Introduction
For a long time, bearings have played an important role in machinery. In order to reduce the vibration and thermal deformation of the machine and improve the working conditions, bearings need to be responsible for the obvious. However, due to the long-term operating conditions, bearings are easy to be damaged, and accordingly the quality of the components is reduced, resulting in decreased performance and subsequent machine failure. Through understanding the failure of the bearing, it is possible to predict the possible fault situation and increase the service life through preventive processing. This paper mainly focuses on the ways to predict and prevent bearing failure.
Predict Bearing Failure
A variety of causes can leading to a bearing failure. In general, bearing failures are mostly caused by fatigue, improper installation, corrosion, corrosion, adhesion, overload, poor lubrication and high temperature. For example, fatigue is the major cause of bearing failure. Fatigue failure occurs when the bearing experiences physical or mechanical stress and vibrates continuously.
Once the connection between the bearing and the location of potential failure is established, it can be predicted in advance. This can be achieved in many ways, such as vibration analysis, lubrication analysis or signal spectra analysis.
Vibration Analysis
The most common and cost-effective way of predicting bearing failure is vibration analysis. It is based on the fact that bearing failure causes changes in the vibration frequency, amplitude or other performance of machinery. The measurement of vibration and changes in the frequency and magnitude of changes must be accurate and reliable. Vibration analysis can detect different types of noise in the operation of the machinery and compare them to the standard bearing vibration frequency. When the vibration of the bearing is too large, the failure of the bearing can be predicted.
Lubricant Analysis
The lubricant is a basic factor in the failure of the bearing. With the help of a lubricant analysis, the service life of the bearing can be extended and the failure can be predicted in advance. The lubricant analysis is based on the trace metals, temperature and viscosity of the oil. By monitoring the properties of the lubricant, the bearing performance degradation can be predicted, such as its viscosity, oil levels, foam characteristics, surface active substances and water content.
Signal Spectrum Analysis
The signal spectrum analysis method is mainly used to observe the nonlinear frequency components and thermal characteristics of the bearing. Signal analysis involves sampling the vibration data of the bearing, performing Fourier transformation, and then analyzing the nonlinear frequency components and thermal characteristics of the data. For analysis, the data is filtered to select the frequency component of the bearing, which is then subjected to a series of statistical analysis to draw inferences.
Prevent Bearing Failure
There are several ways to prevent bearing failure. The most important is to minimise the operation stress of the bearing. The lubrication and surface treatment of the bearing are also critical. In addition, the installation of bearings must be in accordance with the regulations.
Minimise Operation Stress
The best way to prevent bearing failure is to minimise the stress of the bearing. Stress can be caused by improper bearing designs, misalignment, high speeds and heavy loads. Thus, it is important to properly design the bearing, keep it properly aligned and use it in a safe operating environment.
Lubrication and Surface Treatment
Lubrication and proper surface treatment help to improve the performance of the bearing. An effective lubrication reduces metal-to-metal contact, which helps to reduce wear and friction, and also reduces the operating temperature of the bearing. Proper surface treatment can reduce the impact of corrosion and improve the surface roughness and wear resistance of the bearing.
Installation
The installation of the bearing is also very important for its service life. If the bearing is not installed properly, it can lead to misalignment, vibrations and abrasion. Therefore, it is essential to follow the manufacturer’s instructions for installation of the bearing.
Conclusion
In summary, bearing failure is a common problem in machinery. Through understanding the root cause of bearing failure, it is possible to predict and prevent it. Vibration analysis, lubricant analysis and signal spectrum analysis are some of the methods that can be used to predict bearing failure. To prevent bearing failure, it is important to minimise the operation stress of the bearing, use appropriate lubricants and perform proper surface treatment. Lastly, careful installation of the bearing is essential.
