Daily maintenance of bearings: 5 tips to extend life
In the field of industrial production and mechanical equipment, the stable operation of bearings is related to the reliability of the entire system. According to the data of the American Tribologists Association, standardized daily maintenance can extend the average life of bearings by 2-3 times. The following are 5 key maintenance strategies that have been verified in practice:
1. Scientific lubrication management
Lubrication is the first step in bearing maintenance. It is recommended to adopt the lubrication principle of "small amounts and multiple times":
• Check the state of grease every quarter, and replace it immediately if hardening or discoloration occurs
• Use special oiling tools to ensure that the grease is evenly distributed
• Choose synthetic grease (such as polyurea-based) for high temperature environments and ester grease for low temperature environments
2. Strict pollution control
A case of an automobile factory shows that the failure rate of bearings dropped by 67% after the installation of a sealing device. The key points of pollution prevention include:
• Regularly clean the area around the bearing seat
• Use seals that meet the IP protection level
• Install protective covers in dusty environments
• Keep the operating environment clean when replacing bearings
3. Standard installation operations
Improper installation will cause 30% of early failures. Key operating specifications:
• Use professional installation tools (hydraulic nuts/induction heaters)
• Do not hammer the bearing rings directly
• Ensure that the tolerances between the shaft and the bearing chamber meet ISO standards
• Manually rotate after installation to check for sticking
4. Load and alignment monitoring
A wind power company extended the bearing replacement cycle by 40% through vibration analysis. Monitoring points:
• Check the shaft alignment with a dial indicator every month
• Use a vibration analyzer to detect abnormal frequencies
• Avoid long-term over-rated load operation
• Immediately shut down for inspection if the abnormal temperature rise exceeds 15°C
5. Systematic maintenance plan
It is recommended to establish a three-level maintenance system:
• Daily inspection: check noise, temperature rise, and leakage
• Monthly maintenance: add grease and tighten bolts
• Annual overhaul: comprehensive disassembly and replacement of wear parts
• Use the CMMS system to record maintenance history
Frequently Asked Questions
Q: How to determine the amount of grease to be added?
A: It is advisable to fill 1/3-1/2 of the internal space of the bearing, and 1/3 for high-speed bearings
Q: What symptoms must the bearing be replaced?
A: When there are obvious pitting, peeling or radial clearance exceeds the standard value by 50%
By implementing these maintenance measures, the service life of the ball mill bearing of a cement plant was extended from 12 months to 28 months. It is recommended that enterprises establish a complete bearing health file and control the maintenance cost within 3% of the total equipment cost to achieve the best economic benefits.