In theory, the service life of rolling bearings is 20000 to 80000 hours, but the actual life depends on many factors - premature bearing failure can lead to costly equipment downtime, and sometimes even more serious consequences. Cotton provides you with some simple but practical tips for optimizing bearing performance.

Selection of bearings

Satisfactory bearing service life begins with correct bearing selection. From the beginning, bearing designers extended bearing life and equipment performance by selecting the correct bearings for different applications. This process needs to consider many factors, such as load, hardness, bearing life prediction, operating environment, and so on.

Proper storage

In principle, all bearings should be stored in their original packaging before installation. They need to be left in a clean, moisture free, and relatively constant temperature environment. Rolling bearings should be kept away from dust, water, and corrosive chemicals. Shake and vibration may permanently damage the mechanical performance of bearings, so vibration must be avoided during handling and storage.

Basically, all bearings must be stored horizontally, as some heavier bearings may deform due to their own weight after being placed vertically for a long time.

Bearings that are pre coated (or sealed) with grease require special care, as the density of the grease can change after prolonged storage. This way, when the bearing is first used, there will be a certain degree of rotational noise. Therefore, the shelving time of this type of bearing should be controlled according to the principle of first in, first out.

clean

Cleaning is very important for rolling bearings. The surface roughness of the rotating surface of the bearing ring and the rolling element is usually 1/10 μ m. Such a smooth surface is very sensitive to damage caused by pollutants. The lubrication layer between the rotating surfaces is usually 0.2-1 μ m. Granular impurities larger than the lubricant particle size will be subjected to excessive rolling by rolling elements, resulting in local pressure in the bearing steel and ultimately leading to permanent material fatigue. In addition to this, the size of dust particles in the external environment can reach 10 μ m. It can also cause damage to the bearings. Therefore, a clean and dust-free environment is crucial for the storage and installation of bearings.

Fully prepare for reinstallation

Bearings should be carefully installed and disassembled using suitable tools. Industry experts estimate that 16% of premature bearing failures are due to incorrect installation. For large-scale installations (such as in production plants), it is usually necessary to strictly control the installation conditions, and suitable bearing installation equipment can also be used.

However, in maintenance or replacement work, the environment is diverse. Therefore, comprehensive preparation work is necessary for bearing installation to ensure the longest bearing service life.

Firstly, relevant documents, such as drawings, maintenance manuals, product manuals, etc., need to be carefully studied. Next, all bearing components, such as shafts, distance rings, covers, washers, etc., must be kept absolutely clean and free from contamination. The condition of adjacent components should also be carefully checked.

Carefully install and disassemble

Choose appropriate installation methods (mechanical or hydraulic) and tools based on different applications and bearing sizes and types. Here are some basic principles for bearing installation:

1. Do not apply installation force on the rolling element, as this can easily cause local overloading of the contact surface between the rolling element and the seat ring, leading to premature failure of the bearing.

2. Do not use any hard tools (such as a hammer, screwdriver, etc.) to directly hit the bearing surface, as this will cause the bearing ring to break or shatter.

3. Follow the guidance of respected installation equipment suppliers.

About 90% of rolling bearings have never been removed from the equipment where they are located, and usually only larger bearings will be removed due to the scheduled Preventive maintenance procedures. Just like installing a bearing, careful preparation should also be made when disassembling the bearing. During the disassembly process, it is necessary to ensure that adjacent components such as the shaft and shaft sleeve are not damaged. Choose appropriate methods and tools based on the type, size, and application of the bearing.

Designers should note that well-designed bearing positions can greatly simplify the installation and disassembly of bearings, thereby reducing maintenance costs.

lubrication

Lubricants can isolate metal bearing surfaces (such as rolling elements, bearing rings, and bearing covers), thereby reducing friction, protecting metal components, and preventing pollution and impurities. There are various lubricants (including grease, oil, and solids) available for different operating conditions. The correct selection of lubricants is crucial for extending the service life of bearings and equipment.

Due to excessive rolling of rolling components, bearing lubricants undergo prolonged mechanical pressure. Additionally, over time, especially in high temperature, wet, or contaminated environments, the chemical properties of lubricants may change. All of these have led to a gradual decline in lubrication quality. Therefore, to ensure the longest service life, it is necessary to regularly re lubricate the bearings. The lubrication cycle depends on operating conditions, such as temperature, speed, environment, etc. Only in pre lubricated or sealed bearings (also known as "lifetime lubricated" bearings), the bearing life depends on the lubricant life.

Lubricants must be properly stored according to the manufacturer's instructions, with special attention to keeping them clean and free from contamination. Before each use, carefully check the quality of the lubricant. Using old or contaminated lubricants may cause premature bearing failure.

Status detection/maintenance

Generally speaking, rolling bearings are very reliable, despite their limited lifespan. Like all other important components in the machine, they should be regularly inspected and maintained. The frequency of inspection and maintenance depends on the importance of individual applications and the operating conditions of each equipment.

Due to the critical role of bearings, it is recommended to incorporate condition monitoring function in their design phase. The important parameters of machine operation, such as vibration and noise, can be continuously monitored, and preventive measures should be taken before unpredictable and expensive equipment shuts down.

Training - the foundation of good practice

Practice makes perfect, but appropriate training is the foundation of practice. If technical personnel have basic knowledge in handling bearings, they can avoid major mistakes. Design and product development engineers can optimize bearing design to maximize equipment performance and minimize lifecycle costs.

Bearings are important components in equipment. Although first-class bearings are very reliable, to ensure their longest service life, more attention should be paid. Proper preservation, careful installation and disassembly, sufficient lubrication and relubrication, correct condition monitoring, timely maintenance, and finally comprehensive personnel training are all crucial for improving the service life of bearings and equipment performance.