application can predict so many things which can help the industry to function better.

Sanjay Koul, CMD, Timken India Ltd