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Causes and preventive measures for bearing overload
source：织梦技术论坛 time：2024-10-15 09:52
As a key component of mechanical equipment, bearings play a role of load bearing and support, ensuring that the equipment runs smoothly and efficiently under various load conditions. Whether in motors or gearboxes, bearings must be able to withstand radial and axial loads generated during operation. However, when the actual load of the bearing exceeds its design limit, overload occurs. Overload not only causes premature failure of the bearing, but may also cause more serious equipment failures. What is bearing overload? Bearing overload means that the load borne by the bearing during use exceeds its rated load capacity. The rated load is usually the theoretical calculated value of the bearing manufacturer under standard conditions, and improper use in actual work, such as load exceeding the limit, sudden impact, etc., will cause overload. Overload may occur in the long-term operation of the equipment, or it may occur instantly under sudden impact loads.
Hazards of bearing overload According to material standards, such as ISO 281 and ISO 15243, bearing overload will cause the following common hazards to equipment:
1. Accelerated fatigue damage When the bearing operates under overload conditions, the stress at the contact points of the rolling elements and raceways Significant increase. Prolonged overload operation will cause the material of the bearing to fatigue, micro-cracks will appear, and eventually the surface will peel or chip. This fatigue damage is often one of the main reasons for bearing failure.
2. Deformation and aggravated wear Overloading will cause excessive extrusion of the bearing raceway and rolling elements, resulting in plastic deformation. This will not only increase the friction of the bearing, but also aggravate the wear of the rolling surface. As the wear increases, the running accuracy and efficiency of the bearing will gradually decrease.
3. Temperature rise When the bearing is overloaded, the heat generated inside the bearing increases due to increased friction. The increase in temperature not only accelerates the deterioration of the lubricant, but also causes the performance of the bearing material to decline, further increasing the risk of damage.
4. Instantaneous damage caused by impact loads Sudden impact loads, especially in situations such as starting or emergency braking, can cause the bearing to be subjected to stress exceeding the design limit in a short period of time. This stress accumulation may cause local cracks in the rolling element or raceway, or even cause instantaneous failure of the bearing.
The causes of bearing overload are often related to the use conditions, unreasonable design or improper maintenance of the equipment. The following are some common causes of overload: 1. Improper equipment design The actual working conditions are not fully considered during the equipment design, and the bearing selection is insufficient, resulting in the bearing being unable to withstand excessive stress under heavy load, high speed or complex load conditions.
2. Excessive radial and axial loads In the motor or gearbox, if the radial or axial loads borne by the equipment during operation exceed the rated load of the bearing, the bearing will be in an overloaded state for a long time, causing it to be damaged prematurely.
3. Frequent starting and stopping When the equipment is frequently started, stopped or accelerated, instantaneous high impact loads will be generated. The bearings will be subjected to greater stress in a short period of time, which can easily lead to local overload.
4. Improper lubrication Inadequate lubrication will increase the friction inside the bearing, causing the bearing to be subjected to greater friction stress during operation and accelerating overload damage.
5. Improper alignment Improper alignment during equipment installation, especially poor shaft alignment between the motor and the gearbox, will cause the bearing to bear additional eccentric loads. This uneven load will cause local overload of the bearing.
How to avoid bearing overload? To avoid bearing overload, equipment operators and maintenance engineers need to take measures in design, operation and maintenance:
1. Reasonable bearing selection During the design stage, it is necessary to reasonably select bearings according to actual working conditions and load conditions to ensure that their rated loads can meet the long-term operation requirements of the equipment. If the working conditions are complex, higher rated loads or special bearings can be selected.
2. Control the equipment load to avoid long-term overload operation of the equipment, especially in equipment such as motors and gearboxes, and ensure that the load is within the rated load range of the bearing. For working conditions that may cause instantaneous overload, it is recommended to design appropriate overload protection measures.
3. Optimize start and stop operations Reduce the number of frequent starts and stops of equipment, or use soft start devices to avoid damage to bearings caused by impact loads. Soft start technology can reduce impact stress during startup and reduce the risk of bearing overload.
4. Ensure correct lubrication Regularly check the lubrication of bearings, ensure that lubricants are replenished on time, and select lubricating oil or grease suitable for operating temperature and load. Lubrication can effectively reduce friction, reduce temperature rise and wear of bearings under heavy load conditions.
5. Precise alignment and installation During the equipment installation process, ensure the shaft alignment accuracy of the motor and gearbox. Use alignment tools and laser alignment instruments to ensure that the load on the bearing is evenly distributed to avoid local overload.
Bearing overload is one of the main causes of bearing failure and can have a profound negative impact on the normal operation of equipment. Through reasonable design, load control, optimized operation, good lubrication management and installation alignment, bearing overload can be effectively avoided and the service life of bearings and equipment can be extended. In daily use, regular inspection and maintenance to ensure that the equipment operates within a safe load range can significantly improve the operating efficiency and reliability of the equipment.
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1. Accelerated fatigue damage When the bearing operates under overload conditions, the stress at the contact points of the rolling elements and raceways Significant increase. Prolonged overload operation will cause the material of the bearing to fatigue, micro-cracks will appear, and eventually the surface will peel or chip. This fatigue damage is often one of the main reasons for bearing failure.
2. Excessive radial and axial loads In the motor or gearbox, if the radial or axial loads borne by the equipment during operation exceed the rated load of the bearing, the bearing will be in an overloaded state for a long time, causing it to be damaged prematurely.
3. Frequent starting and stopping When the equipment is frequently started, stopped or accelerated, instantaneous high impact loads will be generated. The bearings will be subjected to greater stress in a short period of time, which can easily lead to local overload.
4. Improper lubrication Inadequate lubrication will increase the friction inside the bearing, causing the bearing to be subjected to greater friction stress during operation and accelerating overload damage.
How to avoid bearing overload? To avoid bearing overload, equipment operators and maintenance engineers need to take measures in design, operation and maintenance:
1. Reasonable bearing selection During the design stage, it is necessary to reasonably select bearings according to actual working conditions and load conditions to ensure that their rated loads can meet the long-term operation requirements of the equipment. If the working conditions are complex, higher rated loads or special bearings can be selected.
2. Control the equipment load to avoid long-term overload operation of the equipment, especially in equipment such as motors and gearboxes, and ensure that the load is within the rated load range of the bearing. For working conditions that may cause instantaneous overload, it is recommended to design appropriate overload protection measures.
3. Optimize start and stop operations Reduce the number of frequent starts and stops of equipment, or use soft start devices to avoid damage to bearings caused by impact loads. Soft start technology can reduce impact stress during startup and reduce the risk of bearing overload.
4. Ensure correct lubrication Regularly check the lubrication of bearings, ensure that lubricants are replenished on time, and select lubricating oil or grease suitable for operating temperature and load. Lubrication can effectively reduce friction, reduce temperature rise and wear of bearings under heavy load conditions.
5. Precise alignment and installation During the equipment installation process, ensure the shaft alignment accuracy of the motor and gearbox. Use alignment tools and laser alignment instruments to ensure that the load on the bearing is evenly distributed to avoid local overload.
Bearing overload is one of the main causes of bearing failure and can have a profound negative impact on the normal operation of equipment. Through reasonable design, load control, optimized operation, good lubrication management and installation alignment, bearing overload can be effectively avoided and the service life of bearings and equipment can be extended. In daily use, regular inspection and maintenance to ensure that the equipment operates within a safe load range can significantly improve the operating efficiency and reliability of the equipment.
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