Customized automotive bearings have a wide range of application scenarios, covering five core directions: special working conditions, performance optimization, emerging fields, lightweight and integration, and special environments. Specific scenarios and customization requirements are as follows:
1. Special working condition requirements
High load scenarios
Commercial vehicles and construction machinery: clutch systems of heavy trucks and construction vehicles (such as excavators and loaders) need to withstand the axial impact force generated by frequent gear shifts. Customization requirements include:
Material upgrade: using high-strength bearing steel (such as GCr15) or surface hardening treatment to enhance fatigue resistance.
Structural strengthening: increase the number or diameter of steel balls, optimize the curvature of the raceway, distribute the load, and extend the service life.
. Sealing design: Customized metal dust cover or rubber sealing ring to prevent mud and sand from entering and adapt to harsh road conditions. High performance passenger cars: The clutch of sports cars or SUVs needs to cope with high torque output (such as turbocharged engines). Customization requirements include:Bi directional load-bearing design: Customized bi-directional thrust ball bearings that can withstand both forward and reverse axial forces, improving shifting smoothness. Lightweight materials: using aluminum alloy or composite seat rings to reduce unsprung mass and improve handling response.
Extreme environmental scenarios
Extreme climate regions: vehicles in high-altitude (such as Siberia) or high-temperature (such as the Middle East) areas.
. Customization requirements include:Temperature resistant materials: Full ceramic balls (such as Si ∝ N ₄) or high-temperature alloy seat rings are used for high temperature conditions; Low viscosity lubricating grease is used for low-temperature working conditions.
Anti corrosion coating: galvanized or Dacromet treated to prevent salt spray corrosion (in coastal areas or snowmelt environments).
.New energy commercial vehicles: The clutch of hydrogen fuel cell vehicles or electric trucks needs to be resistant to hydrogen embrittlement or electrochemical corrosion for a long time.
. Customization requirements include:Hydrogen compatible materials: using stainless steel or special alloys (such as Inconel 718) to avoid hydrogen permeation and embrittlement.
Insulation design: Embed insulation layer in the seat ring or retainer to prevent electrochemical corrosion (such as leakage scenarios in battery systems).
.2. Performance optimization requirements
Long life requirements
High mileage operating vehicles such as taxis and logistics vehicles.
. Customization requirements include:Self lubrication technology: using solid lubricants (such as MoS ₂) coating or oil containing retainers to reduce maintenance frequency. Fatigue life testing: Customized accelerated life testing (such as 10 cycles of testing) to ensure a design life of ≥ 500000 kilometers.
High precision requirements
Automatic transmission (AT/CVT): The clutch between the hydraulic torque converter and the planetary gear set requires high-precision axial positioning.
. Customization requirements include:Clearance control: customizing extremely small axial clearance (≤ 0.01mm) to reduce transmission errors and improve shifting accuracy. Surface treatment: using ultra precision machining or laser texturing technology to reduce friction coefficient and vibration noise.
Hybrid/electric vehicles: The clutch in the electric drive system (such as P2 architecture) needs to be compatible with high motor speeds (>10000rpm).
. Customization requirements include:High speed design: optimizing the cage structure, using phenolic resin or copper alloy materials to prevent high-speed centrifugal force failure. Low temperature lubrication: Customized low-temperature grease (working temperature range -40 ℃~150 ℃) to meet the high-efficiency heat dissipation requirements of the motor.
III. Emerging Field Demand
New Energy Vehicles
800V High Voltage Platform: Promoting the penetration rate of ceramic insulated bearings to exceed 30%, with a single unit value of 5000-10000 yuan.
. Customization requirements include:Ceramic ball bearings: using silicon nitride ceramic balls to reduce temperature rise and improve motor efficiency. Vacuum sealing technology: blocks electrical corrosion and extends bearing life to 2.3 times the industry average.
Hydrogen energy field: Developing PTFE self-lubricating bearings that can work normally at liquid hydrogen temperatures (-253 ℃).
.Autonomous driving and intelligent networking
Wire controlled steering system: requires high-precision, low friction customized bearings to ensure steering response speed and accuracy.
.Sensor integrated bearings: built-in temperature and vibration sensors, real-time monitoring of bearing status, supporting predictive maintenance.
.Fourth, Lightweight and Integrated Requirements
New Energy Vehicle Range Optimization
Modular Design: Integrating thrust ball bearings with clutch pressure plates to reduce the number of components and weight.
. 3D printing technology: Metal 3D printing is used to manufacture complex structural seat rings, achieving a balance between lightweight and strength.Electrification trend
Integration of electric drive axle: Customized bearings need to adapt to the compact layout of electric drive axle, while bearing motor torque and reducer load.
. Wheel hub motor bearings: Develop customized bearings with high speed and low noise, supporting distributed drive of wheel hub motors.Fifth, Special Functional Requirements
Self lubrication and Maintenance free
Petroleum Drilling Platform: Copper based graphite self-lubricating sliders are used to achieve oil-free lubrication and meet damping force requirements.
. Food processing machinery: Customized stainless steel bearings that meet hygiene standards and prevent corrosion and contamination.Corrosion and Wear Resistance
Chemical Equipment: Ceramic or composite material bearings are used to resist chemical corrosion.
. Mining Machinery: Customize high hardness steel balls and raceways to enhance wear resistance and extend service life.