Agricultural

Machinery Design

agriculture
How new bearing innovations are propelling
the industry with increased efficiency, enhanced
productivity, and greater value

Agriculture White Paper: V.1

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Agricultural Machinery Design – How new bearing

innovations are propelling the industry with increased
efficiency, enhanced productivity, and greater value
The agricultural equipment industry, which has been a bright spot in a down
economy, is enjoying immense change and significant growth. As the global
population explodes, today’s farmers are being asked to produce more and to do it
faster and more efficiently. Fifty years ago, a typical US family farm fed 26 people—
today it feeds 155. Manufacturers are reporting increased demand for their farming
equipment. Retail sales of self-propelled combines, for example, have increased a
staggering 42.3% when comparing February 2010 to February 2011.
While meeting these growing needs, farmers are still required to follow
restrictive mandates, weather unpredictable climate and economic conditions, and
work with fewer resources. So the question becomes, how can today’s farmers
meet high demand while holding the line on runaway costs? And how can their
equipment manufacturing partners help them improve efficiency and productivity
while reducing time lost to costly maintenance?
One key solution is the integration of machinery and technology, and US farm
equipment manufacturers—the world’s largest exporters—are riding the cusp of
The integration of machinery and
new technology. Innovations such as GPS devices allow multiple machines to
technology is propelling the US
be operated in unison from a single control station. The adoption of Real-Time
agricultural industry forward.
Kinematics (RTK) automates plant, spray, and harvest mapping with astounding
accuracy, within mere centimeters from one track cycle to the next.
And designers of seeders, harvesters and other machines are adjusting their
specs to include lighter, more durable and value-driven bearing components.
These components are quite literally propelling the agricultural industry forward.

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Old-school design meets soaring steel costs and limited supply

Historically, designers have specified steel or bronze for the many pivot points,
assemblies, and cylinders aboard agricultural seeders, combines, tractors and other
workhorses of the farming fleet. The belief was that metal bearings were durable
and could handle the rugged terrain of a demanding farm environment. Metal
bearings worked just fine for generations of equipment owners—or did they?
As time passed, lubricated bearings evolved, and what worked once is not Basic steel prices continue
applicable now. to soar; increasing 20-30%
The price of steel is soaring, jumping nearly 30% from November 2010 to from November 2010 to
February 2011, and is expected to continue climbing in the coming months. February 2011.

The future availability of steel is also uncertain given extremely high demand.
One steel supplier notes two of their agricultural OEMs had increased their original
steel forecasts by 30% for 2011. Clearly, steel is in demand and costs a premium,
and equipment manufacturers are paying attention.
How can manufacturers offset rising steel costs? Simply by exploring the
significant strength and durability advantages of polymer bearing materials.

Weather, compressed seasons strain production Self-lubricating polymer

From the farmer’s perspective, weather challenges, from drought to the record bearings eliminate the need
rainfall in California, for example, have put a strain on farming timetables. And for weekly or daily equipment

federal mandates increasingly impact harvest, cutting and clearing schedules— greasing, leading to savings

sometimes reducing to a scant six week timeframe for certain crops. in labor, lost field time, and

With all of this uncertainty, farmers must optimize their time in the field; equipment costs – all while
promoting a green farming
there is no time for equipment failure or time-consuming maintenance procedures.
environment.
Equipment breakdowns equate not only to lost revenue, but lower field yield,
particularly if a breakdown occurs at a critical juncture in the high seasons of
planting and harvesting.

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The Solution to These Pressing Challenges:

Manufacturers embrace polymer technology
The major players in agricultural equipment and accessories realize that lighter
and more durable bearing components can lead to savings in raw material costs, a
smaller equipment footprint, and lower total weight. In turn, these manufacturing
advances have a direct benefit correlation for farmers: smaller, lighter machines
consume less fuel; more durable materials require less maintenance such as costly
greasing; and durable components can last for multiple seasons without being
changed.
What is this new technology that more and more equipment manufacturers
are embracing? Polymer bearings—the efficient, durable workhorse of the farming
equipment fleet.
Polymer bearings offer distinct advantages over steel or bronze bearings:
• Self-lubricating design for lower maintenance and greasing costs
• Extremely long wear life even under arduous farming conditions TriStar Plastics delivers the
best in polymer bearing
• High strength and low weight (7:1 strength-to-weight ratio)
materials from precision
for extended durability
engineering, to custom
• Resistance to farming fertilizers, pesticides and chemical overspray
fabrication and quality
• Ability to perform consistently in extreme weather conditions
manufacturing.
• Flexible design options to reduce component size and weight
• Competitive value when compared to metal
TriStar Plastics, a leader in engineered plastic solutions, has developed new
engineered materials for the ag industry. TriStar offers a complete line of self-
lubricating bearings, including Rulon®, Ultracomp, CJ, and TriSteel, plus custom
fabricated parts. TriStar unites superior design and durability with in-house
production and engineering to deliver the finest bearing components on the market.
These bearings make a difference not only to equipment manufacturers—but to the
farmers they design for.

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The TriStar Advantage: Enhanced productivity

As the exclusive supplier of Rulon® bearing materials, only TriStar can help
manufacturers select from over 300 different variations of Rulon compounds.
Rulon offers tremendous temperature stability and chemical resistance and can
easily withstand from cryogenic to extreme heat, as well as the chemical and
pesticide applications inherent to a farming application.

Rulon J lifts the boom, resists weather extremes

Challenge:
A leading supplier of harvesting equipment needed a long-lasting, acid-resistant bearing for the
conveyor belts and suspension cylinders aboard their boom lifts. The booms are mounted to
tractors used to harvest pineapples and other produce in steep, hillside terrain. The bearings had
to resist weather extremes, offer long life and low maintenance.

Solution:
The TriStar team fabricated bearings made of Rulon J; a material prized for its low-abrasion and
compliance with softer-mating surfaces. Rulon J is considered “shaft friendly” and outlasts other
materials, even with start/stop applications where stick slip must be eliminated.
Rulon J excelled in this demanding environment because it easily resisted the sugar acidity
SideinBar
the fruit. And because Rulon J bearings are self-lubricating and require no manual greasing or
frequent changes, our partners report they have increased their efficiency and productivity.

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Rulon® J Technical Data

Temperature - Typical Range ˚F (˚C ) -400/+550 (-240/+288)*
Maximum PV (continuous)(MPa•m/s) 7,500 (0.26)*
Maximum P - psi (static)(MPa) 750 (5.2)*
Maximum V -SFM (no load)(m/s) 400 (2)*
Shaft Hardness – Minimum Rb25
Shaft finish recommended Ra μin(μm) 8–16 (0.2-0.4)*
Shaft Material 316 Stainless Steel and Non-Ferrous

Engineering Information
Friction - static & dynamic 0.12–0.20
Water Absorption ASTM D570 0%
Flammability ASTM D635 Non-Flammable
Chemical Resistance Data Available
Thermal Conductivity
BTU/hr/sq. ft./˚F/in. (W/m•K) 1.7 (0.24)*
CoTE 78˚ to 300˚F (26˚ to 149˚C) Diameter 5.2 (9.3)* Length 6.8 (12.2)*
x 10 -5 in/in °F (x 10 -5 m/m °C)

Physical Data
Elongation ASTM D4894 180%
Tensile Strength ASTM D4894 (MPa) 2000 psi (13.8)*
Deformation ASTM D621 3% (1500 psi–24 hr. RT)
Specific Gravity ASTM D792 1.95

*Metric data in parentheses

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The TriStar Advantage: Better sealing

Ultracomp bearings are extremely durable and excel in linear, oscillating, and
rotary applications common to agricultural machinery. They can withstand low
speed, high impact, wet and dry farming conditions. Plus, Ultracomp delivers
compressive strength exceeding 54,000 psi to withstand even the most arduous
farming applications. Ultracomp is available in tube or sheet form, or can be
custom fabricated.

Ultracomp “crushes” maintenance challenge, resists residue

Challenge:
A major producer of sugar cane approached our team to solve a maintenance challenge they were
experiencing. Their worldwide facilities crush approximately 7,000 tons of raw cane each day,
at bearing pressures exceeding 2000 psi, at speeds of 8-10 sfpm. The crushing process produces
a sticky, molasses-like pulp as the juices are drawn, and this residue was becoming “glued” to
the metal bearing journal area. Our client cited the prohibitive cost of supplies, labor, and lost
production needed to constantly grease and clean the metal bearings. They were also alarmed
that a bearing seal failure was imminent.

Solution: Side Bar

Our engineers recommended Ultracomp UC 500 bearings with reinforced fibers that combine a
binding resin and graphite migratory lubrication. Our fabrication team also improved the seal
design at both ends of the journal and eliminated the ingress of sugar onto the bearing surface.

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Ultracomp Technical Data

Property Units UC200 UC300 UC400 UC500
Specific Gravity g/cc 1.35 1.35 1.32 1.35
Tensile Strength psi 17,500 17,500 9,500 17,500
Elongation % 26 26 26 26

Compressive Strength
Perpendicular to Laminate
Yield psi 18,500 14,000 16,000 18,000
Ultimate psi 54,400 45,000 52,000 50,000
Modulus psi 750,000 650,000 730,000 750,000
Impact Strength - Notched ft-lbs/in. >20 >20 >20 >20
Flexural Strength psi 13,500 14,000 13,000 13,500

Operating Temperature
Minimum _ Cryogenic Cryogenic Cryogenic Cryogenic
Maximum - Continuous °F 266 266 335 335
Maximum - Short Term °F 360 360 360 360
Coefficient of Friction – Dry _ 0.15 0.08 0.12 0.15
Water Absorption-
24 hour saturation % <0.1 <0.1 <0.1 <0.1

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The TriStar Advantage: Enhanced strength-to-weight ratio

TriSteel self-lubricating bearings offer a unique, inter-layer substrate to protect farm
machinery in the rare instance of a liner breakthrough. TriSteel can easily manage
the high loads and excessive speeds commonly found in the steering components
and manual control levers of smaller farming machines. They also excel on disc
and harrow tractor attachments.

TriSteel reinforced bearings deliver value, extend use

Challenge:
Our client complained of the cost prohibitive steel bearings used on the undercarriage, steering
column, and control arms of their riding lawnmowers. With steel prices escalating, raw material
costs were continually rising. And their end users (farmers and landscapers) cited a constant
need to grease and maintain the steel bearings; time they simply did not have to devote to
equipment maintenance.

Solution:
Our design experts recommended TriSteel bearings to replace the steel-on-steel units. These
polymer bearings provided enhanced wear life, zero maintenance and a cost-effective solution
to the metal bearing locations throughout the equipment. And because TriSteel bearings Side Bar
are self-
lubricating, they did not require regular maintenance—in fact, our client reports many seasons
of consistent use without the need for regular greasing or bearing replacement.
An added bonus? Our partners were able to go “green” by eliminating the need for greasing.

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TriSteel Technical Data

Property Units PT AC PE
Units (PTFE) (POM) (PEEK)
P Factor
Steady Unidirectional loads, radial psi 20,000 20,000 26,000
Steady Unidirectional loads, oscillating psi 20,000 10,000 26,000
Steady, Continuous rotation, oscillation psi 8,000 10,000 13,500
Dynamic Continuous rotation, oscillation psi 8,000 6,000 8,800
Maximum Static Load psi 36,000 36,000 40,000

V Factor
Maximum Speed – Unlubricated fpm 1,000 Consult with TriStar
Engineering
Maximum Speed – Lube / Oil fpm 2,000 500 2,000
Maximum Speed – Lube / Grease fpm 2,000 100 2,000
Maximum PV Limits psi/fpm 50,000 80,000 100,000
Impact Strength - Notched ft-lbs/in >20 >20 >20
Coefficient of Friction Dynamic - Dry .08–.12 .15–.20 .15–.20
Wear Factor Kx10 -10
9 21 5
Operating Temperature
Minimum °F -300 -40 -140
Maximum – Continuous °F 535 210 500
Coefficient of Thermal Expansion (x10-6)
Parallel to Surface in/in/°F 6 18 4.5
Thermal Conductivity BTU/hr/ft2/°F/in 288 30 28
Water Absorption - 24 hour saturation % 0 0.02 0.15
Liner Thickness in 0.002 .018–.020 .018–.020

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The TriStar Advantage: Exceeding normal operating conditions

CJ composite bearings offer the unique ability to extend the life of agricultural
equipment, without the need for regular lubrication. With a high-load capacity and
chemical resistance, they excel in farming where traditional metals corrode and fail.
Located on conventional machines like back hoes and tractors, CJ bearings adapt
to even the most extreme conditions. We build them to withstand beyond normal
farming operating conditions.

Super CJ bearings support extreme weight and cantilevered loads on sprayer tractors

Challenge:
One manufacturer contacted us because they had tried two different materials on the strut arms
of their tractor booms, and both failed under normal operating conditions. They described how
their boom arms reach to 80' beyond the tractor and carry extreme, cantilevered loads. They also
cited that both cast nylon and another polymer bearing material had failed in this application.

Solution:
After consultation and field trial, our engineers suggested our Super CJ bearings—among the
strongest in our inventory—for the suspension boom arms. Super CJ bearings adapt as the boom
Side Bar
arm weaves and rides over uneven farming terrain, and can easily withstand shaft misalignment.
CJs are built to easily resist the dirt, dust and over spraying of farming, and shine in the most
extreme conditions, even outside of normal farming specifications.
With CJ bearings in place, our client reports a significant increase in machine durability
and longevity.

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CJ Technical Data
Properties CJ FCJ
Maximum Pressure (P)
(static) psi 35,000 (1) 20,000
MPa 241 138
(dynamic) psi 20,000 20,000
MPa 140 140
Maximum Velocity
(V) ft/min 150 500
(no load) m/sec. 76 2.54
Lubrication No No
Temperature °F -320/+300 -320/+300
— Typical Range °C -195/+149 -195/+149
Shaft Hardness Rc 50 Rb 25
— Minimum, Rockwell Scale
Shaft Finish 8-16 8-16
Recommended
Ra (Microinches)
Shaft Material Steel Steel
Coefficient of Friction .02–.25 .01–.20
(Static/Dynamic Range)
Water Absorption <.5% <.5%
(ASTM D570)
Corrosion Resistance Excellent Excellent
Linear Coefficient of in/in/°F 7 x 10 7 x 10–6
–6

Thermal Expansion cm/cm/°C 13 x 10

–6
13 x 10–6
(ASTM D696)
78°F to 300°
F26°C to 149°C

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The TriStar Advantage: Custom design and expert machining

Only TriStar delivers fabricated parts—from prototype to production—and all from
our in-house facility. We have all of the equipment needed to machine, stamp, bond,
punch and form plastic parts to meet any agricultural need. We work with virtually
all materials, and our experienced team knows the nuances of machining each.

Trilon AR fabricated parts save on maintenance, reduce friction

Challenge:
Our partner, a manufacturer of silage bagging equipment, was using steel parts on the wear
blocks, slide pads and bushings of their conveyor equipment. Their 30’ x 40’ bags are used
to store bales of collected wheat straw for later use as high-quality feed. The client found
that steel-on-steel became a maintenance problem, and caused high levels of friction that
impeded productivity.

Solution:
The TriStar design and fabrication teams crafted new parts made of Trilon, a modified UHMW
compound. Trilon is extremely abrasion-resistant, does not absorb moisture, and self-lubricates.
With new Trilon custom components in place, our client reports zero maintenance costs, fewer
Side Bar
production slowdowns, and reduced friction on the surface of the bagging devices.

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Trilon AR Technical Data

Property Units ASTM Test Value
Specific Gravity/Density gm/cm3 D792 .932–.960
Molecular Weight — — 4-6 million
Tensile Strength at Yield 73º F psi D638 2700–2900
Impact Strength ft-lb/in D256 No Break
Izod Double Notch ft-lbs/in D785 -25
Shore D Hardness — D785 62–67
Elongation at Break % D638 ≥300
Water Absorption — — Nil
Linear Thermal Expansion in/in/ºF — 7.8 x 10–5
Melt Point ºF D789 275–280
Max Operating Temperature ºF — 180
Short Term Temperature ºF — 225
Max Static Load (P) psi — 1200
Max Unlubricated Velocity (V) ft/min — 75
Max Limiting PV (unlubricated) psi x ft/min — 2000
Coefficient of Friction: Static — — .12–.15
Coefficient of Friction: Dynamic — — .07–.10

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Experience the TriStar Advantage

Clearly, the integration of technology is the future of precision agricultural
machinery, and TriStar Plastics is at the forefront of bearing innovations. Our line
of durable, self-lubricating composite bearings outlasts and outperforms all others,
including metal. We propel the linkage and pivot points, steering and hydraulics TriStar’s polymer bearings
deliver enhanced efficiency,
in a range of agricultural equipment, from tractors and harvesters, to mowers,
productivity and value to the
cultivators, sprayers and cutters.
agricultural industry—all the
Experience the TriStar Advantage to see how we can help enhance efficiency,
way from factory to farm.
productivity, and value to both the manufacturers—and users—of agricultural
equipment.

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