Bearing relubrication control method and device, computer readable storage medium

Abstract

The application provides a bearing re-lubrication control method and device, and a computer readable storage medium. The method comprises the following steps: determining the content of contaminants and aging index of lubricating grease of a bearing; determining the failure form and failure degree of the bearing according to the running condition of the bearing, the content of contaminants and the aging index, and a pre-established bearing failure standard; and determining the re-lubrication scheme of the bearing according to the failure form and failure degree of the bearing. The bearing failure standard comprises the corresponding relationship between the content of contaminants and the aging index in the lubricating grease and the failure form and failure degree of the bearing, and the re-lubrication scheme comprises the grease injection period and the grease injection amount of the bearing. According to the method, potential problems of the bearing can be found in time, the re-lubrication is planned in advance, sudden failures are avoided, and the equipment operation stability is greatly improved.

Description

Technical Field

[0001] This application relates to the field of bearing technology, and more specifically, to a bearing relubrication control method and apparatus, and a computer-readable storage medium. Background Technology

[0002] The lubrication condition of a bearing directly affects its service life and reliability. Currently, traction motor bearings in the rail transit industry mostly use grease lubrication, and their working condition is monitored during operation. Based on the bearing's working condition or according to a pre-set relubrication plan, the bearing is relubricated to avoid problems such as spalling and pitting caused by poor lubrication, which could threaten the bearing's life and the safe operation of rail transit vehicles.

[0003] In related technologies, the operating status of bearings is monitored using vibration or temperature signals. For example, temperature sensors are installed at the bearing positions at both ends of the motor to monitor the temperature of the bearing outer ring. If the temperature of the bearing outer ring rises to a preset temperature threshold, it indicates that the bearing may have abnormal wear. Alternatively, an acceleration sensor can be used to detect the vibration signal of the bearing. When the vibration acceleration time-domain or frequency-domain index reaches a preset threshold, the monitoring system will issue an alarm to determine the bearing fault.

[0004] The methods described above, based on vibration or temperature signals, are not applicable in some scenarios. For example, early traction motors in rail transit vehicles lacked vibration and temperature sensors, making online monitoring impossible. Vibration signals are sensitive to failure modes with periodic impact signals, such as bearing raceway spalling and scratches, but their accuracy in diagnosing failure modes like abnormal wear and minor electrolytic corrosion is low. Temperature signals only provide feedback when bearing failures become severe in later stages, making them less effective for identifying early-stage bearing faults.

[0005] If vibration and temperature signals cannot be used to monitor the condition of traction motor bearings in rail transit, and the motors are required to be installed without being disassembled, and the operating conditions of bearings of the same model vary, then how to detect the operating condition of the bearings and develop a reasonable relubrication plan becomes an urgent problem to be solved. Summary of the Invention

[0006] This application mainly provides a bearing relubrication control method and device, and a computer-readable storage medium. The technical solution of this application is implemented as follows:

[0007] In a first aspect, a bearing relubrication control method is provided, the method comprising: determining the contaminant content and aging index of the bearing grease; determining the failure mode and degree of failure of the bearing based on the bearing's operating conditions, the contaminant content, the aging index, and pre-established bearing failure criteria; and determining a relubrication scheme for the bearing based on the bearing's failure mode and degree of failure; wherein the bearing failure criteria include the correspondence between the contaminant content and aging index in the grease and the bearing's failure mode and degree of failure, and the relubrication scheme includes the grease injection cycle and grease injection amount for the bearing.

[0008] Based on the aforementioned technical methods, and considering the bearing's operating conditions, the contaminant content and aging indicators of the grease, and according to pre-established bearing failure criteria, the failure mode and degree of the bearing are determined, thereby enabling precise control of bearing relubrication. The relubrication scheme determined by this method is no longer blind lubrication based on fixed cycles and grease amounts, but rather determined according to the actual needs of the bearing. This allows for the rational use of grease, avoiding insufficient lubrication that leads to accelerated bearing wear, and also preventing waste and potential problems caused by over-lubrication. This optimizes bearing lubrication management, extends bearing service life, and improves equipment operating efficiency and economy.

[0009] In some embodiments, the contaminants are iron and / or copper, and the aging indicators include the cone penetration, oil separation rate, and water content of the grease; determining the contaminant content and aging indicators of the bearing grease includes: collecting grease from the waste oil chamber of the bearing; determining the content of contaminants in the grease based on X-ray fluorescence spectroscopy; and detecting the cone penetration, oil separation rate, and water content of the grease.

[0010] In some embodiments, the method further includes: collecting a plurality of first sample bearings; extracting grease from each of the first sample bearings; determining the failure mode and failure degree of each of the first sample bearings; determining the contaminant content and aging index of the grease in each of the first sample bearings; and establishing the bearing failure standard based on the contaminant content and aging index of each of the first sample bearings with the failure mode and failure degree; wherein the contaminants include iron and copper, and the aging index includes the grease penetration, oil separation rate, and water content.

[0011] In some embodiments, before determining the failure mode and failure extent of each first sample bearing, the method further includes: if the cage of the first sample bearing is a corrugated steel cage, removing the rivets of the corrugated steel cage by drilling to separate the first sample bearing; if the cage of the first sample bearing is a frame-type cage, removing the rivets of the frame-type cage by electrical discharge machining or milling to separate the first sample bearing; determining the failure mode and failure extent of each first sample bearing includes: determining the failure mode and failure extent of each first sample bearing based on the damage to the inner ring, outer ring, and rolling elements of each disassembled first sample bearing.

[0012] Based on the aforementioned technical means, drilling, electrical discharge machining, or milling can avoid damage to bearing components caused by improper disassembly methods, thus making it impossible to distinguish whether the damage occurred during operation or was caused by disassembly during subsequent inspection and evaluation.

[0013] In some embodiments, the plurality of first sample bearings satisfy at least one of the following conditions: the plurality of first sample bearings are of different models; the rail transit vehicles using the plurality of first sample bearings have different operating environments; the rail transit vehicles using the plurality of first sample bearings have different mileages; the plurality of first sample bearings are located at different axle positions of the rail transit vehicles; the plurality of first sample bearings are located at different parking spaces of the rail transit vehicles.

[0014] Based on the aforementioned technical methods, the multi-sample bearings meet various conditions, greatly enriching the diversity of the samples. Samples of different models, operating environments, mileage, axle positions, and parking positions can simulate various actual working conditions, enabling the established failure criteria to adapt to complex and ever-changing application scenarios and ensuring effective evaluation of bearing condition under different circumstances.

[0015] In some embodiments, the failure mode includes at least one of electrical erosion, spalling, corrosion, and fracture, and the degree of failure is determined based on at least one of the following: the damaged area, depth, color change, number of failed parts, and degree of influence on operating temperature of the first sample bearing.

[0016] In some embodiments, determining the relubrication scheme for the bearing includes: determining the grease injection cycle based on the failure mode and failure degree; and determining the grease injection amount based on the bearing model and the optimal grease injection scheme corresponding to the bearing model.

[0017] Based on the aforementioned technical methods, the grease replenishment cycle is determined according to the failure mode and severity, and the amount of grease replenished is determined in conjunction with the bearing model, making the relubrication plan more scientific and reasonable. A reasonable grease replenishment cycle and amount can maintain good bearing lubrication, extend service life, reduce failures caused by improper lubrication, and improve equipment operating efficiency.

[0018] In some embodiments, before determining the relubrication scheme for the bearing, the method further includes: determining the theoretical grease amount for the bearing based on the bearing model, the theoretical grease amount being related to the outer diameter and width of the bearing; determining multiple grease injection schemes based on the theoretical grease amount and different grease replenishment increments; conducting multiple grease injection tests on the second sample bearing according to the multiple grease injection schemes; and, in the multiple grease injection tests, selecting the grease injection scheme in which grease does not leak from the equipment using the second sample bearing and the proportion of replaced contaminated grease is the optimal grease injection scheme.

[0019] Based on the above technical means, starting from the theoretical amount of grease to be added, and through multiple scheme tests, the best scheme was determined with the standard of no grease overflow and the highest replacement rate of contaminated grease, so as to ensure the best grease addition effect and avoid resource waste and environmental pollution while ensuring lubrication effect.

[0020] Secondly, a bearing relubrication control device is provided, the device comprising: a first determining unit for determining the contaminant content and aging index of the bearing grease; a second determining unit for determining the failure mode and degree of failure of the bearing based on the bearing's operating conditions, the contaminant content, the aging index, and pre-established bearing failure criteria; and a third determining unit for determining a relubrication scheme for the bearing based on the bearing's failure mode and degree of failure; wherein the bearing failure criteria include the correspondence between the contaminant content and aging index in the grease and the bearing's failure mode and degree of failure, and the relubrication scheme includes the grease injection cycle and grease injection amount of the bearing.

[0021] Thirdly, a computer-readable storage medium is provided for storing a computer program that, when executed, implements the method described in the first aspect. Attached Figure Description

[0022] Figure 1 A schematic flowchart illustrating the bearing relubrication control method provided in this application embodiment;

[0023] Figure 2 A schematic flowchart illustrating the method for establishing bearing failure criteria;

[0024] Figure 3 An example diagram showing the iron content in the grease of a sample bearing;

[0025] Figure 4 An example diagram showing the copper content in the grease of a sample bearing;

[0026] Figure 5 A schematic flowchart illustrating the method for determining the optimal grease injection plan;

[0027] Figure 6 This is a schematic structural diagram of the bearing relubrication control device provided in an embodiment of this application. Detailed Implementation

[0028] This application provides a bearing relubrication control method and apparatus, and a computer-readable storage medium. The technical solution of this application will be further described in detail below through embodiments and in conjunction with the accompanying drawings. In the specification, the same or similar reference numerals indicate the same or similar components. The following description of the embodiments of this application with reference to the accompanying drawings is intended to explain the overall concept of this application and should not be construed as a limitation thereof.

[0029] Before introducing the technical solution of this application, we will first provide detailed examples of bearing relubrication methods in related technologies and their existing problems.

[0030] When locomotives and EMUs are in operation, they are typically powered by traction motors. A traction motor consists of a shaft and bearings; the inner rings of the shaft and bearings fit together, and the bearings support the shaft. Factors such as the operating environment of the traction motor on the locomotive or EMU and the rotational speed of the traction motor shaft all affect the structural stability and service life of the bearings.

[0031] The lubrication condition of a bearing directly affects its service life and reliability. Currently, traction motor bearings in the rail transit industry mostly use grease lubrication. The operating condition of the bearing is monitored during operation, and relubrication is performed according to the bearing's operating condition or a pre-set relubrication plan to avoid problems such as peeling and pitting caused by poor lubrication, which threaten the bearing's life and the safe operation of rail transit vehicles.

[0032] Currently, bearing status is typically monitored using vibration or temperature signals. For example, temperature sensors can be installed at the bearing locations at both ends of the motor to monitor the temperature of the bearing outer ring. If the temperature of the bearing outer ring rises to a preset temperature threshold, it indicates that the bearing may have abnormal wear. Alternatively, an acceleration sensor can be used to detect the vibration signal of the bearing. When the vibration acceleration time-domain or frequency-domain index reaches a preset threshold, the monitoring system will issue an alarm to determine if the bearing is faulty.

[0033] The methods described above, based on vibration or temperature signals, are not applicable in some scenarios. For example, early traction motors in rail transit vehicles lacked vibration and temperature sensors, making online monitoring impossible. Vibration signals are sensitive to failure modes with periodic impact signals, such as bearing raceway spalling and scratches, but their accuracy in diagnosing failure modes like abnormal wear and minor electrolytic corrosion is low. Temperature signals only provide feedback when bearing failures become severe in later stages, making them less effective for identifying early-stage bearing faults.

[0034] In some related technologies, the condition of bearings can also be determined by ferrographic analysis of the lubricating medium. For example, for bearings lubricated using a circulating oil supply system, the condition of the bearing can be analyzed by examining the content and type of contaminants in the lubricating oil. However, this method is mostly used in scenarios where the lubricating medium is lubricating oil. Alternatively, for bearings lubricated with grease, the motor must be disassembled to extract grease from inside the bearing for testing and analysis. Traction motors in the rail transit industry mostly use grease lubrication. If this method were used, the motor would need to be disassembled and the grease extracted for testing, resulting in excessively high costs and severely disrupting train operation. Therefore, this method cannot meet the application requirements of the rail transit industry.

[0035] Traction motor bearings are typically maintained by periodically replenishing grease. The relubrication cycle and amount of grease required for bearings are related to parameters such as operating speed, temperature, load, and size. Most relubrication solutions in the industry are derived using theoretical calculations, which determine the theoretical amount of grease based on the aforementioned parameters and perform lubrication maintenance at a preset relubrication cycle.

[0036] For bearings of the same model, the operating conditions can vary. For example, in environments with high winds and sandstorms, the bearing wear rate is faster; and in environments with high humidity, the probability of corrosion is usually greater. Therefore, for bearings of the same model, due to different operating conditions, using the same relubrication scheme may result in problems such as poor lubrication of individual shaft positions and a high failure rate.

[0037] In summary, if the condition of traction motor bearings in rail transit cannot be monitored using vibration and temperature signals, and given that the motors cannot be disassembled without being removed from the vehicle, and that bearings of the same model may have different operating conditions, how to detect the operating condition of the bearings and develop a reasonable relubrication plan becomes an urgent problem to be solved.

[0038] In view of the above problems, embodiments of this application provide a bearing relubrication control method and apparatus, and a computer-readable storage medium. The technical solution of this application will be described in detail below with reference to the accompanying drawings.

[0039] Figure 1 This is a schematic flowchart of the bearing relubrication control method provided in the embodiments of this application. Figure 1 The method includes steps S110-S130.

[0040] In step S110, the contaminant content and aging index of the bearing grease are determined.

[0041] In this embodiment, the bearing may be a bearing in a rail transit vehicle, such as a bearing in a traction motor of a high-speed railway train, or the bearing may also be a bearing in a traction motor of a subway train.

[0042] It should be noted that the relubrication method provided in this application is applied to bearings lubricated with grease. These bearings are typically housed in a bearing housing, with their inner ring connected to the motor shaft and their outer ring connected to the bearing housing. The bearing housing is provided with an oil injection hole and an oil drain hole.

[0043] The bearing housing also includes an oil filling chamber and a waste oil chamber, both of which are connected to the bearing. For example, when adding grease, the grease is pumped to the bearing through the grease nipple on the filling hole. At the same time as adding new grease, the waste grease in the bearing flows from inside the bearing into the waste oil chamber. When there is a lot of waste grease in the waste oil chamber, it will flow out through the drain port.

[0044] In the embodiments of this application, the content of pollutants and the aging index are measured by measuring the waste grease in the waste oil chamber or after it is discharged through the oil drain.

[0045] Contaminant levels and aging indicators are crucial factors affecting bearing performance and lifespan. Understanding this information provides a foundation for subsequent decision-making, enabling more targeted relubrication strategies.

[0046] In some embodiments of this application, the contaminant may be one or more of iron, copper, and silicon. The contaminant content can be determined by methods such as X-ray fluorescence spectrometry.

[0047] In some embodiments, the degree of aging of the grease can be measured by one or more of the following indicators: oil separation rate, dropping point, and water content. More specifically, the oil separation rate of the grease can be determined by a static stencil oil separation test and the dropping point of the grease can be determined by a wide temperature range dropping point test.

[0048] It's understandable that after multiple grease replenishments, the aged and contaminated grease inside the motor bearing will flow into the waste oil chamber. Therefore, grease replenishment and drainage tests are necessary to determine how many grease replenishments are required before grease flows into the waste oil chamber. Since traction motors typically use mileage-based grease replenishment, once the number of grease replenishments is determined through testing, it's possible to determine at what mileage the vehicle will travel before waste grease accumulates in the waste oil chamber. This mileage can then be used as the initial grease sampling mileage. Subsequent sampling intervals can be determined based on the bearing failure progression rate and the vehicle's operation, maintenance, and repair cycle, generally sampling at 1 / 10 of the bearing's service life.

[0049] In step S120, the failure mode and degree of failure of the bearing are determined based on the bearing's operating conditions, contaminant content and aging index, as well as the pre-established bearing failure criteria.

[0050] As described above, there is a correlation between the failure modes of bearings and their operating conditions. For example, in arid and windy environments, the main failure mode of bearings is abnormal wear; in high-humidity environments, the main failure mode is corrosion. Therefore, in the solutions of this application embodiment, in addition to the aforementioned pollution and aging indicators, the operating conditions of the bearings also need to be considered.

[0051] In some embodiments, operating conditions may include actual working conditions such as bearing speed, load, operating temperature, and operating time.

[0052] By combining this operating condition information with the detected grease contaminant content and aging indicators, and comparing it with the pre-established bearing failure criteria, we can determine the current failure mode (such as wear, fatigue, corrosion, etc.) and the severity of the failure (mild, moderate, severe, etc.) of the bearing.

[0053] The bearing failure criteria are the correspondence between the possible failure modes and corresponding failure degrees of bearings under different combinations of contaminant content, aging indicators, and operating conditions. In other words, the bearing failure criteria include the correspondence between the contaminant content and aging indicators in the lubricating grease and the failure modes and degrees of bearing failure. The method for establishing bearing failure criteria will be described in detail later and will not be elaborated here.

[0054] In step S130, a relubrication scheme for the bearing is determined based on the bearing's failure mode and degree of failure.

[0055] Relubrication schemes include the grease injection cycle and the amount of grease injected into the bearing. Different grease injection cycles and amounts can be selected for different failure modes and degrees. For example, for bearings with significant wear, following a conventional relubrication scheme may result in a longer cycle, exacerbating bearing wear. In this case, the grease injection cycle can be adjusted to shorten the time difference between two injections, accelerating the removal of contaminated grease through timely injection. Conversely, if the contaminant content in the grease is low and its aging indicators are favorable, indicating that the bearing is operating under ideal conditions, the grease injection cycle can be appropriately extended to reduce maintenance costs.

[0056] The amount of grease injected into a bearing is related to the bearing model. Specifically, the larger the bearing width and diameter, the more space it has to hold grease, meaning a larger amount of grease is required. At the same time, the amount of grease injected must meet the following requirements: it should replace the maximum proportion of the original grease inside the bearing, and the grease should not overflow from the bearing's sealant structure after injection.

[0057] The amount of grease injected into a bearing is usually determined through a grease injection test, the specific method of which will be described in detail later.

[0058] Based on the aforementioned technical methods, and considering the bearing's operating conditions, the contaminant content and aging indicators of the grease, and according to pre-established bearing failure criteria, the failure mode and degree of the bearing are determined, thereby enabling precise control of bearing relubrication. The relubrication scheme determined by this method is no longer blind lubrication based on fixed cycles and grease amounts, but rather determined according to the actual needs of the bearing. This allows for the rational use of grease, avoiding insufficient lubrication that leads to accelerated bearing wear, and also preventing waste and potential problems caused by over-lubrication. This optimizes bearing lubrication management, extends bearing service life, and improves equipment operating efficiency and economy.

[0059] The following is combined with Figure 2 The method for establishing bearing failure criteria is described in detail. Figure 2 The method includes steps S210-S250.

[0060] In step S210, multiple first sample bearings are collected. These multiple first sample bearings should meet the first grease sampling mileage mentioned above; that is, the first sample bearing is a bearing that meets a certain working mileage or working time. For example, the working mileage of the first sample bearing is greater than 500,000 kilometers.

[0061] In some embodiments, the plurality of first bearing samples satisfy at least one of the following conditions: the plurality of first bearing samples are of different models; the rail transit vehicles using the plurality of first bearing samples have different operating environments; the rail transit vehicles using the plurality of first bearing samples have different mileages; the plurality of first bearing samples are located at different axle positions of the rail transit vehicles; the plurality of first bearing samples are located at different parking spaces of the rail transit vehicles.

[0062] The multi-sample bearings meet various conditions, greatly enriching the diversity of the sample. Samples of different models, operating environments, mileage, axle positions, and parking positions can simulate various actual working conditions, enabling the established failure criteria to adapt to complex and ever-changing application scenarios and ensuring effective evaluation of bearing condition under different circumstances.

[0063] In step S220, the grease is extracted from each first sample bearing. For the collected first sample bearing, the grease inside the bearing is separated. The extraction of the grease is for subsequent testing and analysis of its various parameters.

[0064] In some embodiments, the mass of grease extracted from the first sample bearing is greater than 5 grams, or the mass of the extracted grease is determined according to a selected criterion.

[0065] Indicators for assessing bearing condition can be related to the characteristics of the bearing's operating environment. For example, in environments with high winds and sandstorms, where bearing wear is severe, the silicon (Si) content in the grease can be selected as a criterion. In environments with high humidity, indicators such as water content and acid value in the grease can be chosen. Alternatively, appropriate criterions can be selected based on the materials, failure modes, and severity of the bearing components. For instance, if abnormal wear or spalling occurs in the bearing rings or cages, the content of elements such as Fe and Cu should be selected as criterions. Furthermore, grease aging indicators such as cone penetration, oil separation rate, and dropping point can be used to reflect grease aging.

[0066] In step S230, the failure mode and failure degree of each first sample bearing are determined.

[0067] In some embodiments, the failure mode of the bearing includes at least one of electrical erosion, spalling, corrosion, and fracture, and the degree of failure is determined based on at least one of the following: the damaged area, depth, color change, number of failed parts, and degree of influence on operating temperature of the first sample bearing.

[0068] In some embodiments, before determining the failure mode and degree of failure for each sample bearing, the method further includes:

[0069] When the cage of the first sample bearing is a corrugated steel cage, the rivets of the corrugated steel cage are removed by drilling. When the cage of the first sample bearing is a frame-type cage, the rivets of the frame-type cage are removed by electrical discharge machining or milling, thereby disassembling the first sample bearing into an inner ring, an outer ring, and rolling elements.

[0070] By using the drilling, EDM, or milling methods described above, damage to bearing components caused by improper disassembly can be avoided, making it impossible to distinguish whether the damage occurred during operation or was caused by disassembly during subsequent inspection and evaluation.

[0071] After disassembling the first sample bearing, the failure mode and corresponding degree of failure of each bearing can be determined based on the damage to individual components. More specifically, various testing methods and tools can be used to conduct a detailed inspection of each sample bearing to determine its specific failure mode (such as electrolytic corrosion, spalling, corrosion, fracture, etc.). Simultaneously, based on the specific details of the bearing damage, such as the damaged area, depth, color change, number of failed parts, and impact on operating temperature, the degree of failure can be quantitatively assessed to determine whether it is a mild, moderate, or severe failure.

[0072] In step S240, the contaminant content and aging index of the grease in each first sample bearing are determined.

[0073] The grease extracted from each first sample bearing was analyzed and tested. The main contaminants tested were iron and copper content, which could be determined using specific chemical or spectroscopic analysis methods. Aging indicators included grease cone penetration (reflecting grease consistency), oil separation rate (reflecting grease stability), and water content (affecting grease quality and performance), all of which required appropriate testing methods to obtain specific values.

[0074] In step S250, the failure criteria of the bearing are established based on the contaminant content and aging index of the first sample bearing for each failure mode and degree of failure.

[0075] Based on the bearing failure type and degree, the test results of multiple bearing samples and the corresponding grease contamination content test results are classified and statistically analyzed. Based on the distribution of the test results of the corresponding judgment indicators for different failure types and degrees of multiple samples, the mean, minimum value, etc. can be selected as the threshold for failure judgment.

[0076] Table 1 below is an example of the bearing failure criteria determined based on the distribution of the above-mentioned various test results.

[0077] Table 1

[0078]

[0079] After determining the above bearing failure criteria, the test results of the bearing grease can be analyzed to determine the measured values ​​of contaminant content and aging indicators. Then, based on the limits of the selected indicators in the table above, the bearing failure mode and degree can be determined.

[0080] The following example will provide a more detailed explanation of the method for establishing bearing failure criteria.

[0081] Taking the traction motor bearings of a certain type of EMU as an example, the lubricating grease in the faulty bearings and their waste oil chambers of the EMU were tested by collecting the bearings undergoing maintenance. The test revealed that the bearing failures were mainly of three types: raceway spalling, washboard-like electrical erosion, and slight electrical erosion with darkened rolling elements. Based on the degree of impact on the bearing operating temperature, spalling was classified as severe, washboard-like patterns as moderate, and darkened rolling elements as mild. Figure 3 and Figure 4 Example diagrams showing the iron and copper content of grease in the waste oil cavity corresponding to three faults: bearing peeling, washboard pattern, and darkened ball bearings.

[0082] like Figure 3 and 4 As shown, analysis of the iron and copper content in the lubricating grease reveals the following:

[0083] When the bearing shows signs of spalling, the iron content is concentrated in the range of greater than 1000ppm and less than 2500ppm, and the copper content is concentrated in the range of greater than 250ppm and less than 450ppm.

[0084] When a bearing exhibits a washboard pattern, the iron content is concentrated in the range of greater than 600 ppm and less than 1400 ppm, while the copper content is concentrated in the range of greater than 100 ppm and less than 250 ppm.

[0085] When the rolling elements of a bearing become dark, the iron content is concentrated in the range of greater than 400 ppm and less than 1000 ppm, and the copper content is concentrated in the range of greater than 20 ppm and less than 100 ppm.

[0086] Based on the above statistical results, the bearing failure criteria shown in Table 2 can be determined.

[0087] Table 2

[0088]

[0089] Based on the above technical means, through multi-fault sample detection and failure mode classification, a correspondence between motor bearing failure modes, failure rate, lubricant contaminant content, and aging degree was established, laying the foundation for effectively identifying early bearing failures.

[0090] In some embodiments, step S130, which involves determining a relubrication scheme for the bearing, includes:

[0091] The grease injection cycle is determined based on the bearing's failure mode and degree of failure; and the amount of grease is determined based on the bearing model and the optimal grease injection scheme corresponding to the bearing model.

[0092] The grease injection cycle refers to the time difference between the next time grease is added to the bearing and the current time. The magnitude of this time difference is related to the current failure mode and / or failure degree of the bearing.

[0093] Taking failure modes as an example, for defects such as abnormal wear, the grease injection cycle should be shortened as much as possible. For early failure characteristics such as washboard patterns and darkening of rolling elements, the shortening of the grease injection cycle can be set to a relatively small extent.

[0094] Taking the traction motor bearing of a rail transit vehicle as an example, the conventional grease injection cycle is to replenish grease every 100,000 kilometers. If the current failure mode of the bearing is wear, the grease injection cycle can be shortened to 50,000 kilometers. If the current failure mode is the darkening of the rolling elements, the grease injection cycle can be set to 70,000 kilometers.

[0095] For the same type of failure, the grease injection cycle should be set differently depending on the degree of failure. Taking the current failure mode of the bearing as corrosion as an example, for moderate corrosion, after the grease is added, most of the grease with high water content in the oil cavity will be replaced, and the possibility of further corrosion expansion is small. In this case, the grease injection cycle can be, for example, 80,000 kilometers. For severe corrosion, after the current grease injection is completed, the water content of the grease in the oil cavity may still exceed the normal value. At this time, there is still a possibility of corrosion expansion. In this case, the grease injection cycle can be set to a shorter period of time, such as 50,000 kilometers, so that the condition of the bearing can be checked again after a shorter period of time.

[0096] The optimal grease filling scheme for a bearing is related to the bearing model, and more specifically, to its diameter and width. Larger bearing diameters and widths provide more internal space for grease, thus requiring a larger grease volume. Simultaneously, the grease filling process must replace as much of the existing contaminated grease as possible while ensuring no grease overflows from the bearing housing. The grease volume can be determined based on the bearing model and its corresponding optimal grease filling scheme.

[0097] The following is combined with Figure 5The method for determining the optimal grease injection plan is explained in detail. Figure 5 The method includes steps S510-S540.

[0098] In step S510, the theoretical grease amount of the bearing is determined according to the bearing model.

[0099] The theoretical grease filling amount is related to the bearing's outer diameter and width. For example, the theoretical grease filling amount G = 0.05D * B, where D is the bearing's outer diameter and B is the bearing's width.

[0100] In step S520, based on the theoretical amount of grease injected, multiple grease injection schemes are determined according to different increases in the amount of grease added.

[0101] For example, taking a certain type of traction motor bearing as an example, the theoretical calculation shows that the grease replenishment amount for the drive end bearing of this type of motor is Gg per X 10,000 kilometers. However, analysis revealed that some vehicle / axle motors experienced rapid bearing wear and a high failure rate due to poor operating conditions. The method of reducing the bearing grease injection cycle was used to reduce the contaminant content in the grease and slow down bearing wear. The relubrication grease amount was determined experimentally: Grease injection scheme 1 involves G grams of grease inside the bearing; grease injection scheme 2 involves G+A grams; and grease injection scheme 3 involves G+B grams.

[0102] In step S530, multiple grease injection tests are performed on the second sample bearing according to multiple grease injection schemes.

[0103] Grease injection tests were conducted on the second bearing using different grease replenishment schemes described above. During the tests, the amount of contaminated grease that was replaced inside the second bearing was determined, and whether grease overflowed from the sealing structure was observed.

[0104] In step S540, in multiple grease injection tests, the grease injection scheme in which the grease does not leak from the equipment using the second sample bearing and the proportion of contaminated grease that is replaced is taken as the optimal grease injection scheme.

[0105] For example, when using the above-mentioned scheme 1 for grease injection, the new grease enters about 50% of the bearing's interior, and this scheme can replace 50% of the contaminated grease inside the bearing; when using the above-mentioned scheme 2 for grease injection, the new grease can replace more than 70% of the contaminated grease inside the bearing; when using the above-mentioned scheme 3 for grease injection, the new grease can replace more than 90% of the contaminated grease inside the bearing.

[0106] Experiments show that the C-grade new grease can replace the largest amount of contaminated grease, but this solution has the problem of some grease overflowing from the sealing gap of the motor bearing unit. Therefore, this solution is not an option. Considering the replacement effect and whether grease overflow occurs during grease replenishment, solution 2 is selected as the optimal solution.

[0107] Based on the above technical means, starting from the theoretical amount of grease to be added, and through multiple scheme tests, the best scheme was determined with the standard of no grease overflow and the highest replacement rate of contaminated grease, so as to ensure the best grease addition effect and avoid resource waste and environmental pollution while ensuring lubrication effect.

[0108] The above text combined Figures 1-5 The method embodiments of this application have been described in detail. The device embodiments of this application will be described in detail below with reference to the accompanying drawings.

[0109] Figure 6 This is a schematic structural diagram of the bearing relubrication control device provided in the embodiments of this application. Figure 6 The device 600 includes:

[0110] The first determining unit 610 is used to determine the contaminant content and aging index of the bearing grease.

[0111] The second determining unit 620 is used to determine the failure mode and degree of failure of the bearing based on the bearing's operating conditions, contaminant content and aging index, as well as pre-established bearing failure standards.

[0112] The third determining unit 630 is used to determine the relubrication scheme of the bearing based on the failure mode and degree of failure of the bearing.

[0113] The bearing failure criteria include the correspondence between the content of contaminants and aging indicators in the grease and the failure mode and degree of the bearing, while the relubrication scheme includes the grease injection cycle and the amount of grease injected.

[0114] This application also provides a computer-readable storage medium storing executable code, which, when executed, implements the method described in any of the preceding embodiments.

[0115] This application also provides a computer program product. The computer program product includes a program. The computer program product can be applied to the electronic device provided in this application embodiment, and the program causes the computer to perform the methods in the various embodiments of this application.

[0116] It should be understood that the units described above as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0117] In the various embodiments of this application, the order of the above-mentioned processes does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of this application.

[0118] In the several embodiments provided in this application, it should be understood that the disclosed systems, apparatuses, and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between apparatuses or units may be electrical, mechanical, or other forms.

[0119] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0120] In addition, the functional units in the various embodiments of this application can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit.

[0121] In the above embodiments, implementation can be achieved entirely or partially through software, hardware, firmware, or any combination thereof. When implemented using software, it can be implemented entirely or partially in the form of a computer program product. The computer program product includes one or more computer instructions. When the computer program instructions are loaded and executed on a computer, all or part of the processes or functions described in the embodiments of this application are generated. The computer can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable device. The computer instructions can be stored in a computer-readable storage medium or transmitted from one computer-readable storage medium to another. For example, the computer instructions can be transmitted from one website, computer, server, or data center to another website, computer, server, or data center via wired (e.g., coaxial cable, fiber optic, digital subscriber line (DSL)) or wireless (e.g., infrared, wireless, microwave, etc.) means. The computer-readable storage medium can be any available medium that a computer can read or a data storage device such as a server or data center that integrates one or more available media. The available media may be magnetic media (e.g., floppy disks, hard disks, magnetic tapes), optical media (e.g., digital video discs, DVDs) or semiconductor media (e.g., solid-state disks, SSDs), etc.

[0122] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A bearing relubrication control method, characterized in that, The method includes: Determine the contaminant content and aging index of the bearing grease; Based on the bearing's operating conditions, contaminant content, aging indicators, and pre-established bearing failure criteria, the failure mode and degree of failure of the bearing are determined. Based on the failure mode and degree of failure of the bearing, determine the relubrication scheme for the bearing; The bearing failure criteria include the correspondence between the content of contaminants and aging indicators in the grease and the failure mode and degree of the bearing; the relubrication scheme includes the grease injection cycle and grease injection amount of the bearing. The method further includes: Collect multiple first-sample bearings; Extract the grease from each of the first sample bearings; Determine the failure mode and degree of failure for each of the first sample bearings; Determine the contaminant content and aging index of the grease in each of the first sample bearings; Based on the contaminant content and aging index of the first sample bearing for each failure mode and degree, the bearing failure standard is established. The contaminants include iron and copper, and the aging indicators include the penetration of the grease, the oil separation rate, and the water content.

2. The method according to claim 1, characterized in that, The contaminants are iron and / or copper, and the aging indicators include the penetration, oil separation rate, and water content of the grease. The determination of the contaminant content and aging index of the bearing grease includes: Collect lubricating grease from the waste oil chamber of the bearing; The content of contaminants in the lubricating grease was determined using X-ray fluorescence spectroscopy. The cone penetration, oil separation rate, and water content of the grease were tested.

3. The method according to claim 1, characterized in that, Before determining the failure mode and degree of failure for each of the first sample bearings, the method further includes: In the case where the cage of the first sample bearing is a corrugated steel cage, the rivets of the corrugated steel cage are removed by drilling in order to separate the first sample bearing; If the cage of the first sample bearing is a frame-type cage, the rivets of the frame-type cage are removed by electrical discharge machining or milling to separate the first sample bearing. Determining the failure mode and failure extent of each of the first sample bearings includes: Based on the damage to the inner ring, outer ring, and rolling elements of each of the first sample bearings after disassembly, the failure mode and degree of failure of each first sample bearing are determined.

4. The method of claim 1, wherein, The plurality of first sample bearings satisfy at least one of the following conditions: The multiple first sample bearings are of different models; The operating environments of the rail transit vehicles using the multiple first sample bearings are different; The mileage of the rail transit vehicles using the multiple first sample bearings is different; The multiple first sample bearings are located at different axle positions on the rail transit vehicle; The multiple first sample bearings are located in different positions of the rail transit vehicle.

5. The method according to claim 1, characterized in that, The failure mode includes at least one of electrical erosion, spalling, corrosion, and fracture. The degree of failure is determined based on at least one of the following: the damaged area, depth, color change, number of failed parts, and degree of influence on operating temperature of the first sample bearing.

6. The method according to claim 1, characterized in that, The determination of the relubrication scheme for the bearing includes: The grease injection cycle is determined based on the failure mode and degree of failure. The amount of grease to be injected is determined based on the bearing model and the optimal grease injection scheme corresponding to the bearing model.

7. The method according to claim 6, characterized in that, Before determining the relubrication scheme for the bearing, the method further includes: Based on the bearing model, determine the theoretical grease injection amount of the bearing. The theoretical grease injection amount is related to the outer diameter and width of the bearing. Based on the theoretical amount of fat injected, multiple fat injection schemes are determined according to different increases in the amount of fat added. Based on the aforementioned multiple grease injection schemes, multiple grease injection tests were conducted on the second sample bearing; In the multiple grease injection tests, the grease injection scheme in which no grease leaked from the equipment using the second sample bearing and the largest proportion of contaminated grease was replaced was selected as the optimal grease injection scheme.

8. A bearing relubrication control device, characterized in that, The apparatus is used to perform the method as described in any one of claims 1-7, the apparatus comprising: The first determining unit is used to determine the contaminant content and aging index of the bearing grease. The second determining unit is used to determine the failure mode and failure degree of the bearing based on the operating conditions of the bearing, the content of the contaminants and the aging index, as well as the pre-established bearing failure criteria. The third determining unit is used to determine the relubrication scheme for the bearing based on the failure mode and degree of failure of the bearing; The bearing failure criteria include the correspondence between the content of contaminants and aging indicators in the grease and the failure mode and degree of the bearing; the relubrication scheme includes the grease injection cycle and grease injection amount of the bearing. The device further includes a failure criterion establishment unit, used for: Collect multiple first-sample bearings; Extract the grease from each of the first sample bearings; Determine the failure mode and degree of failure for each of the first sample bearings; Determine the contaminant content and aging index of the grease in each of the first sample bearings; Based on the contaminant content and aging index of the first sample bearing for each failure mode and degree, the bearing failure standard is established. The contaminants include iron and copper, and the aging indicators include the penetration of the grease, the oil separation rate, and the water content.

9. A computer-readable storage medium, characterized in that, The computer-readable storage medium is used to store a computer program that, when executed, implements the method as described in any one of claims 1-7.

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