Reasons and treatment measures for bearing failure of roller press reducer

1、 Analysis of the Failure Causes of Roller Press Reducer Bearings

1. Load exceeding the standard and fluctuating impact

Roller press is a low-speed, high load equipment. In actual operation, due to the mixing of foreign objects in materials, uneven feeding, and uneven unevenness caused by long-term operation of the roller surface, the reducer inevitably experiences overloading, jamming, and fluctuating overloading during operation. The excessive and fluctuating loads can cause the tooth surface and bearing surface to crack. If not detected in a timely manner, the situation will deteriorate rapidly.

2. Metal foreign object intrusion causing severe impact

When larger metal objects (such as grate cooler hammers, loader shovel heads, steel balls, etc.) enter the roller gap compression zone, they will cause a huge instantaneous impact on the roller surface and bearings. This type of impact can cause local fatigue damage to the bearing surface. As the equipment continues to operate, the fatigue area further expands, ultimately leading to bearing pitting and peeling. In severe cases, it can even cause the outer and inner rings of the bearing to fracture and fail due to impact.

3. Compression deformation and misalignment of bearing chamber

Overloading or jamming under harsh working conditions may cause compression deformation and damage to the bearing chamber of the gearbox. For example, if there are obvious compression marks and inward protrusions on the bearing chamber stopper, or even cracks on the outside, this will directly cause a slight misalignment of the center of the bearing chamber, leading to bearing damage.

4. Lubrication and sealing failure

Reducer usually adopts oil bath lubrication or centralized lubrication system. If the oil circuit of the lubrication system is blocked, the oil injection hole is blocked by dust, or the seal is worn, causing dust and water to enter the bearing and contaminate the lubricating oil, it will cause insufficient lubrication and poor heat dissipation of the bearing, leading to overheating or even erosion of the bearing.

5. Loose fastening bolts and changes in clearance

After running the equipment for a period of time, the fastening bolts of the bearings may become loose. If the secondary fastening is not carried out in a timely manner, it will cause relative motion between the bearing and the bearing position, increase the working clearance, reduce the number of rolling elements involved in the work, and even change from rolling friction to sliding friction, seriously damaging the normal working state of the bearing.

2、 Bearing Failure Handling and Repair Measures

1. Emergency response measures

When mild wear or abnormalities are found in the bearing position, immediate shutdown for maintenance may affect production, and the following emergency measures can be taken to maintain operation:

Replace fastening bolts: Timely replace with new bolts that meet the specifications to ensure the stability of the connection between the bearing and the bearing position.

Accurate detection of clearance: Measure the bearing clearance with professional tools, adjust and fix the axial position of the bearing based on the results, and ensure uniform force distribution.

Adjust preload force: If the bearing does not have preload force, the bearing pressure ring needs to be machined and resized to form an effective preload force on the inner ring of the bearing.

2. Online repair of bearing chamber wear and deformation

In response to the problems of deformation, protrusion or wear of the bearing chamber due to compression, traditional welding repair is prone to generate thermal stress and deformation, and the embedding process has potential strength hazards. At present, polymer composite materials such as Fushilan 2211F can be used for "cold welding" repair. The specific process includes: