Bearings in the Age of Electrification & Automation – Challenges & Opportunities

At NBC Bearings, we have developed high-RPM, low-friction, & sensor-integrated bearings specifically for EV applications to help improve vehicle efficiency & contribute to greater battery range.

Rohit Saboo
President & CEO, NBC Bearings

The rise of electrification and automation is reshaping industries, placing greater demands on precision-engineered components. Bearings play a critical role in ensuring efficiency, reliability, and sustainability across sectors such as electric vehicles (EVs), industrial automation, and smart manufacturing. As a leading bearing manufacturer, NBC Bearings is actively innovating to meet these evolving needs.

 EVs and Renewable Energy – Reshaping Bearing Design:

The growing adoption of EVs and renewable energy is driving significant changes in bearing technology. Bearings in electric drivetrains must support higher speeds, lower friction, and extended durability while minimizing energy losses. At NBC Bearings, we have developed high-RPM, low-friction, and sensor-integrated bearings specifically for EV applications. These innovations help improve vehicle efficiency and contribute to greater battery range.

Similarly, renewable energy applications, such as wind turbines, require specialized bearings capable of handling extreme loads and environmental conditions. The industry is seeing advancements in high-durability, corrosion-resistant, and self-lubricating bearings to support this transition.

Automation & Robotics:

The Next Frontier for Bearings Industrial automation is accelerating, with robotics, CNC machines, and smart factories demanding bearings that deliver higher speed, precision, and reliability. Bearings used in robotics must accommodate rapid movements, high load variations, and minimal maintenance. The shift towards collaborative robots (cobots) and AI-driven automation is further increasing demand for high-performance, friction-optimized bearings.

At NBC, we are actively working on advanced materials, coatings, and lubrication technologies to extend the lifespan and efficiency of bearings in industrial applications. Our focus on process automation ensures consistent quality while enhancing operational efficiency.

Connected Factories –
Leveraging Digital Transformation: As part of Industry 4.0, manufacturing is becoming increasingly data-driven, enabling predictive maintenance and operational excellence. NBC Bearings has adopted connected factory technology, where machines, production lines, and quality systems are digitally linked to optimize performance.

By integrating IoT, AI-driven analytics, and cloud-based monitoring, NBC ensures real-time production insights, automated quality control, and reduced downtime. These innovations not only enhance product consistency but also allow us to respond rapidly to changing customer demands.

AI, IIoT & Smart Sensors –
The Future of Predictive Maintenance:The integration of AI, Industrial IoT (IIoT), and smart sensors is transforming bearing monitoring and maintenance strategies. NBC Bearings has invested in sensorized bearings that provide real-time condition monitoring, allowing industries to predict failures before they occur.

These intelligent bearings collect critical data on vibration, temperature, and load conditions, which is analyzed through AI-driven algorithms. By shifting from reactive to predictive maintenance, manufacturers can increase uptime, enhance efficiency, and lower operational costs.

Addressing Supply Chain & Raw Material Challenges:

The post-pandemic landscape has highlighted vulnerabilities in raw material availability and supply chains. To mitigate these risks, NBC Bearings has focused on localizing supply sources, optimizing inventory management, and leveraging digital procurement platforms.

Additionally, our commitment to sustainable manufacturing includes:

10 MW of solar power generation to reduce dependency on non-renewable energy

Over 6 million liters of water conservation annually through rainwater harvesting

Zero wastewater discharge to ensure environmentally responsible operations

Low-carbon manufacturing practices to support global climate goals

Looking Ahead – The Future of Bearings in Electrification & Automation:

The bearing industry must continuously evolve to meet the demands of electrification and automation. NBC Bearings remains committed to innovation, digital transformation, and sustainability, ensuring we provide cutting-edge solutions for the automotive, industrial, and renewable energy sectors.

With the rapid evolution of smart factories, AI-driven manufacturing, and energy-efficient designs, the bearings we develop today will shape the efficiency, reliability, and sustainability of tomorrow’s mobility and industrial ecosystems.

Bearings in electric vehicles (EVs) must be designed to handle higher speeds, lower friction, electrical insulation requirements, and extended durability compared to conventional internal combustion engine (ICE) vehicles.

Vikas Manral
Global Bearing Expert

EV Ushers in a Revolution:
The electric vehicle (EV) industry is revolutionizing the future of the automotive sector by driving advancements in technology, sustainability, and mobility. With a shift away from internal combustion engines (ICEs), EVs are reducing carbon emissions and dependence on fossil fuels, addressing critical environmental concerns. The demand for cleaner transportation is pushing automakers to innovate battery technology, leading to higher energy densities, faster charging times, and longer driving ranges. This transformation is also influencing infrastructure, with rapid expansion in charging networks and smart grid integration to support the growing number of EVs on the road.

Beyond sustainability, EVs are redefining vehicle performance with instant torque, quieter operation, and simplified mechanical design, reducing the need for complex maintenance. The rise of connected and autonomous driving technologies is further integrating with EV platforms, enabling smarter, more efficient mobility solutions. Traditional automotive supply chains are being reshaped as automakers invest in electric drivetrains, battery manufacturing, and power electronics, creating new business models and job opportunities. Governments worldwide are accelerating this transition with incentives and stringent emission regulations, making EVs the future standard.

As battery costs decline and charging infrastructure expands, electric vehicles will become more accessible, ultimately transforming the way people commute and shaping the future of transportation.

Evolution in Bearing Design:

Bearings in electric vehicles (EVs) must be designed to handle higher speeds, lower friction, electrical insulation requirements, and extended durability compared to conventional internal combustion engine (ICE) vehicles. One of the most suitable designs for EVs is hybrid ceramic bearings, which use steel rings with ceramic rolling elements such as silicon nitride.

These bearings offer reduced friction, improved wear resistance, and the ability to operate at extremely high speeds, making them ideal for EV motors that frequently exceed 20,000 RPM. Additionally, electrically insulated bearings are essential in EV applications to prevent electrical discharge damage (EDM), which can degrade conventional steel bearings due to high-frequency currents from the powertrain. These bearings either feature ceramic coatings on their outer rings or use ceramic rolling elements to block electrical currents and extend operational lifespan.

Low-friction deep groove ball bearings are another crucial design optimized with advanced polymer cages and special lubrication to minimize energy losses. By reducing heat generation and operational noise, these bearings enhance the efficiency of EV transmissions and auxiliary systems, ultimately extending battery range. For high-torque applications such as EV axles and differential systems, tapered roller bearings (TRBs) are widely used due to their ability to handle both radial and axial loads effectively. These bearings ensure better load distribution, reducing heat buildup and enhancing durability under demanding driving conditions.

Improved Reliability:
To further improve reliability and performance, sensor-integrated bearings with IoT-enabled monitoring are being increasingly adopted in EVs. These bearings provide real-time data on temperature, load, and wear, allowing predictive maintenance and minimizing unexpected failures. Overall, EVs require advanced bearing designs that incorporate ceramic hybrids, electrical insulation, low-friction materials, and smart monitoring capabilities to achieve higher efficiency, reduced maintenance, and longer service
life. The evolution of bearing technology is playing a critical role in enhancing the performance and sustainability of modern electric vehicles.

Bearing manufacturers are scaling up production and enhancing quality control to meet the EV industry’s demands. They are investing in advanced automation, precision manufacturing, and high-speed production lines to ensure consistency and efficiency. Quality is being improved through rigorous testing, including higher-speed endurance, electrical insulation, and thermal resistance assessments.

The use of AI-driven inspection systems ensures defect-free products. By collaborating with EV makers and focusing on innovation, they are optimizing designs to support the industry’s need for reliable, energy-efficient, and long-lasting bearings.”