During the use of rolling bearings, due to their own quality and external conditions, their load-bearing capacity, rotation accuracy and friction reduction performance will change. When the performance indicators of the bearings are lower than the use requirements and cannot work normally, abnormal phenomena such as machine equipment stopping running and function damage will occur. Therefore, the maintenance of rolling bearings is particularly important, but incorrect maintenance methods often cause more serious damage to the bearings and are counterproductive. Today, bearing technology engineer Maxwell will introduce the correct maintenance methods for rolling bearings in this article.
1. The Correct Way to Install and Remove Rolling Bearings
Installation: A Precise Beginning
Proper installation is the foundation of rolling bearing performance. Incorrect installation can lead to premature failure, misalignment, or reduced efficiency.
Steps:
Preparation: Ensure the shaft, housing, and bearing are clean and free of dirt, rust, or burrs. Even minor contaminants can affect the fit and cause uneven stress.
Alignment: Align the bearing perfectly with the shaft or housing to avoid forcing it into place. Misalignment can lead to excessive wear or internal damage.
Pressing the Bearing: Use suitable tools to apply uniform force. Never apply force directly to the rolling elements or the cage, as this can cause deformation. For tight fits, heating the bearing to expand it slightly can ease installation.
Final Checks: After installation, rotate the shaft or bearing manually to ensure smooth operation without abnormal resistance.
Tools:
Bearing fitting kits: Ensure uniform force application.
Hydraulic or mechanical presses: Ideal for large bearings.
Induction heaters or oil baths: For thermal expansion.
Removal: Safe and Efficient Dismantling
Proper removal is essential to prevent damage to the bearing and associated components.
Steps:
Preparation: Assess the fit and select appropriate tools. Ensure the surrounding area is clean to avoid contamination.
Application of Force: Use pullers or hydraulic tools to apply even force, ensuring the bearing is removed smoothly.
Thermal Assistance: For tightly fitted bearings, heating the housing can help loosen the fit.
Tools:
Pullers: Available in mechanical and hydraulic variants for different sizes.
Induction heaters: For precise heating without damaging components.
Protective gloves: To handle heated components safely.
Correct installation and removal are critical to maintaining the structural integrity of rolling bearings, ensuring their optimal performance and longevity.
In another article of mine, I introduced in detail the misunderstandings about bearing installation and the correct use of tools, and provided a schematic diagram. Please click the link below to read it.
2. Lubricating Of Rolling Bearing
Lubricating Materials: The Lifeblood of Bearings
Selecting the right lubricant is essential to reduce friction, prevent wear, and protect against corrosion.
Types of Lubricants:
Greases: Suitable for most applications, grease provides a long-lasting film. Choose based on operating conditions, such as load, speed, and temperature.
Multi-purpose grease: Covers a broad range of applications.
High-temperature grease: For bearings operating in extreme conditions.
Oils: Preferred for high-speed or high-temperature applications where grease may not circulate effectively.
Mineral oils: Commonly used for general purposes.
Synthetic oils: Offer superior performance in demanding environments.
Lubrication Methods
Manual Lubrication: Using grease guns or oilers for periodic maintenance.
Automatic Lubrication Systems: Ensure consistent application, ideal for continuous operation.
Circulating Oil Systems: Used in large machinery, where oil is filtered and reused.
Lubrication Cycles
Follow manufacturer’s guidelines for re-lubrication intervals.
Adapt cycles based on operating conditions like load, temperature, and environmental contaminants.
Proper lubrication ensures reduced friction, minimizes wear, and dissipates heat effectively, enhancing the bearing’s lifespan.
3. How to Properly Clean Disassembled Rolling Bearings
Cleaning disassembled bearings is a meticulous process that ensures optimal performance upon reassembly.
Steps:
Initial Cleaning: Remove loose dirt and contaminants with a clean, dry cloth.
Soaking: Immerse the bearing in a solvent such as kerosene to dissolve old grease and debris.
Brushing: Use soft-bristle brushes to gently remove stubborn contaminants. Avoid harsh scrubbing that could damage the surface.
Rinsing: Rinse the bearing with fresh solvent to remove residues.
Drying: Use compressed air or lint-free cloths to dry the bearing completely. Ensure no moisture remains, as it can cause corrosion.
Inspection: Examine the bearing for wear, cracks, or other damage. Replace if necessary.
Tools:
Solvent baths: For thorough cleaning.
Soft brushes: Prevent scratches or damage.
Compressed air: For effective drying.
Cleaning disassembled bearings ensures they are free from contaminants that can cause premature failure or operational inefficiencies.
4. Daily Training for Maintenance Personnel
Skilled maintenance personnel are crucial to the effective upkeep of rolling bearings.
Key Training Areas:
Understanding Bearing Types: Familiarity with different designs, materials, and applications.
Handling and Storage: Proper techniques to avoid damage during transportation or storage.
Installation and Removal: Mastery of tools and methods for precise handling.
Failure Analysis: Recognizing signs of wear, misalignment, or lubrication issues.
Importance of Training:
Reduces human errors that lead to bearing failures.
Enhances the team’s ability to detect and resolve issues early.
Improves efficiency and reliability of machinery.
Regular training sessions ensure maintenance teams remain up-to-date with the latest techniques and technologies, fostering a culture of excellence.
5. Daily Online Detection of Rolling Bearings to Troubleshoot Problems in a Timely Manner
Advanced monitoring techniques are essential for proactive maintenance.
Techniques:
Vibration Analysis: Detects imbalances, misalignments, or early signs of wear.
Temperature Monitoring: Identifies overheating caused by inadequate lubrication or excessive load.
Acoustic Emission Monitoring: Detects high-frequency signals associated with surface defects or cracks.
Tools:
Vibration Analyzers: Provide real-time data on bearing condition.
Infrared Thermometers: Measure surface temperatures accurately.
Ultrasonic Detectors: Capture sound waves to identify defects.
Benefits of Online Detection:
Early identification of potential issues prevents catastrophic failures.
Reduces downtime by enabling planned maintenance.
Enhances overall machine reliability.
Conclusion
By following these comprehensive maintenance practices, businesses can maximize the performance and lifespan of rolling bearings, ensuring operational efficiency and minimizing downtime. Investing in proper tools, training, and monitoring systems not only protects equipment but also contributes to long-term cost savings and productivity gains.
