REWITEC Surface Technology

Transcription

1 REWITEC Surface Technology Energy Efficient Lubricants for Gears, Bearings and Engines Renewable Energy and Energy Efficiency for the Mining Industry in Australia, 20 th Oktober 2014 I Perth/Australia REWITEC GmbH Stefan Bill, CEO REWITEC GmbH 1

2 Who we are REWITEC is developer, manufacturer and distributor of active ingredients on nano and micro bases for surface refinements, which are used to reduce friction and wear on metal surfaces in tribologic systems. Establishment in 2003 Since then dealer based and direct sales world-wide Founder and CEO: Stefan Bill REWITEC GmbH 2

3 Our target groups wind energy marine industry automotive REWITEC GmbH 3

4 Our products Synthetic and mineral silicate-based active ingredients in nano and micro segment Reducing friction, temperature and roughness of metal surfaces in tribologic systems (e.g. gears, bearings, combustion engines etc.) Replacing the friction pair Metal/Metal by Metal Ceramic/Metal Ceramic REWITEC GmbH 4

5 The coating process Friction and pressure in engines, gears and bearings generates high temperature on metal surfaces that trigger the physical-chemical bonding process of the REWITEC coating. The nano-micro particles remove dirt from the rubbing metal surfaces and react with the metal atoms to form a smooth and protective layer on the surface. The final result is a new and very smooth metal surface structure. Their properties, in turn, give the machine higher efficiency and longer life-time. REWITEC GmbH 5

6 Advantages of our technology Reduction of friction in gears and bearings up to 33%* Lowering of gearbox and bearing temperatures up to 20 %* Reduction of roughness on gear and bearing surfaces up to 50 %* Prevention of surface pittings and micro-pittings Reduction of abrasion and wear, plus reconditioning of rubbing metal surfaces Reduction of vibration and operating noise Surface conditioning during ongoing operation (with no downtime) * Rolling wear tests on a 2-disc test bench at the Tribology Centre of Excellence at Mannheim University of Applied Science 09/2012 REWITEC GmbH 6

7 Fields of application and opportunities Wind turbines and industrial equipment: Gears Bearings Combustion engines Compressors Hydraulic pumps and engines Vacuum pumps Chain conveyors Pinions Gear racks and many more REWITEC GmbH 7

8 Before/after comparison (wind turbine gears) REWITEC GmbH 8

9 Before/after comparison (wind turbine gears) Topography analysis of a 1MW wind turbine gear surface: untreated treated REWITEC GmbH 9

10 Load test of ball bearings Images of the raceway of ball bearings after 50hrs of operation in a range of fatigue Without REWITEC : Raceway shows micropitting damages after 50 rhs and 5,000 N load. Bearing type: No (d=25mm D=52mm) Lubricant: Special bearing grease (original) Rotatinal speed: 500 min -1 Nominal load: 5,000 N radial (range of fatigue) With REWITEC : Raceway does not show any wear. The running surfaces proves the wear resistant coating. REWITEC GmbH 10

11 Examples of use Coating and analysis of a industry gear: Macroscopic surface imprint before the treatment Macroscopic surface imprint after the treatment Various significant differences of the both surfaces Significant lower pitting structure on the tooth flank The aim of the REWITEC DuraGear is very clear to see of freezing / improving the current condition by adding the wear-protection coating has thus been fully achieved. Additionally the energy consumption was reduced by >10%. REWITEC GmbH 11

12 Scientific testings How does friction, temperature and surfaces are changing if REWITEC is applied to the gear oil? Short-term and long-term tests with two types of oil from Agip (viscosity ISO VG 150 and 320) Evaluated with white-light interferometer, SEM etc. REWITEC GmbH 12

13 Scientific testings Test 10: Agip Blasia 320 without REWITEC Test 11: Agip Blasia 320 with REWITEC REWITEC GmbH 13

14 Scientific testings Surface images after long-term testings in 1:1 comparison: without with REWITEC coating REWITEC GmbH 14

15 Scientific testing with CASTROL X320 Red graph without REWITEC Blue graph with REWITEC added after 20 hours Green graph with REWITEC added at the beginning Clearly a postive effect Reduction of the surface roughness due to wear up to 47% (!) Reduction of the friction force up to 22% (!) REWITEC GmbH 15

16 > 1,000 Treated Wind Turbines REWITEC GmbH 16

17 Advantages for our customers REWITEC provide customers concrete benefits: +++ Higher Reliability and Availability (less downtime = less outage = longer runtime) +++ Higher Returns (less spare parts and less maintenance costs, higher energy efficiency) Returns Reliability Availability REWITEC GmbH 17

18 Extract of partners and customers and many more! REWITEC GmbH 18

19 More informationen available on our website REWITEC GmbH Stefan Bill, Managing Director, Dr.-Hans-Wilhelmi-Weg Lahnau (Germany) Tel / stefan.bill@rewitec.com Many thanks for your kind attention! REWITEC GmbH 19