When one of the world’s largest automotive manufacturers asked TriStar to evaluate production challenges in their assembly plant, our team was eager to help. During a walkthrough where we reviewed several issues, we ultimately zeroed in on a critical piece of equipment: the overhead conveyor wheels that carried heavy engines down the line.
Recurring Conveyor Headaches
The problems with conveyor wheels weren’t new to us. We’d seen the same issues on paint lines and production runs across multiple industries. Internal ball bearings would lose lubrication, causing drag and chatter as wheels locked up. Maintenance required popping off seals, re-lubricating, and re-sealing—a time consuming and expensive process that often cost more than simply replacing the wheel. To make matters worse, some facilities tried greasing the tracks directly, which only led to grease drips on the floor—and sometimes on the product itself!
A Hybrid Approach
For this customer, TriStar engineers recommended a unique solution: Ultracomp UC200 paired with a hybrid ball bearing assembly featuring self-lubricating cages. This design eliminated the need for constant maintenance while offering the ability to easily disassemble and repair the wheel in minutes, something impossible with traditional sealed units.
Clean and Quiet Performance That Lasts
The Ultracomp® UC200 wheel and seal assembly brought multiple benefits. UC200 is a composite of polyester resins and fibers with graphite lubricants, giving it exceptional compressive and impact strength. A self-lubricating Rulon® cage maintained a thin PTFE film on the balls and races for smooth, maintenance-free operation.
Loads were no issue—the wheel’s high-capacity design carried engines station to station without fail. And unlike noisy steel-on-steel systems, UC200 wheels ran quieter, reducing overall plant noise while delivering years of reliable service.
Engineering Time into Savings
Though more costly up front, the UC200 solution paid off quickly. For an automotive assembly line, uptime is everything, and eliminating constant wheel failures saved this manufacturer both money and production time. It’s a reminder that smart material choices not only solve recurring issues but also create lasting value.
Have a similar challenge in your plant? Contact our experts to discuss how TriStar solutions can improve performance and reduce downtime.