Bearing assemblies are used in almost all types of industrial equipment where rotational motion is present. They are included in the design of electric motors, pumps, gearboxes, fans, compressors, conveyors, metalworking machines and other production equipment. The accuracy of shaft rotation, vibration level, energy consumption and overall reliability of the mechanism depend on the condition of the bearings.
Bearing wear rarely leads to instant failure. Usually, the malfunction develops gradually: first there is a slight increase in vibration or temperature, then the noise increases, the resistance to rotation increases, and only after that serious damage occurs. Therefore, timely monitoring makes it possible to detect a defect long before an emergency shutdown of the equipment.
Why do industrial equipment bearings wear out
Even a high-quality bearing has a limited resource. However, the actual service life may differ significantly from the estimated one. It is affected by load, rotation speed, temperature, installation quality, and the condition of the lubricant.
The most common causes of accelerated wear include:
- insufficient amount of lubricant;
- use of unsuitable lubricant;
- ingress of metal dust and abrasive particles;
- increased temperature of the working unit;
- shaft misalignment and misalignment;
- permanent or short-term overloads;
- bearing mounting errors;
- vibration of equipment;
- corrosive effect of moisture and aggressive media.
In production, the reasons often combine. For example, a slight misalignment of the shaft increases the load on individual sections of the raceways. This leads to an increase in temperature, deterioration of the lubricant and accelerated destruction of surfaces.
How does improper installation affect
Installation errors can shorten the life of even a new bearing. The seats must meet the required dimensions and tolerances, and the mounting force must be applied correctly.
The transfer of the mounting load through the rolling elements may cause damage to the tracks even before the equipment is started. In the future, such defects are manifested by noise and increased vibration.
After repairs, it is also necessary to check the position of the shafts. If the connected units are installed with misalignment, the bearing units receive additional radial or axial load.
The role of lubrication in bearing operation
The lubricant reduces friction between the work surfaces, removes some of the heat and protects the metal from corrosion. Therefore, a violation of the lubrication regime is one of the most frequent