A main bearing inspection method based on simulated main bearing working conditions

Abstract

The present invention proposes a main bearing inspection method based on simulating the main bearing operating conditions. Specifically, the method sets theoretically optimal technical parameters, conducts a full-cycle equivalent life accelerated test on the main bearing, calculates the full-cycle equivalent life accelerated test time, collects multiple load parameter sets consisting of load parameter elements within the full-cycle equivalent life accelerated test time, uses the load parameter elements to calculate a comprehensive evaluation value and a comprehensive evaluation theoretical value, and calculates the theoretical value corresponding to the load parameter element based on the distribution law of the load parameter elements. When the deviation rate of the comprehensive evaluation value relative to the comprehensive evaluation theoretical value exceeds 8%, or the deviation rate of any load parameter element relative to the theoretical value exceeds 10%, the manufacturing process of the main bearing is unqualified. The advantage is that by setting the theoretically optimal technical parameters for the main bearing, collecting load parameters and calculating the comprehensive evaluation value, the comprehensive evaluation value and load parameters can be used to accurately determine whether the bearing is qualified.

Description

Technical Field

[0001] The present invention relates to the technical field of main bearing testing, and in particular to a main bearing inspection method based on simulating main bearing working conditions. Background Art

[0002] A roadheader is a large-scale construction equipment specially used for excavating tunnels and underground passages. The main bearing is the most critical structural component of a roadheader. The life of the main bearing directly affects the maintenance and use of the roadheader. Existing main bearings are mainly composed of an inner ring, auxiliary rollers, auxiliary roller cages, radial rollers, radial roller cages, main roller cages, main rollers, and an outer ring. Traditional main bearing life estimation methods mostly use qualitative judgment. The disadvantage is that due to the complex and changeable surrounding rock types during the construction process, qualitative judgment methods will have large deviations. Especially in some extreme working conditions such as high altitude, high geothermal, high stress and deep burial, it is difficult to evaluate fatigue damage of the main bearings. This requires simulating the actual working conditions encountered by the main bearings during the main bearing manufacturing process to determine whether the main bearing processing technology is qualified.

[0003] In summary, there is an urgent need for a main bearing inspection method based on simulating the main bearing working conditions to solve the problems existing in the prior art. Summary of the Invention

[0004] The present invention aims to provide a main bearing inspection method based on simulating the main bearing working conditions. The specific technical solution is as follows:

[0005] A main bearing inspection method based on simulating main bearing working conditions is as follows:

[0006] The theoretically optimal technical parameters are set, a full-cycle equivalent life accelerated test is performed on the main bearing, and the full-cycle equivalent life accelerated test time is calculated. During the full-cycle equivalent life accelerated test time, multiple groups of load parameter sets consisting of load parameter elements are collected, and the load parameter elements are used to calculate the comprehensive evaluation value and the comprehensive evaluation theoretical value. The theoretical value corresponding to the load parameter element is fitted and calculated in combination with the distribution law of the load parameter elements. When the deviation rate of the comprehensive evaluation value relative to the comprehensive evaluation theoretical value exceeds 8% or the deviation rate of any load parameter element relative to the theoretical value exceeds 10%, the manufacturing process of the main bearing is unqualified.

[0007] Preferably, the theoretically optimal technical parameters include axial load, radial load, overturning moment, driving torque and rotational speed.

[0008] Preferably, the full-cycle equivalent life accelerated test time is calculated based on the Lundberg-Palmgren fatigue life theory.

[0009] Preferably, the load parameter is one or more of axial load, radial load, overturning moment, and driving torque.

[0010] Preferably, m groups of load parameters are collected within the full cycle equivalent life accelerated test time, where m≥10.

[0011] Preferably, the load parameters are collected as follows:

[0012] The full-cycle equivalent life accelerated test time is evenly divided into m time periods, and the arithmetic mean of the load parameter value in each time period is calculated as the load parameter element, where the load parameter value is the data collected by the sensor.

[0013] Preferably, the theoretical value is an average value of the load parameter elements in all time periods.

[0014] Preferably, after the full-cycle equivalent life accelerated test is completed, the main bearing is subjected to a type inspection, which is used to detect the status of the main bearing and determine whether the main bearing meets the design requirements based on the results of the type inspection.

[0015] Preferably, the comprehensive evaluation value is calculated using load parameters such as axial moment X, radial load Y, overturning moment Z and driving moment Q, and the expression is as follows:

[0016] P = aX·bY·cZ·dQ;

[0017] Where P represents the comprehensive evaluation value, the value range of a is 0.6-0.85, the value range of b is 0.05-0.1, the value range of c is 0.15-0.2, and the value range of d is 0.01-0.05;

[0018] The comprehensive evaluation theoretical value P a The expression is as follows:

[0019] P a =aX a ·bY a ·cZ a dQ a ;

[0020] Among them, X a Indicates the theoretical value of axial load, Y a Indicates the theoretical value of radial load, Z a Indicates the theoretical value of the overturning moment, Q a Indicates the theoretical value of the driving torque.

[0021] The application of the technical solution of the present invention has the following beneficial effects:

[0022] The present invention introduces load parameters to judge the movement state of the main bearing, simplifies the existing main bearing defect judgment method, and performs quantitative analysis of the main bearing defects; the present invention realizes a simulated loading test by setting theoretically optimal technical parameters, avoiding the problem that the existing main bearing detection method is unable to judge the true condition of the main bearing during actual tunneling conditions, resulting in large errors in the detection results; the main bearing inspection method proposed by the present invention is applicable to main bearings of various specifications, and provides reliable data support for the processing, manufacturing and design schemes of the main bearings.

[0023] In addition to the above-described objects, features and advantages, the present invention has other objects, features and advantages. The present invention will be further described in detail below with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The accompanying drawings, which constitute part of this application, are intended to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are intended to explain the present invention and do not constitute an undue limitation of the present invention. In the accompanying drawings:

[0025] Figure 1 It is a structural diagram of the main bearing;

[0026] Figure 2 is a flowchart of the steps of the main bearing inspection method according to an embodiment of the present invention;

[0027] Figure 3 1 is a flow chart of the steps of type inspection in an embodiment of the present invention. DETAILED DESCRIPTION

[0028] The technical problem to be solved by the present invention is to quantitatively determine the load-bearing capacity of the main bearing, thereby providing a main bearing inspection method based on simulating the main bearing working conditions. Generally, the main bearing structure is shown in the figure below. Figure 1 As shown, 1 - radial roller; 2 - auxiliary roller cage; 3 - auxiliary roller; 4 - inner ring; 5 - radial roller cage; 6 - main roller cage; 7 - main roller; 8 - outer ring. Based on the fatigue life damage theory of main bearings, this invention applies loads such as axial load, radial load, overturning moment, and driving torque to the main bearing and records the operating conditions in real time. This allows for quantitative assessment of the main bearing's load capacity and fatigue life. Furthermore, type testing determines whether the main bearing meets design requirements, ensuring quality during the main bearing manufacturing process and improving the accuracy of main bearing life prediction.

[0029] The embodiments of the present invention are described in detail below with reference to the accompanying drawings. However, the present invention can be implemented in many different ways as defined and covered by the claims.

[0030] Example 1:

[0031] See Figure 1 This embodiment discloses a main bearing inspection method based on simulating the main bearing working condition, which is as follows:

[0032] This embodiment implements a loading test and an accelerated fatigue test on the main bearing by setting the theoretically optimal technical parameters in the design process, namely, a full-cycle equivalent life accelerated test. The theoretically optimal technical parameters include axial load X, radial load Y, overturning moment Z, driving torque Q, and speed S, as shown in Table 1:

[0033] Table 1 Theoretical optimal technical parameters

[0034]

[0035]

[0036] As shown in Table 1, the R 10 to R n0 Respectively represent the diameters of main bearings of different specifications, X 10 to X n0 They represent the axial load of the main bearing of the corresponding specifications, Y 10 to Y n0 Respectively represent the radial load of the main bearing of the corresponding specifications, Z 10 to Z n0 They represent the overturning moment of the main bearing of corresponding specifications, Q 10 to Q n0 They represent the driving torque of the main bearing of corresponding specifications, S 10 to S n0 They respectively represent the speed of the main bearing of the corresponding specifications.

[0037] Furthermore, a full-cycle equivalent life accelerated test is performed on the main bearing. During the full-cycle equivalent life accelerated test of the main bearing, the main bearing can be rotated in the forward direction or the reverse direction, and corresponding axial load, radial load, overturning moment, driving torque and test speed are applied during the test.

[0038] Furthermore, the full cycle equivalent life accelerated test time is calculated based on the Lundberg-Palmgren fatigue life theory, and the expression is as follows:

[0039]

[0040] Where D represents the full cycle equivalent life accelerated test time, Qc is the rated dynamic load, and Qe is the equivalent dynamic load.

[0041] It should be noted that both the rated dynamic load and the equivalent dynamic load can be obtained through the theoretically optimal technical parameters in the full-cycle equivalent life accelerated test, which is common knowledge and will not be explained here.

[0042] Furthermore, the full-cycle equivalent life accelerated test time of main bearings of different specifications is obtained, as shown in Table 2.

[0043] Table 2 Full cycle equivalent life accelerated test schedule for main bearings of different specifications

[0044]

[0045]

[0046] As shown in Table 2, D1 to Dn represent the full-cycle equivalent life accelerated test time of the main bearing of the corresponding specifications.

[0047] Furthermore, during the full-cycle equivalent life accelerated test, multiple groups of load parameter sets consisting of load parameter elements are collected through sensors. Specifically, the full-cycle equivalent life accelerated test time is evenly divided into m time periods t, and the arithmetic mean of the load parameter values in each time period t is calculated as the load parameter element. The load parameter value is the data collected by the sensor.

[0048] It should be noted that the load parameter is one or more of axial load, radial load, overturning moment or driving torque. This embodiment uses axial load, radial load, overturning moment and driving torque as load parameters.

[0049] For the main bearing of specification R1, D1 is divided into m time periods on average, and the axial load elements collected in the axial load set X1 are X 11 、X 12 、X 13 ...X 1m ; The radial load element collected in the radial load set Y1 is Y 11 、Y 12 、Y 13 ...Y 1m ; The overturning moment element in the overturning moment set Z1 collected is Z 11 、Z 12 、Z 13 ...Z 1m ; The driving torque element of the driving torque set Q1 is Q 11 , Q 12 , Q 13 ...Q 1m .

[0050] X 11 、X 12 、X 13 ...X 1m About the theoretical value of axial load X a It is linearly distributed, and the linear relationship expression is as follows:

[0051]

[0052] Y 11 、Y 12 、Y 13 ...Y 1m Around the theoretical value of radial load Y a It is linearly distributed, and the linear relationship expression is as follows:

[0053]

[0054] Z 11 、Z 12 、Z 13 ...Z 1m Theoretical value of overturning moment Z a It is linearly distributed, and the linear relationship expression is as follows:

[0055]

[0056] Q 11 , Q 12 , Q 13 ...Q 1m Around the theoretical value of the driving torque Q a It is linearly distributed, and the linear relationship expression is as follows:

[0057]

[0058] Furthermore, after extensive data analysis and long-term experience accumulation, it was concluded that there is a comprehensive evaluation formula for the four factors that affect the life of the main bearing: axial torque X, radial load Y, overturning moment Z, and driving torque Q:

[0059] P = aX·bY·cZ·dQ;

[0060] Among them, P represents the comprehensive evaluation value, the value range of a is 0.6-0.85, the value range of b is 0.05-0.1, the value range of c is 0.15-0.2, and the value range of d is 0.01-0.05.

[0061] Furthermore, the comprehensive evaluation theoretical value P is calculated a :

[0062] P a =aX a ·bY a ·cZ a dQ a ;

[0063] When the deviation rate of any load parameter element relative to the theoretical value exceeds 10%, or P relative to Pa When the deviation rate exceeds 8%, the manufacturing process of the main bearing is unqualified and the manufacturing process of the main bearing needs to be adjusted.

[0064] Further, see Figure 2 After completing the full-cycle equivalent life accelerated test, the main bearing can also be subjected to type inspection. The type inspection is as follows:

[0065] In particular, check that there are no concentrated fretting corrosion pits on the inner and outer diameter mating surfaces of the inner and outer rings of the main bearing.

[0066] In particular, check that there is no running of the inner and outer rings of the main bearing and no scratches on the end faces.

[0067] In particular, check that the main bearing ribs are free of scratches and severe wear.

[0068] In particular, check that the main bearing raceways are free of scratches, fatigue pitting, fatigue spalling, strains, and cracks.

[0069] In particular, check that the gear oil in the main bearing raceway is free of iron chips, copper chips and large metal particles.

[0070] In particular, check that the main bearing rolling elements are free of scratches, fatigue pitting, fatigue spalling, strains and cracks.

[0071] In particular, check that the main bearing cage is free of damage, friction and wear.

[0072] In particular, check the size, shape, and position accuracy of the main bearing.

[0073] In particular, check the roughness of the main bearings.

[0074] In particular, check that the hardness of the main bearing is not lower than the initial value.

[0075] By conducting type inspection on main bearings that have completed accelerated fatigue life testing, it can be determined whether the main bearings meet design requirements. If the main bearings do not meet design requirements, it is necessary to adjust the main bearing manufacturing process and then conduct loading tests and fatigue life tests until the main bearings meet design requirements.

[0076] This embodiment discloses a main bearing inspection method based on simulating main bearing operating conditions. The method first simulates the torque carried by the main bearing under extreme operating conditions, records the stress conditions of the main bearing under load, performs an accelerated fatigue life test on the main bearing, and disassembles the main bearing after the test to perform a type inspection to determine whether the main bearing meets the design and use requirements. If the main bearing does not meet the design requirements, it is necessary to adjust the main bearing manufacturing process and then conduct loading tests and fatigue life tests until the main bearing meets the design requirements.

[0077] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that various modifications and variations of the present invention are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention are intended to be within the scope of protection of the present invention.

Claims

1. A main bearing inspection method based on simulating main bearing working conditions, characterized in that: The details are as follows: Theoretically optimal technical parameters are set, a full-cycle equivalent life accelerated test is conducted on the main bearing, and the full-cycle equivalent life accelerated test time is calculated. During the full-cycle equivalent life accelerated test time, multiple load parameter sets consisting of load parameter elements are collected, and a comprehensive evaluation value and a comprehensive evaluation theoretical value are calculated using the load parameter elements. The theoretical values corresponding to the load parameter elements are calculated by fitting in combination with the distribution law of the load parameter elements. If the deviation rate of the comprehensive evaluation value relative to the comprehensive evaluation theoretical value exceeds 8%, the manufacturing process of the main bearing is unqualified. The theoretically optimal technical parameters include axial load, radial load, overturning moment, driving torque and rotational speed; The load parameters are collected as follows: The full cycle equivalent life accelerated test time is evenly divided into m time periods, and the arithmetic mean of the load parameter value in each time period is calculated as the load parameter element, wherein the load parameter value is the data collected by the sensor; The theoretical value is the average value of the load parameter elements in all time periods; The comprehensive evaluation value is calculated using axial moment X, radial load Y, overturning moment Z and driving moment Q, and the expression is as follows: ； Where P represents the comprehensive evaluation value, the value range of a is 0.6-0.85, the value range of b is 0.05-0.1, the value range of c is 0.15-0.2, and the value range of d is 0.01-0.05; The comprehensive evaluation theoretical value P a The expression is as follows: ； Among them, X a Indicates the theoretical value of axial load, Y a Indicates the theoretical value of radial load, Z a Indicates the theoretical value of the overturning moment, Q a Indicates the theoretical value of the driving torque.

2. The main bearing inspection method according to claim 1, characterized in that: The full cycle equivalent life accelerated test time is calculated based on the Lundberg-Palmgren fatigue life theory.

3. The main bearing inspection method according to claim 1, characterized in that: Collect m groups of load parameters within the full cycle equivalent life accelerated test time, where m≥10.

4. The main bearing inspection method according to claim 1, characterized in that: After the full-cycle equivalent life accelerated test is completed, the main bearing is subjected to a type inspection, wherein the type inspection is used to detect the status of the main bearing and to determine whether the main bearing meets the design requirements based on the result of the type inspection.

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