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Ball bearings set to help with fuel efficiency in hybrid vehicles

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Because of a more efficient integration of the engine and electric motor, which in turn has encouraged a culture of lowering fuel consumption and fuel emissions, the demand for hybrid vehicles has dramatically increased in recent years.  But there is also an increasing need to reduce torque loss in the bearings that are used in the transmissions of the next generation of hybrid cars. 

Ball bearings, a staple component in the industrial world, and many would argue part of the problem, may now provide an unlikely source of environmental joy for consumers. 

A new ball bearing has been developed that designers claim achieves the mechanical holy grail of delivering high speed whilst greatly reducing friction. In fact, designers believe that this new bearing is capable of improving friction loss by up to 65% in comparison to other, more conventional bearings. Obviously such a system leads to lower fuel emission and greater fuel efficiency.

The new device is set to be used in the next generation of hybrid cars, by facilitating high-speed rotation in both motors and power generators. 

Designers claim that the device will be able to reach high-speed rotations of an impressive 30,000 revolutions per minute, which is around 50% faster than other, more conventional bearings. 

It works using optimised ball diameter and groove dimensions inside the bearing module, controlling the friction and heat, even under extreme high-speed rotations. This system also means that seizing within the machinery is unlikely. 

The vibration of the component's "cage" is dampened by adjusting the gap between it, the balls and inner ring, reducing the amount of wear at the contact points.

Another favourable feature of this system is the fact that lubrication is improved. A plate controls the flow-rate of lubricants at the port of the bearing module, ensuring oil is supplied to the inner ring, where lubrication has a tendency of becoming more depleted. This is all carried out in an environment where a tremendous centrifugal force is generated during high-speed rotation, reducing the heat that is usually generated by friction.

Because of this considerable centrifugal force applied to the cage during the high-speed rotation of the bearings, the annular part of the cage is thicker and strengthened in order to prevent deformation.

Designers are adamant that the new product will lead the way in terms of hybrid vehicle technology, as the thought of better fuel efficiency, along with lower emissions is one that will not only help those concerned about the planet, but also those who are concerned about the money in their pocket too. 

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