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Trelleborg Sealing Solutions

The world of seals and servicegroovein the

Tomorrow’s solutions

Innovation Award

Rewarding new ideas

Investing in the futureWe are constantly looking for new challenges in the renewable energy sector

Trelleborg launches the Trelleborg Sealing Solutions Innovation Award

Special Edition: Wind Energy

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contents

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Research & Development

Constantly tackling new challengesR&D is a vital ingredient in making sure we keep up with our customers requirements.

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Service

Our innovative apps for engineersTrelleborg Sealing Solutions offers an innovative range of tools and services for mobile applications.

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Products

Trelleborg Sealing Solutions Products for Renewable EnergyA spotlight on products most frequently used in wind energy applications.

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Innovation Award

Rewarding new ideasTrelleborg launches the Trelleborg Sealing Solutions Innovation Award.

News4

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Hydropower

Green ElectricThe hydropower sector offers a wide range of opportunities to produce ‘green energy’.

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Investing in the futureTrelleborg Sealing Solutions is constantly looking for new challenges and opportunities in the renewable energy sector.

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Wind power

Gone GlobalWith 22 manufacturing units worldwide, we can always supply locally, providing close support to the customer.

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08 One-Stop-ShopTrelleborg Sealing Solutions offers an outstandingly comprehensive sealing portfolio.

A solid foundationTrelleborg has become the world market leader in offshore grout seals.

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Materials

Turcon® M12 The material of choice for a wide variety of hydraulic applications.

Trelleborg Sealing Solutions in the groove Special Edition Wind Energy

editorial3

The global potential for renewable energy is enormous, and events like the 2011 nuclear catastrophe in Fukushima have again encouraged discussions about the generation of power. “Green energy”, a buzzword for power generated by clean and ethical means, is still the focus of much debate in the energy sector, and renewable sources – the only obvious solution – are being viewed as increasingly more important for the future. However, generating clean energy is not without its difficulties, and requirements for the sector are demanding.

Let’s take the example of an offshore wind park. The expected life span of a turbine is more than 25 years, the operating environment is harsh and variable, and when repairs are very complex and costly, using the correct materials and developing the ideal component is essential. The kind of knowledge required to design a seal for this type of application isn’t just about choosing the seal, it requires the expertise that can only be obtained through practical insights and a close relationship with industry leaders.

Many companies in this sector are global players. Reliability, proximity to global customers, innovation and competence are some of the attributes that are necessary for a beneficial collaboration and a small number of suppliers can provide these. But few can boast dependable solutions already proven successful for this sector and demonstrate the ability to design parts from scratch that outperform the application.

Trelleborg Sealing Solutions has worked in the wind power sector from the very beginning, and through our experience, expertise and competence, we will find or develop the optimum solution for every application. Reliability is our top priority.

We are continuously developing new products and materials for the renewable energy sector, from concept to installation, in one of our seven development centers worldwide.

One of these is our new Turcon® M12 material – a breakthrough PTFE based compound. It is capable of unrivalled performance in key hydraulic sealing characteristics, such as friction, wear and high pressure operation, while being resistant to virtually all media. Offering a wide window of operating conditions, it extends seal life, regardless of application.

With more than 5,100 employees, 49 marketing companies, seven development centers, four logistic centers and 22 manufacturing sites, we are close to you on every continent and perfectly prepared for upcoming challenges.

Take a few minutes to read this special edition of our in the groove magazine. It will give you great insights on the latest projects and the variety of sealing solutions available for wind power and renewable energies in general.

Jürgen Bosch, General Manager, Trelleborg Sealing Solutions, Germany

Seals for Renewable Energy

editorial


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+++ news +++ news +++ news +++ news +++ news news

Trelleborg Sealing Solutions Trelleborg Sealing Solutions – in the groove – Special Edition Wind Energy99GBW5MAGEE0912

© 2012 Trelleborg Group. All rights reserved® All trademarks are the property of Trelleborg AB.The turquoise color is a registered trademark of Trelleborg AB.

At time of publication the information contained in this literature is believed to be correct and accurate.

Editorial team:

Jan Winther, Ferdinand Krauss, Ruud Bokhout, Cees Wien, Claudius Göller, Holger Jordan, Wolfgang Heinrich, Donna Guinivan, Jan Sklucki

Responsible under German Press Law: Robert Zahiri

Graphic Arts: dialogart gmbh, Stuttgart, Germany

Printing: W. Kohlhammer, Stuttgart, Germany

Source information: p. 12: 2jenn © www.fotolia.dep. 16-19: © www.iStockphoto.com/TommLp. 17: Beboy © www.fotolia.dep. 24: © www.iStockphoto.com/Elenathewise

... and puts them through their paces before they face an application’s demanding tasks.

Trelleborg Sealing Solutions has developed and installed a 260kW, floating suspension test bed at its R&D facility in Stuttgart, Germany. It is believed to be the most powerful in the world and will support the effective engineering of seals for aircraft landing gear, mining equipment and other industrial applications.

The state-of-the-art, high-tech 18-ton seal test bed can simulate the toughest operating conditions as well as unexpected events that deviate from the norm. Movement and pressure patterns are run for rod seals of 100 to 400 millimeters in diameter under the toughest and most realistic conditions, that are as similar as possible to actual applications.

Sinusoidal, trapezoidal or freely configurable movement and pressure patterns can be run at speeds of up to one meter per second. In endurance tests, information is additionally acquired on the long-term behavior of seals, for example, through the simulation of 25,000 aircraft landings or millions of strokes of a press. With up to 225 kN, it can act on the rod continuously or dynamically depending on the stroke.

The test bed was designed and developed within Trelleborg Sealing Solutions and is based on 35 years of experience building test equipment. The entire system sits in a specially poured concrete pit that is isolated from the vibrations of the rest of the building. The powerful drive is located in a separate room, with the outlet air used to heat the building in an energy-efficient and eco-friendly way.

A further special feature of the system is its ability to model different temperature scenarios. This allows media to be tested between 25° C and the application limit, as well as at ambient temperatures of between -60° C and 90° C. In this way, operating conditions can be simulated for seals in a mine excavator for use in the cold temperatures of northern Canada just as well as the extreme heat of the Australian desert.

Trelleborg Sealing Systems tests rod sealing systems in the world’s most powerful test bed...

Test bed


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+++ news +++ news +++ news +++ news +++ news

TOP 100 is the most important award for small- and medium-sized companies in Germany when it comes to innovation management. For almost 20 years, the best companies have competed for the TOP 100 seal of quality – because TOP 100 honors companies for structures that ensure that they will be innovative over and over again.

Examination of the innovation management of Trelleborg Sealing Solutions, Germany, produced excellent results and it is now officially one of the TOP innovators in Germany.

At the awards ceremony on 22 June 2012 at the Dornier Museum in Friedrichshafen, Germany, the award was presented by Ranga Yogeshwar to directors Jürgen Bosch and Jochen Sanguinette.

Trelleborg Sealing Solutions Innovation Days

SOLuTIONS FOR TOMORROW’S ENGINEERING

INNOvATION DAYS

In the top 100

In July 2012, Trelleborg Sealing Solutions held its first Innovation Days in the company’s history, which were a great success. Over 150 invited customers were shown the “Trelleborg Sealing Solutions Innovation Force” in numerous technical presentations and company tours.

Our customers experienced exciting presentations about solutions for tomorrow’s challenges. Each person was able to individually put together his or her own program from many current topics such as materials expertise, the PTFE innovation, Turcon® M12, or the increasing requirements for the technical cleanliness of seals.

The event was rounded off by a keynote speaker, Bernhard Wolf, who talked about the emergence and development of innovations, a social gathering with good music, and the latest in molecular gastronomy.

Award

Trelleborg Sealing Solutions Innovation Force


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Wind power

Designing and manufacturing hydraulics for wind turbines is now an international business. In the past, development, prototyping, testing and manufacturing all would have taken place at the same location. Nowadays, these functions may be spread over several countries, even over several continents. This calls for a business partner that is capable of supporting the customer and their needs, wherever they may be and Trelleborg Sealing Solutions meets those requirements.

As Denmark did not have its own natural energy source, the country was instrumental in the foundation of wind power. Several companies key to the industry were founded there, including a number specializing in development of hydraulics.

Sealing is key

Important in any hydraulic system is its sealing configuration. Designing and specifying the right combination of sealing solutions is crucial for a reliable and long service life. To facilitate this, a close collaboration between the hydraulic equipment manufacturer and sealing supplier is a necessity.

To ensure the optimum solution, all parameters have to be taken into account – hardware design and material, surface roughness and texture, operating conditions such as temperature, pressure, and speed, and the nature of any media in the system – among many others. Without taking everything into consideration, the reliability and service life will be compromised.

Trelleborg Sealing Solutions is a global company. With our worldwide representation, we can support our customers no matter where their operations are situated.

At our research and development centers, Trelleborg Sealing Solutions works closely with customers to define and decide on the optimum sealing configuration for specific hydraulic cylinders used in wind turbines. Tests are carried out to verify a robust solution before moving on to the next step.

Trelleborg Sealing Solutions uses its global internal network to ensure all specifications of seals and materials are transferred from the original country of design to anywhere where the product is manufactured. Production of the seals can take place locally, minimizing transport and lead times.

The wind energy sector is very demanding. It has changed from a local to a “glocal” business. Today, corporations in this sector are spread over several countries or even continents. This calls for an internationally set up, professional business partner. With the right contact on every continent, Trelleborg Sealing Solutions meets those requirements.

Design and manufacturing; Where it’s required

Gone Global


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Relationship for effective design

“Only when working in close collaboration with our customers can we reach the best solution for each application,” says Jan Winther, General Manager and Director of Fluid Power. “Such a close relationship is what results in successful hydraulic equipment with outstanding performance specifications.”

Having concluded the design phase and started the manufacturing and supply of parts, it is also important that the customer can be supported around the globe. Be it a customer with manufacturing units in Brazil, China or India, we will be close, not only with technical support, but also with local supply services.

The “Glocal” approach

The wind power business is a truly international business and calls for suppliers with a developed network, providing technical support and delivery services all around the world. Trelleborg Sealing Solutions, as an international, global supplier, has years of experience in serving customers in the aerospace, automotive and industrial markets. A global approach is necessary, but always combined with a focus on how to locally optimize the supply and support.

“Glo

cal”Global but Local

With 22 manufacturing units worldwide, we can supply locally, providing close support to the customer.

Every location brings the same advantages to you:

Technical support to the customer ensuring the optimum solution

Liaison with local technical support

Local manufacturing

Minimized transportation, lowering both cost and impact on the environment, reducing lead times and stockholding for customers

Gone Global


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Wind power

Worldwide, wind power is the most developed alternative energy source. Growth has been stimulated by rising oil prices, a greater concern for the environment and a growing need for energy.

Trelleborg Sealing Solutions offers an outstandingly comprehensive sealing portfolio – a one-stop-shop providing the best in elastomer, thermoplastic, PTFE and composite technologies.

For wind turbines, Trelleborg has been supplying parts since the technology began. Numerous advanced seals from Trelleborg Sealing Solutions contribute to effective operation of hydraulics, withstanding rigors on land and the tough conditions of offshore installations.

Seals for Main BrakeAssists the turbine in stopping at critical rotor speed or for maintenance.

Trelleborg products: scrapers, rod seals, wear rings

Seals for Main GearConverts the rotation of the blades into a speed suitable for the generator.

Trelleborg products: rotary seals

Seals for accumulatorsAct as hydraulic power batteries for safety and energy saving.

Trelleborg products: piston seals, wear rings, static seals

High Performance MountsRA/RAEM and XK mounts have become the preferred solution of the major players in the wind power industry. They are designed

to have a high-degree of isolation, to be easy to install and to demonstrate extreme durability and service life.

Flexible hoses for cooling and Filter SystemsLarge diameter, flexible hoses are used in oil cooling and filter system for turbine gear boxes.

ShopOne-Stop-


Want to find out more? Check out our wind power movie

tss.trelleborg.com/films

Trelleborg as a whole serves the wind power industry

Other parts of the Trelleborg Group supply advanced polymer solutions for wind power and some are featured in this breakout.

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Sandwich MountsDesigned to provide a high compressive strength and low shear stiffness, SAW sandwich mounts have become a versatile high-performance solution. They are used mainly under gearboxes.

Seals for Main BearingHolds the main shaft in position.

Trelleborg products: rotary seals

Seals for Lock CylinderLocks the rotor blades in order to avoid rotation in strong winds or for maintenance.

Trelleborg products: piston seals, wear rings, static seals

Damping BearingsDesigned to accomodate torsional movements and axial and radial loads, Teater Bearings and uD bushes enable structures to be silent

and vibration free. These mountings are mainly used in the main turbine shaft and blades.

Seals for Yaw BrakeKeeps the nacelle in a steady position towards the wind.

Trelleborg products: rod seals, wear rings, scrapers

Seals for Pitch CylinderControl the angle at which the rotor blades face the wind.

Trelleborg products: piston seals, rod seals, wear rings, scrapers, static seals

For more information on these products:

www.trelleborg.com/IndustrialAVS

www.trelleborg.com/IndustrialHose

www.trelleborg.com/Infrastructure


Trelleborg has become the world market leader in offshore grout seals, designing and producing them at its manufacturing and development facility in Ridderkerk in the Netherlands.

In short...

Grout

Seal

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Wind power

One of the most important requirements for offshore wind turbines is a solid foundation. The expected life span of a wind turbine is more than 25 years; the operating environment is harsh and variable. Trelleborg’s Grout Seals make sure that you have the perfect seal for a solid and long lasting foundation.

A solid foundation


Transition piece

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Gwynt y MôrGwynt y Môr is one of the largest offshore wind farms in construction in the world and is expected to provide a major boost to the Welsh economy. It is to be built with an installed capacity of 576 megawatts in Liverpool Bay, around 18 kilometers off North Wales, uK, coast in the Irish Sea. Consisting of 160 Siemens 3.6MW turbines, it will be capable of generating enough energy to meet the average annual energy needs of around 400,000 homes. Onshore construction is already well underway and the wind farm is due to be fully operational by the end of 2014.

Bladt Industries and EEW SPC have successfully completed the load-out of the first two foundations. Special to this project is the choice of a combination of a fully operational self-activating lip seal and an inflatable spare seal. Trelleborg has been awarded the contract to supply 160 inflatable grout seals and self-activating lip seals for this prestigious project.

Fact

s

Wind farm specific

For each wind farm, there are specific design criteria. Based on these criteria, Trelleborg develops a dedicated seal using finite element analysis. Finally, the seals are tested at a scale of one-to-one, normally in the presence of the client, consultants, certifying bodies and the contractor.

“Our grout seals are successfully operating on wind farms globally,” says Cees. “We’re proud of our work on many installations offshore and how we have helped develop the technology to bring sustainable technology to the world.”

The wind energy market offers oceans of opportunity for Trelleborg’s grout seals.

A wind turbine normally consists of a foundation in the seabed, a transition piece and the mast with turbine section and blades on top. For the foundation there are different options. At the moment monopile foundations are most common. In this, the monopile is hammered into the seabed and a transition piece slides over the pile. The function of the transition piece is to correct the misalignment of the pile on the seabed and create a stable and rigid base for positioning the mast and turbines. It needs to withstand forces acting on the end of the windmill’s turbine blades for the entire life of the wind turbine, which is at least 25 years.

Making the connection

“The transition piece is usually around 25 meters high, will be clearing the water by around 10 to 15 meters and is pushed about 15 meters over the steel pile in the seabed. The steel pile itself can be 40 to 50 meters long and will generally be around five meters below the water table,” says Cees Wien, Sales Manager, Trelleborg Infrastructure.

At the bottom of the transition piece a flexible grout seal is mounted. During installation of the transition piece, the seal slides over the monopile. It seals the annulus between monopile and transition piece, takes the tolerances in the thick steel bended surface and corrects for a small misalignment up to 0.5 degree.

The transition piece is leveled with hydraulic jacks and to create the stable foundation with the pile on the seabed, the annulus is filled with grout . The grout is injected under the water level, just above the seal up to a height of eight to 10 meters. The seal is designed to close a large gap and simultaneously carry a substantial weight of the grout during hardening. After the grout has hardened and become solid, the seal will continue to function for the life of the wind turbine, preventing loss of grout and ensuring a solid foundation.

Flexibility is key

“The reason for choosing a rubber seal for this specific issue is related to the flexibility of the material,” continues Cees. “A rubber seal is able to handle varying gap sizes with minimum and maximum tolerances.”

The self activating seal is a full rubber lip seal that initially seals with a tight fit. The sealing properties increase as the pressure becomes higher. The design and choice of material are the key factors in the function and life expectancy of the seal.

A solid foundation


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Hydropower

The hydropower sector offers a wide range of opportunities to produce ‘green energy’. One single turbine can generate as much electricity as a nuclear power station and some countries cover 100 percent of their energy requirements through hydropower.

For more information, go to

tss.trelleborg.com

GreenElectric

Orkot® is the world renowned material from Trelleborg Sealing Solutions that for over 20 years has been used to produce self-lubricating bearings in hydropower applications.

In short...


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Hydroelectricity, typically, is electricity generated by the use of the gravitational force of water taken from a reservoir or barrier in a river. It is currently the most widely used form of alternative energy. Hydropower provides 20 percent of the world’s electricity and is a clean, renewable energy source that does not contribute to global warming.

Environmentally-friendly alternative

Orkot® self-lubricating polymer bearings, from Trelleborg Sealing Solutions, are replacing classic greased bronze bearings on new and refurbished Francis, Kaplan and Bulb turbines, allowing for a cleaner downstream environment. Trelleborg Sealing Solutions also supplies bearings and seals for the equipment surrounding the actual turbine including penstock valve bearings, spilgate hinge bearings, gate roller bearings and bearings for fish screens and fish ladders.

Next to conventional hydropower stations, there are a growing number of so-called pump storage stations in operation and new ones under construction. Water has a high energy density and pump storage is applied to temporarily store energy generated by wind or other sources, thereby making the combined installation economically and environmentally effective.

Advantages over metallic bearings

Orkot® Material is a proven solution in all these applications. It is safe for the environment, extending the service life and reliability of installations without using any grease or oil. Compared to metallic bearings, Orkot® has specific advantages, such as low friction in particular operating conditions, for example when the movements are small or when there are long stationary periods. Orkot® caters for an even transfer of bearing forces thereby reducing stress concentrations in shafts and surrounding steel components, extending service life and time between overhaul.

Trelleborg also contributes to the development of new forms of energy generation such as sea current, tidal motions or wave energy. Orkot® material has a proven track record in the marine industry, being fitted to safety critical items such as steering and propulsion. Its low friction and ability to operate directly in sea water offer major advantages for this up and coming industry.

La Muela Pump, an example of a pump storage station in Iberdrola, Spain

Orkot® bearings are used on numerous hydropower applications.


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Investing in the

Trelleborg Sealing Solutions is constantly looking for new challenges and opportunities in the renewable energy sector. One way of doing that is to support research and development projects. In the case of the “Wave Power Project – Lysekil”, Trelleborg Sealing Solutions works in close cooperation with Seabased AB and researchers at the Division for Electricity, Department of Engineering Sciences, at uppsala university (uu), Sweden. We are not only providing seals and bearings but also technical advice and knowhow.

future


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For more information, go to

el.angstrom.uu.se

In a small research area on the west coast of Sweden, a group of Seabased AB workers and researchers from Uppsala University are testing a whole new concept to generate green electricity from the motion of waves. Initiated by Uppsala University, the project was launched in 2006 and is expected to remain in operation until 2014.

Smart system with simple setup

With a very simple setup, the wave energy converter (WEC) consists of a linear generator that is placed on the seabed and a floating buoy. Buoy and generator are connected through a 15-150 meter long rope, depending on water depth at the site.

Through the motion of waves, the buoy is driving a directly linked translator with permanent magnets inside the encapsulated generator. The motion induces an alternating current (AC) in the generator. In a wave power park the individual ACs from several WECs are transferred to an underwater substation where they are converted into direct current (DC) and interconnected.

The combined DC voltage from several WECs may then be inverted back to a common AC voltage at power grid frequency and transformed to high voltage before being transferred to an onshore power grid connection point. The power rating of a WEC varies between 10kW and 100kW, basically depending on the size of waves in certain areas and stroke length of the generator.

Many advantages

“This new technology offers many advantages”, states Erland Strömstedt, PhD candidate and Project Manager at UU. “Wave power provides a higher degree of utilization with a higher energy density compared to most other renewables. Due to a scalable unique generator design, electrical energy can even be utilized in wave climates with relatively low wave amplitudes and directly connected to the main grid through a standard transmission.

“Furthermore, the generator, located on the seabed, is protected from harsh weather. Should a buoy break adrift, it is easily replaced a minor cost. In addition, the technology is expected to have little or limited effect on the environment. Wave energy converters do not produce any emissions, will not be visible from land and may protect the marine environment. Also, the material used for construction of the equipment has been used before and is well known.”

Trelleborg Sealing Solutions provides hardwareand expertise

In close cooperation, Trelleborg Sealing Solutions has not only provided hardware for the pilot project, but is also constantly delivering technical expertise and support.

Holger Hagen, Technical Manager at Trelleborg Sealing Solutions, Sweden says: “We are proud to be involved in such research projects. This is one part of our contribution to push the development of ‘green energy’ in general and wave power in particular. We see a great opportunity in the production of wave energy. Our cooperation with UU so far has been great and we are very positive that we will have a good result in this project!”

Evidence of the cooperation is that Trelleborg Group, represented by Trelleborg Sealing Solutions and Trelleborg Engineered Systems, was invited to the eighth European Wave and Tidal Energy Conference 2009 in Uppsala as one of the few suppliers to this unique industry.

The new technology is expected to have a substantial commercial potential with the possibility of 3,000 jobs being created.

A linear generator and floating buoys

Diagram of a linear generator


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Constantly tackling new

challengesR&D is a vital ingredient in making sure we keep up with our customers requirements. Development Engineer Ferdinand Krauss and Holger Jordan, Manager Fluid Power Technology, give us an insight into how the department works in Stuttgart, Germany.

Demands made on seals are changing constantly. Modifying products or varying operating conditions often requires more efficient seal designs. In addition, novel sealing concepts are sometimes necessary for new applications. In all cases, a creative and structured research and development environment at Trelleborg Sealing Solutions ensures efficient and reliable, standard and customized solutions.

“Customers all over the world utilize our expertise and the close working relationships developed with Trelleborg Sealing Solutions to regularly present us with new challenges,” says Ferdinand Krauss.

Such requests for new sealing solutions from existing or potential customers are welcomed by our product developers

at Trelleborg Sealing Solutions. In fact, they are a great opportunity to demonstrate the efficiency of the globally positioned and optimally networked research & development environment of the Group.

As an effective seal manufacturer, Trelleborg Sealing Solutions supervises the changing requirements of industries by means of its own R&D departments with in-house testing facilities and laboratories.

Seals are often optimized or new sealing solutions are developed for existing applications when operating conditions change. This might become necessary because, for example, requirements have become more demanding, immobilization periods are extended or higher pressures are required.

START

Ferdinand KraussProduct Development Engineer

Holger JordanManager Fluid Power Technology


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Request

RequirementsThrough close customer collaboration and discussions, our product developers find out important details and insights that cannot be determined by any questionnaire.

“The choice of the most suitable materials, as well as a design tailored to the application, is of prime importance for the success of a seal,” explains Krauss. “At Trelleborg Sealing Solutions we work continuously on the development of new materials which are then used in existing and new applications.”

Structured and efficient procedures worldwide

In all cases, the procedures at the R&D centers of Trelleborg Sealing Solutions located in America, Asia and Europe are structured in a similar way.

In the first step, a list of requirements is created including all parameters of the application and all underlying conditions of the operating environment. This is first done by means of a standardized questionnaire, which upon evaluation, is followed by discussions between the customer and Trelleborg engineers. The appropriate solution can only be developed by those who understand the applications and requirements.

“We learn important details and insights by talking to the customer, that could never be determined by any questionnaire, no matter how sophisticated,” emphasizes Krauss.

Here, the important factors and variables of use are determined and the application is analyzed for the seal-specific requirements.

The earlier the R&D experts from Trelleborg Sealing Solutions are involved, the more efficiently a solution can be developed.

In addition to freedom from leakage, seals must always display good properties in terms of robustness during operation and immobilization periods as well as a diverse range of requirements depending on what is important in the application. This can be the ability to withstand high or low temperatures, as well as large temperature ranges or fluctuations.

As an example, high pressures or the use of steam and liquids require a high mechanical or chemical resistance. This applies equally to various types of seals such as hydraulic and pneumatic seals, rotary and shaft seals or O-Rings. This particularly concerns the requirements for safe functionality, long maintenance cycles and long service life. Energy-efficient operation is also becoming an increasingly important factor.

Solving challenging tasks

In wind turbines, seals are needed that work for long periods of time without leaks and display low-friction to work in an energy-efficient manner. In addition, they should demonstrate low stick-slip and good sealing effect to ensure that components work consistently.

DevelopmentAt Trelleborg Sealing Solutions, efficient and reliable standard or customized solutions are developed in a creative and well-structured R&D environment.



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The example of a bearing seal, such as the type installed at the base of a rotor blade, demonstrates the particular requirements that can be met.

The seal - with a diameter of up to four meters / 13 feet - must always keep the grease in the bearing, withstand pressure and cope with a local lack of lubrication. It should also keep dirt, dust, salt crystals and water away from the bearing and must be easy to replace when servicing.

However, since gravitational and centrifugal force cause the size of the sealing gap to constantly change its shape during the rotation of the rotor, a solution must be found where the seal geometry and material adapts to this movement and the bearing remains perfectly tight. In addition, the seal must keep secure contact tightly when the gap increases in size. And when it decreases in size, the frictional force must not become too great to ensure energy efficiency and minimize abrasive forces to extend seal life.

Developing initial ideas in a good working environment

Once the application and underlying conditions have been determined, the brainstorming and concept phase begins. In the course of this, an appropriate material is selected, initial designs are collected and functional diagrams are prepared.

Holger Jordan, the Manager of Fluid Power Technology, summarizes an important aspect: “Innovations initially start in the mind of each individual. Creativity and good teamwork, understanding of the applications and visions for further improvements enable these innovations to become marketable solutions.”

Trelleborg Sealing Solutions cultivates an environment in which this principle is fundamental in development and offers sufficient freedom for its realization.

Afterwards, the collected ideas are assessed. Our R&D centers use a special rating system for this, which is adjusted to suit the application. Individual criteria are defined and rated in a matrix, creating a ranked list of ideas. This can vary depending on the focus.

In one case, the main focus may be placed on the costs, in another case, it could be ease of replacement of the seal when servicing.

Ferdinand Krauss explains the advantages: “This rating system based upon what are known as “hard factors” has proved to be effective because different concepts can be compared systematically and decisions can be better understood.” But equally as important are the so-called “soft factors”.

“In each new task, we apply our many years of experience in R&D and insights gained from similar applications. By sharing

FEAIn virtual FEAs (Finite Element Analysis), concepts are tested rotational-symmetrically or three-dimensionally for resilience.

PrototypeAs an efficient seal manufacturer, Trelleborg Sealing Solutions examines changing requirements by means of its own R&D departments with in-house testing facilities and laboratories.

Product


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ideas with colleagues as well as with the other R&D centers, the entire expertise of the Group is always involved.”

As a result, from one to three concepts can emerge from the assessment stage that will then be presented to the customer.

An atmosphere of cooperation and transparencythat involves customers

Customers and users are closely involved in the decision-making process aided by an atmosphere of cooperation and openness. The concept for further development is selected and then worked out in detail. This results in 2D technical drawings and a 3D model.

The next stage involves the seal – though virtually – the concepts are tested rotational-symmetrically or three-dimensionally for resilience by means of FEA (Finite Element Analysis). In this way, the limit ranges for the material and geometry of the seals are determined. The behavior of the product is examined when exposed to stress with regard to contact forces, deformations and internal stresses.

Prototypes are then produced from the chosen solution and extensively tested in verification processes under real operating conditions. Our in-house laboratories and test rigs achieve excellent results here. Only prototypes that successfully pass

simulations and tests beforehand can later meet the high demands of modern assembly lines and satisfy even the most demanding customers.

Efficient in-house laboratories and test rigs

One potential option is that material behavior is examined with regard to strength, permanent elasticity and resistance to media. Test rigs for endurance determine the behavior of the seals under the influence of temperature and pressure, as well as deflection properties and gas permeability.

“If no suitable test rig is available in the R&D centers, we build a special structure with the necessary units,” explains Krauss.

This demonstrates how serious Trelleborg Sealing Solutions considers the achievement of meaningful results to be. Hence, for instance, the latest rod test rig in the company with its 400mm/16 inch rod diameter is the most effective in the world. Field tests at the customer’s site then round off the verification process. After that, the newly developed sealing solution can become operational.

Research & Development FacilitiesIn all cases, the procedures at the R&D centers of Trelleborg Sealing Solutions located in America, Asia and Europe are structured in a similar way.

Tokyo, Japan

Helsingør, Denmark

Stuttgart, Germany

Shanghai, China

Fort Wayne, U.S.

Malta

Bridgwater, U.K.


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Materials

Turcon® M12 – Unrivaled performance in hydraulic sealingTurcon® M12 from Trelleborg Sealing Solutions is a polytetrafluoroethylene (PTFE) based sealing material whose performance is unrivaled in key hydraulic sealing characteristics, such as friction, wear and high pressure operation.

Want to find out more? Check out our Turcon M12 movie


Turc

on® M

12Features and benefits of Turcon® M12

Resistant to virtually all media including a broad range of lubricants

Outstanding wear resistance and friction characteristics

Provides extended seal life

Operates in wide temperature, pressure and velocity ranges

Minimal abrasion of hardware, preventing damage to counter surfaces

Robust for harsh environments

Good resistance to extrusion

Reduced environmental impact as it does not include bronze fillers

Sealing material for universal use in hydraulic applications

Lower stock holding and fewer items to handle

Cost-effective solution

No other material can give such universally exceptional performance

Extensive testing shows that Turcon® M12 is resistant to virtually all media, including a broad range of lubricants, and has outstanding wear resistance and friction characteristics. This cost-effective material provides customers with extended seal life, as well as a wide operating window in terms of temperature, pressure and velocity. Comprehensive testing has shown that no other PTFE material can give such universally exceptional performance, and Turcon® M12 is now recommended by Trelleborg Sealing Solutions as the material of choice for a wide variety of hydraulic applications.


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Key applications

Turcon® M12 is the material of choice for a wide variety of hydraulic applications.

Robust for difficult environments

Superior for short stroke and high frequencies

Rail

Avoids damage to counter surfaces

Low friction gives smooth movement

Withstands high system pressure

Automotive

Low friction and suited to short stroke linear movement

Compatible with all types of hydraulic fluid, especially those fluids with low lubrication performance

Withstands constant activation

High wear resistance

Operates under high pressure

Heavy duty

Hydraulic machinery

Withstands harsh environments

High sealing efficiency

Improved absorption of abrasive contaminants

Extended seal life reduces maintenance

24-7 operation

Segment Turcon® M12 advantagesApplication

Shock absorbers

Cylinders for convertibles

Shock absorbers

Active body control

Machine tools and machining centers

Injection molding machines

Hydraulic presses

Press brake and punching machines

Steel and rolling mills

Lifting and telescopic cylinders

Active suspension and stabilizer cylinders

Hydraulic pitch cylinders

Turbine piston accumulators

Hydraulic cylinders and actuators

Giant cylinders

Hydraulic jacks

Clamping cylinders

Compatible with all types of hydraulic fluid, including fluids with low lubrication performance

Low abrasion

Low friction for frequent movement

Avoids hardware damage on counter surface

Mobile hydraulics

Wind power

Fluid power



TuRCON® M12 A NEW GENERATION OF HYDRAuLIC SEALS

Innovations in hydraulic sealing are perfectly matched by the Turcon® M12 material from Trelleborg Sealing Solutions. It’s engineered to set the standard for improved performance in hydraulic equipment, today and in the future.

Find more information at www.tss.trelleborg.comor check out www.seals-innovation.com

Trelleborg Sealing Solutions offers an innovative range of tools and services for mobile applications to make your life easier. We are continually working to improve those mobile applications. Have a look and download the Apps free-of-charge by simply scanning the QR-Code or visiting the App store or Google play.

This app covers two of the most important SAE aerospace groove standards for hydraulic systems, AS4716 Rev B and AS5857 Rev A. It makes it really easy to find the size of grooves and hardware and it indicates if the groove is suitable for a dynamic seal and/or a static seal. It also provides an instant conversion between inch and mm sizes.

Aerospace Groove Selector App

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Service

Our innovative apps

for engineers


O-Ring Selector App

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ISO Fits & Tolerances “ISO Fits & Tolerances” is intuitive and very easy to use. Upon entering the nominal diameter needed, users simply select the tolerance classes for bore and shaft. The app then provides the complete ISO fits definition with all relevant values including the type of fit. Tolerances are shown for the most commonly used ISO tolerance classes, and convenient graphs illustrate these classes by bore and shaft. The app provides results based on the ISO 286 System of Limits and Fits.

Unit and Hardness Converter The “Unit and Hardness Converter” is intuitive and very easy to use. By simply selecting the dimension and entering the value for conversion, the app offers a wide range of engineering and scientific units for each dimension. For the hardness conversion, the user selects the appropriate material type table and upon entering a value, the input can be converted to other hardness scales.

Based on our online O-Ring calculator, renowned as the leading application of its type, the new smartphone app calculates O-Ring dimension tolerances according to ISO 3601 and recommends the appropriate Trelleborg Sealing Solutions part numbers. You can search for O-Ring and housing dimensions according to ISO 3601 recommendations by simply entering bore or rod diameters and pre-selecting the desired O-Ring cross sections. The app also incorporates an O-Ring quick search facility that allows you to search for O-Ring dimensions according to various national and international standards. A nice feature is that the “Chemical Compatibility Check,” a separate tool on the web, is integrated into the mobile app. That means you can quickly find out which material types are compatible with the media used in your application.


Want to find out more? Check out our Rotary Shaft Seals and Oil Seals movies


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Products

Trelleborg Sealing Solutions Products for Renewable Energy

Rotary Seals

V-R

ing

®

Rotary seals are used in components with oscillating or rotating parts, and keep lubrication fluids in place while preventing the ingress of contaminants.

Trelleborg Sealing Solutions components are proven to improve the life and long-term performance of your application, demonstrating superior low-friction properties and excellent resistance to wear.

Trelleborg offers one of the most extensive ranges of rotary seals on the market including Radial Oil Seals, the rubber v-Ring®, Mechanical Face Seals and the Turcon® varilip® PDR.

Highlighted here are two of the most important seals for wind power applications. Full details of the rotary seal range can be found in the rotary seals catalog.

Rad

ial O

il Se

als


Pressure: Not applicable

Speed: up to 12 m/s / 40 ft/s

Temperature: -54°C to +170°C / -65°F to +338°F

Pressure: up to 0.5 MPa /72 psi



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Trelleborg Sealing Solutions Products for Renewable Energy

A unique all-rubber seal for rotary shafts that is suitable for a wide range of bearing types.

•Frictional losses and heat kept to a minimum

•Low contact pressure allows dry running in many applications

•Excellent wear characteristics

•Extended seal life

•Can perform even with certain amounts of run out, eccentricity and shaft misalignment

•Easy to install

•Can be installed over various other components without need for dismantling

The v-Ring® is the perfect seal to prevent the ingress of dirt, dust, water or combinations of these media while positively retaining grease. It can also be used as a secondary seal to protect primary seals that do not perform well in hostile environments.

Radial Oils Seals are available with metal or fiber-reinforcement.

•Excellent chemical resistance

•Outstanding resistance to heat and low temperature

•Good resistance to ozone and weathering

•High resistance to wear

•Low friction and compression set

•Highly elastic

•To ease the mounting or in case of repair, a split version Radial Oil Seal is available

For more information on Radial Oil Seals see the Radial Oil Seals catalog.


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Products

Pressure: up to 80 MPa / 11,600 psi



Turcon® Stepseal® 2K

Hydraulic Seals

It is challenging to ensure seal life and performance in hydraulic applications. Not only must leak-free operation be achieved, but high pressures, temperatures and transverse forces must be sustained. Trelleborg offers one of the most extensive ranges of hydraulic seals on the market. Highlighted here are a few of the most important seals for wind power applications.

Full details of the hydraulic seal range can be found in the hydraulic seals catalog. Contact your local Trelleborg Sealing Solution marketing company for a printed version or download a digital copy from

www.tss.trelleborg.com.

Pressure: up to 40 MPa /5,800 psi

Speed: up to 0.5 m/s / 20 in/s


Zurcon® U-Cup RU9 Boasting long service life, high wear and extrusion resistance with low friction operation, the Zurcon® u-Cup Ru9 is the preferred u-Cup seal for wind power applications.

•Lower friction and heat generation than standard u-Cups

•High extrusion resistance and seal stability within the groove

•Back-pumping ability over the entire pressure range achieved by grooved profile

•Suitable for use with the Zurcon® Buffer Seal as secondary seal in tandem design

The result of years of research into providing an all purpose fluid seal, revolutionizing fluid sealing in cylinder applications. The seal demonstrates high extrusion resistance and supports dynamic, high frequency operation.

•Low-friction, increasing performance and working life

•Stick-slip-free starting, no sticking even after extended periods of rest

•High abrasion resistance

•Compatible with virtually all media

•Simple installation without seal edge deformation

Load: up to 100 N /mm2


Temperature: -60°C to 200°C / -75°F to +392°F

Slydring® Slydring® eliminates local stress concentrations and dampen mechanical vibrations. This simple non-metallic guide ring has decades of engineering behind it, offering major benefits compared to its traditional metal counterpart.

• Simple closed groove, easy installation

•Highloadbearingcapacity

•Wear-resistant,longservicelife

•Favorablefrictionbehaviour


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Pressure: up to 80 MPa / 11,600 psi



Turcon® Stepseal® VEngineered to meet continuously increasing demands. Offers a uniform, low friction characteristic, throughout its whole life with its distinctive hydrostatic ventilation function.

•Check valve function eliminating potential build up of disruptive intermediate pressure between seals

•Hydrodynamic back-pumping

•Available for ISO 7425/2 groove

•Prolonged seal life

•Increased leakage control

Trelleborg Ridderkerk Bv, PO Box 4007, 2980 GA Ridderkerk, The NetherlandsTel: +31 180 49 55 55 [email protected] www.trelleborg.com/infrastructure

Trelleborg seals give lifetime certaintyNew technologies come with new challenges.Trelleborg seals are robust, durable and secure your investment for decades to come.

Grout

Seal

The ‘grout capturing’ seal


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Innovation Award

Rewardingnew ideas

Aiming to continue to pioneer new sealing developments, ideas are being sought that can provide engineering solutions for today and tomorrow. The competition is open to anyone, with prizes for the best submissions.

The philosophy behind the award is that everything around us started with somebody having an idea. That idea then needs to be taken and made into reality, to form it into something tangible. The scope of the award is broad so that innovation suggestions are not limited.

Innovation: A core value

Director Global Marketing and Communications, Trelleborg Sealing Solutions, Robert Zahiri, says: “Open Innovation is one of Trelleborg’s core values and we know that there are lots of ideas out there that can add value to existing applications today and those in the future. We’re not just interested in suggestions for products and materials but anything that relates to improving our business or the way we do business, for instance, novel suggestions for online tools, manufacturing processes or logistic related services.”

As well as receiving a 5,000 EuR prize, the winning idea will be converted into a tangible project, if feasible. iPads will be awarded to the ideas in second and third places.

Trelleborg launches the Trelleborg Sealing Solutions Innovation Award

Why not visit our innovation site? Not only will you find information on the award but also details of some of our latest innovations.

www.seals-innovation.com

Further details on the Trelleborg Sealing Solutions Innovation Award and how to submit ideas can be found by going to

seals-innovation.com


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new ideasI am always struggling with certain issues connected to sealing when I am designing applications. If I submit them, does that count as an idea? Yes, certainly. These type of issues fuel our research and development and can be the foundation for new e-tools to make your engineering job easier.

Our latest design project is a little bit different and has presented some new challenges. Would you like to consider that in the innovation award? Of course. At Trelleborg most of our new materials are developed to meet new requirements that are specific to applications.

For me, sustainability is a key issue. I have some ideas of how you could cut waste in the sealing production process. Please tell us! Sustainability is another one of Trelleborg’s core values and we are always looking for ways to improve sustainability, whatever they are.

I don’t buy seals but am involved in equipment to produce seals. I’ve some thoughts on how sealing technology could be improved. Is that outside the scope of the award? Certainly not. The award is broad so that we can capture ideas such as yours.

Are you interested in suggestions to improve logistics and the way that you supply your product to customers? I’m thinking of different packaging and delivery methods, for instance. Definitely these are of interest. We’re looking for anything that improves our service to our customers.

You have some really excellent e-tools on your website already but I’ve some thoughts on other ones. Can I submit those as ideas? We’d love to know about those. We devote a lot of resources to our e-tools as we know the internet is so important to engineers when developing applications.

I am often designing applications that use seals and I have views on where the industry may go in the future. Would that be in the scope of the award too? We’re looking for ideas for today and tomorrow, so these future visions are totally in the scope of the award. Don’t be afraid to submit ideas that are different. Those could be the most interesting!

Innovation Award – Questions and Answers


Years of experience allows Trelleborg Sealing Solutions to offer the Sealing Solutions Configurator, making future applications easier to specify. Innovation in online services means that engineers have access to proven seal configurations at the click of a mouse or touch of a button.

Find more information at www.tss.trelleborg.comor check out www.seals-innovation.com


SEAL MATCHING AT YOuR FINGERTIPS

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