For the maintenance of CA copper insulated self-aligning roller bearings, specific methods can be started from regular inspection, cleaning, lubrication, operation monitoring, installation specifications, environmental protection, etc. The following are specific methods:
Regular inspection and cleaning Regular inspection: Regularly inspect the bearings, including the status of the raceway surface, rolling surface, mating surface, wear of the cage, increase in bearing clearance, and whether there is damage or abnormality related to the decrease in dimensional accuracy. For non separable ball bearings, use one hand to support the inner ring horizontally and rotate the outer ring to confirm if it flows smoothly; For self-aligning roller bearings and equally spaced bearings, the raceway surfaces of the rolling elements and outer rings can be inspected separately; Large bearings cannot be rotated by hand, so attention should be paid to checking the appearance of rolling elements, raceway surfaces, retainers, and retaining surfaces. The higher the importance of bearings, the more careful the inspection must be.
Cleaning: Wipe the surface impurities with diesel/kerosene every 2 weeks to avoid "running with problems".
. When disassembling the bearing for maintenance, first record the appearance of the bearing, confirm the residual amount of lubricant, take a sample of the lubricant used for inspection, and then clean the bearing. Cleaning is divided into coarse cleaning and fine cleaning, each in a container. First, place a metal mesh bottom to prevent the bearing from directly contacting the dirt in the container. During rough cleaning, use a brush or other tool to remove lubricating grease or adhesives from the oil. If the bearing is rotated in the oil at this time, be careful not to damage the rolling surface due to foreign objects; When performing precision cleaning, slowly rotate the bearing in oil, and it must be done carefully. The commonly used cleaning agents are neutral, water free diesel or kerosene, and sometimes warm alkaline solutions are also used as needed. Regardless of which cleaning agent is used, it is necessary to filter it regularly to maintain cleanliness. After cleaning, immediately apply rust proof oil or grease to the bearings.Lubrication Management Lubrication Selection: Ceramic grease is used for high temperature environments, lithium based grease is selected for normal working conditions, and different brands of grease should not be mixed.
. The initial grease injection amount is 30% of the internal space, and an oil air lubrication system is used for high-speed operating conditions (DN value>500000). The lubrication cycle formula is T=K × (14 × 10 ^ 6)/(n × √ d), where K is the environmental coefficient (0.5 for dust environment). Compatibility testing is required when mixing lubricating grease to avoid damage to the soap based structure.Refueling operation: When refueling, it is forbidden to have dust in the surrounding environment; Use clean hands to add oil, slowly rotate the entire bearing with one hand, and use the middle and index fingers to inject oil pressure into the bearing cavity with the other hand. Add one side before proceeding to the other. Remove excess grease based on the number of motor poles. Oil filling amount for bearings and bearing covers: The oil filling amount for bearing covers is 1/2 to 2/3 of the bearing cover capacity (with the upper limit for motor poles); Bearing oil volume: 1/2 to 2/3 of the inner and outer ring cavities of the bearing (with the upper limit for the number of motor poles). The motor end cover with oil replenishment and drainage holes must also be cleaned during oil change to ensure smooth passage. Motors with oil refilling holes must be refilled regularly, and the refilling cycle is determined based on the motor's operating requirements and conditions (usually running a two pole motor for 500 hours within 24 hours). When refueling, the refueling port must be clean, and the amount of refueling should be limited to a bearing temperature increase of only 2 ℃ (for 2-pole motors, quickly inject oil twice with an oil gun and observe for 10 minutes, and decide whether to continue refueling based on the situation).
Operation monitoring and monitoring of vibration, temperature, and noise: During use, it is necessary to regularly monitor the basic external conditions of bearing operation, such as temperature, vibration, and noise measurement, etc. These regular inspections will detect potential problems early and prevent unexpected machine shutdowns, enabling production plans to be realized and improving factory productivity and efficiency.
Iron spectrum analysis detection: Using iron spectrum analysis technology, regularly detect the content of metal abrasive particles in lubricating oil (>15 μ m particles should be<1000/ml).
. Magnetic particle inspection: MTF (magnetic particle inspection) testing is conducted every 2000 hours, with a focus on inspecting the stress concentration area on the roller end face.Accurate installation and disassembly: Use hydraulic disassembly tools to control the pressing force (≤ 200MPa), and direct hammering is prohibited.
. Induction heaters are used for heating assembly, with a temperature gradient not exceeding 5 ℃/min and a maximum heating temperature of 120 ℃. The fitting tolerance follows the ISO 286 standard, and the interference fit is controlled at H7/k6 level. When disassembling and assembling bearings, it is necessary to ensure that the force points are correct (the inner ring on the shaft is subjected to force, and the inner and outer rings on the end cover are subjected to force), and the force is uniform. When installing the bearing, apply a small amount of grease evenly on the contact surface. The temperature of the bearing heating method is controlled between 80 and 100 ℃, and the time between 80 and 100 ℃ is controlled within 10 minutes. Ensure the use of non corrosive mineral oil with good thermal stability (preferably transformer oil) for oil heating, and both the oil and container should be clean. Set up a metal mesh at a distance of 50 to 70mm from the bottom of the oil tank, and place the bearings on the mesh. Large bearings also need to be lifted with hooks.Proper disassembly: When the bearing is about to reach its final service life, it should be replaced.
. Although bearings can no longer be used, correctly removing the original self-aligning roller bearings and replacing them with new ones in a timely manner can greatly promote the extension of the service life of the new bearings.Environmental protection and rust prevention treatment: Spray WD-40 rust inhibitor every quarter, and inject gas-phase rust prevention oil when it is not in use for a long time.
.Insulation design: The outer ring is sprayed with alumina ceramic layer, and the retainer is made of polytetrafluoroethylene material.
. Drainage structure: A 45 ° inclined drainage hole is set at the bottom of the bearing seat to prevent liquid retention.