How to Solve the Failure of Four-Point Contact Slewing Bearings
There are various methods to deal with the failure of four-point contact slewing bearings. It is essential to strictly control the materials, optimize the processing technology, handle emergencies when fractures occur, analyze the causes for improvement, and ensure the quality and installation accuracy when replacing components.
What is a Four-Point Contact Slewing Bearing
A four-point contact slewing bearing is a type of bearing structure. It consists of components such as an inner ring, an outer ring, rolling elements, and a cage. Its uniqueness lies in that the rolling elements have four-point contact with the raceways of the inner and outer rings, enabling it to simultaneously withstand axial forces, radial forces, and tilting moments. This design gives the slewing bearing a high load-carrying capacity and rotational accuracy within a limited space. It is commonly used in construction machinery and large-scale equipment such as cranes, excavators, and wind turbines. It can achieve smooth rotational motion between components, adapt to complex working conditions, and improve the reliability and stability of the equipment.
Different Solutions for Four-Point Contact Slewing Bearings
Wear
– Strengthen Lubrication Management: Strictly follow the equipment’s operation manual to develop a scientific and reasonable lubrication plan. Select appropriate lubricants according to the working environment and operating conditions of the slewing bearing. For example, in high-temperature environments, high-temperature-resistant synthetic grease can be used, and in dusty environments, grease with good sealing and anti-pollution capabilities can be selected. At the same time, ensure that the lubrication frequency and quantity are accurate. Insufficient lubrication cannot effectively reduce friction, while excessive lubrication may cause waste and pollution.
– Precise Installation and Adjustment: When installing the slewing bearing, professional measuring tools and equipment must be used to precisely control the installation accuracy. For example, high-precision theodolites and levels are used to adjust the concentricity and perpendicularity of the slewing bearing, keeping the deviation within the allowable range. During the operation of the equipment, regularly check the installation accuracy and adjust it in a timely manner if there is any deviation to avoid aggravated local wear caused by installation problems.
– Timely Replacement of Worn Components: Establish a perfect wear monitoring mechanism. Evaluate the degree of wear by measuring parameters such as the dimensions and surface roughness of the raceways and steel balls. When the raceway wear exceeds the specified tolerance, or when there are obvious wear marks and dimensional changes on the surface of the steel balls, decisively replace the slewing bearing or relevant worn components. At the same time, when replacing, pay attention to selecting products with reliable quality and matching the original components.
Fatigue Spalling
– Scientific Selection and Design: In the equipment design stage, accurately calculate and analyze the operating conditions of the slewing bearing, such as working load, rotational speed, and operating time. Based on these data, refer to relevant design standards and manuals to reasonably select the model and specifications of the slewing bearing to ensure that it has sufficient load-carrying capacity and fatigue life. In addition, the anti-fatigue performance can be improved by optimizing the design structure, such as increasing the curvature radius of the raceway and improving the quality of the steel balls, to reduce the contact stress.
– Comprehensive Detection and Prevention: Establish a regular comprehensive inspection system. In addition to using non-destructive testing techniques such as magnetic particle inspection and ultrasonic testing to detect fatigue cracks, it is also possible to judge whether there are signs of fatigue spalling by observing the operating state of the slewing bearing, such as abnormal vibration and noise. For the slewing bearings of some key equipment, online monitoring technology can be used to monitor their working conditions in real time and discover potential problems in a timely manner.
– Stable Operation and Maintenance: During the operation of the equipment, try to keep the operating parameters stable and avoid frequent starting, braking, and large-amplitude load changes. At the same time, regularly maintain the slewing bearing, such as cleaning the surfaces of the raceways and steel balls and replenishing lubricants, to reduce the impact of external factors on its fatigue performance.
Plastic Deformation
– Strict Load Control: During the use of the equipment, it is necessary to strictly operate according to the rated load of the slewing bearing and it is strictly prohibited to operate overloaded. In the equipment design stage, reliable overload protection devices such as pressure sensors and limit switches should be installed. When the load exceeds the set value, the equipment will automatically stop running or take corresponding protective measures.
– Optimize the Operation Process: Optimize the starting and braking processes of the equipment through advanced control technologies and equipment to make them more stable. For example, frequency conversion speed regulation technology can be used to achieve soft starting and soft braking of the motor, reducing the impact current and impact force during starting and braking. In addition, buffer devices such as elastic couplings and fluid couplings can be installed in the transmission system of the slewing bearing to further reduce the impact load.
– Deformation Assessment and Repair: Once plastic deformation of the slewing bearing is found, the equipment should be stopped immediately, and a detailed assessment of the deformation should be carried out. Analyze the impact degree of the deformation on the performance of the slewing bearing by measuring parameters such as the size and shape of the deformation. For slight plastic deformation, cold correction or hot correction methods can be used for repair, but strict quality inspection is required after repair. For severe plastic deformation, it is usually necessary to replace the slewing bearing or relevant components.
Corrosion
– Efficient Surface Protection: Effective surface protection treatment of the slewing bearing is a key measure to prevent corrosion. Appropriate surface protection methods can be selected according to different working environments. For general industrial environments, anti-corrosion paint spraying can be used. Select paints with good corrosion resistance and adhesion and construct strictly in accordance with the spraying process requirements. For some harsh corrosive environments, such as humid seashores or chemical workshops, metal plating methods such as galvanizing and chrome plating can be used to improve the corrosion resistance of the slewing bearing.
– Environmental Optimization and Control: Try to improve the working environment of the slewing bearing. Install the equipment in a dry and well-ventilated place to avoid exposure to humid, corrosive gas or liquid environments. For some unavoidable harsh environments, corresponding protective measures can be taken, such as installing dehumidification equipment and ventilation ducts to reduce the humidity and concentration of corrosive media in the environment.
– Regular Maintenance and Treatment: Establish a regular inspection and maintenance system. Regularly check the surface condition of the slewing bearing, and promptly clean the dirt, dust, and corrosion products on the surface. For slightly corroded parts found, methods such as grinding and rust removal can be used for treatment, and then re-protect. For severely corroded parts, timely repair or replacement of components is required to prevent further corrosion expansion.
Fracture
– Strict Material Control: When purchasing a slewing bearing, strictly review the qualifications of the supplier and the material quality certification documents to ensure that the purchased slewing bearing is made of high-quality materials. At the same time, random inspections of the materials can be carried out, such as chemical composition analysis and mechanical property testing, to verify whether the material quality meets the requirements. For important slewing bearings, the supplier can also be required to provide a material flaw detection report to ensure that there are no internal defects in the materials.
– Optimize the Processing Technology: In the processing process of the slewing bearing, optimize each processing technology link, especially the heat treatment process. By reasonably controlling parameters such as heating temperature, holding time, and cooling rate, eliminate processing stress, and improve the uniformity of the material structure and its strength and toughness. In addition, strictly control the surface quality during the processing process to avoid defects such as tool marks and scratches, which may become the origin of fractures.
– Emergency Treatment and Improvement: Once a fracture accident occurs, immediately take emergency measures, stop the equipment operation, set up safety warning signs to prevent the accident from expanding. At the same time, conduct a detailed analysis of the fractured components. Through methods such as fracture surface analysis and material inspection, find out the cause of the fracture. According to the analysis results, take corresponding improvement measures, such as changing materials, improving the processing technology, and optimizing the equipment structure, to prevent similar fracture accidents from occurring again. When replacing the fractured components or the entire slewing bearing, ensure that the quality and installation accuracy of the new components meet the requirements.
Prices of Four-Point Contact Slewing Bearings
Materials are a crucial factor. Using high-quality steel and special alloys can enhance strength and wear resistance. This increases the cost, and thus the price will be higher. For example, slewing drives made of materials containing special alloys are more expensive than those made of ordinary materials. Machining accuracy is also important. High-precision machining requires advanced equipment and technologies, which increases the cost, and as a result, the product price is naturally higher. The slewing drives used in precision equipment generally have high prices. The manufacturing process also affects prices. Advanced processes can optimize performance but also increase costs, thereby raising the selling price.
Suppliers of Four-Point Contact Slewing Bearings
LDB bearing company has risen from obscurity to become well-known in the industry, relying on its dedication to quality and pursuit of innovation. The company is located in Luoyang, Henan Province, where the bearing industry is developed, enjoying the advantages of industrial resources. For example, its self-developed straight-tooth slewing drives have high precision and strong stability, greatly improving the accuracy and efficiency of industrial robots. With high-quality products and attentive services, it has won numerous praises and is bound to create more glories in the future!
