Introduction: A challenge for manufacturing reliability
Proper bearing molding is critical to ensuring the durability and efficiency of industrial equipment. Incorrect molding type selection, improper remoulding intervals, or lack of automatic molding systems can lead to increased repair costs, reduced productivity, and unpredictable leaks. This article reviews the basic principles of bearing molding, compares thick oil and oil, discusses remoulding intervals and the use of automated molding systems, and provides technical recommendations.
Basic principles of molding bearings
Molding bearings has two main purposes: to ensure effective friction and to protect surfaces from corrosion. Molding materials used have different properties that affect the choice of molding method.
Thick oil provides a thick layer between surfaces, which reduces friction, but has less resistance to temperature effects. Oils, on the other hand, have high resistance to temperatures, but require a larger volume to ensure effective coverage.
The choice of molding type depends on the environment in which the bearing operates, as well as operating conditions such as temperature, rotational speed and load.
Technical requirements and standards
Adhesive materials must meet the requirements of the following standards:
- ISO 281 - establishes standard methods for determining bearing durability.
- DIN 51825 – requirements for molding oils for industrial use.
- ISO 15166 – requirements for molding bearings in industrial conditions.
- ISO 9001 - quality certification.
- UkrSEPRO – certification for products for the Ukrainian market.
Criteria for choosing stucco material include:
- Temperature range of use
- Moisture and corrosion resistance
- Viscosity under working conditions
- Resistance to high pressures
- Restorative properties
Recommendations for selection and calculation
To choose the right type of molding, use the following table:
| Factor | Thick oil | Oil |
|---|---|---|
| Temperature | -20°C to +120°C | -30°C to +200°C |
| Rotation speed | up to 1500 rpm | up to 3000 rpm |
| The load | Up to 5000 N | Up to 10,000 N |
| Required volume | 10–20 g/bearing | 15–30 g/bearing |
| Cost | ₴15–₴30 | ₴20–₴45 |
The calculation of recasting intervals is carried out according to the formula:
T = (V * L) / (Q * K) where:
- T – re-molding interval (hours)
- V – volume of molding material (g)
- L – molding material consumption (g/h)
- Q – molding material consumption (g/h)
- K is the coefficient of wear
Installation and commissioning protocols
The correct installation of stucco material must be done in the following order:
- Remove the old molding material and clean the bearing.
- Use a special stucco compound to ensure full surface coverage.
- Install the bearing in the pivot location.
- Use manual or automated filling systems.
- Do a test check for wear.
It is important to ensure full ventilation and the absence of dust during installation.
Modal modes of knock-out and analysis of the causes of knock-out
The most common reasons for knocking out bearings:
- Insufficient volume of stucco material
- Contamination of stucco material
- Incorrect temperature of the working environment
- Heavy load
- High rotation speed
Determining the reasons for knocking out can be done using the following criteria:
- Increase in noise
- An increase in the consumption of stucco material
- Increase in temperature
- Changing the behavior of the bearing
- Visual degradation
Knockout prediction and condition monitoring
The following methods are used to monitor the state of bearings:
- Temperature measurement - thermal sensors are used to detect an increase in temperature.
- Noise measurement – noise sensors are used to analyze changes in the noise level.
- Measurement of the consumption of stucco material - automated measurement systems.
- Vibration detection – vibration sensors are used to analyze changes in behavior.
- Spectral analysis - measuring devices are used for frequency analysis.
The use of these methods allows timely detection of knockouts and reduction of unplanned costs.
Comparison table of alternatives
| Parameter | Thick oil | Oil | Automated system |
|---|---|---|---|
| Temperature range | -20°C to +120°C | -30°C to +200°C | -40°C to +250°C |
| Rotation speed | up to 1500 rpm | up to 3000 rpm | up to 5000 rpm |
| Consumption of stucco material | 10–20 g/bearing | 15–30 g/bearing | 20–40 g/bearing |
| Cost | ₴15–₴30 | ₴20–₴45 | ₴50–₴100 |
| Minimum interval | 1000–2000 hours | 2000–4000 hours | 1000–3000 hours |
| Special requirements | There is none | There is none | Available |
Conclusion
Correct bearing molding is a key factor in ensuring the reliability and efficiency of industrial equipment. Choosing the right type of moulding, reasonable re-moulding intervals and the use of automated systems affects the durability and cost-effectiveness of the work. For reliable and certified components that meet the standards, visit our e-catalog at https://www.unitecd.com/e-catalog/.
List of references
- ISO 281 – "Bearings: Endurance Definition"
- DIN 51825 - "Sculpting materials for industrial use"
- ISO 15166 - "Sculpting of bearings in industrial conditions"
- ISO 9001 - "Quality certification"
- UkrSEPRO - "Certification of products for the Ukrainian market"
