Method for producing hybrid rolling bearing and hybrid rolling bearing
By disassembling, cleaning, and reassembling the used ceramic rolling elements with new steel inner and outer rings, the problem of ceramic rolling element waste was solved, resulting in cost and energy reduction and a decrease in environmental impact.
Patent Information
- Application Number
- CN202380097309.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2023-04-24
- Publication Date
- 2025-11-14
AI Technical Summary
The production cost of ceramic rolling elements in existing hybrid rolling bearings is high, energy consumption is large, and they are difficult to recycle, resulting in waste and accounting for a high proportion of the total bearing cost.
By disassembling, cleaning, repolishing, and reassembling the used ceramic rolling elements with new steel inner and outer rings, a new hybrid rolling bearing is formed, avoiding the waste of ceramic rolling elements.
It reduces the financial cost, energy consumption, and environmental impact of ceramic rolling elements, reduces energy consumption in raw material extraction and manufacturing, and lowers the environmental footprint.
Smart Images
Figure CN120958250A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to a method for manufacturing a hybrid rolling bearing. Furthermore, this invention relates to a hybrid rolling bearing in general. Background Technology
[0002] Hybrid rolling bearings, comprising rolling elements made of ceramic materials and bearing rings made of steel, are being used in an increasing number of applications. Typically, the ceramic material used to manufacture the ceramic rolling elements for hybrid rolling bearings is silicon nitride (Si3N4). However, the manufacture of ceramic rolling elements based on Si3N4 powder and sintering aids is energy-intensive, and the energy consumption and cost per rolling element increase with the diameter of the rolling element. In particular, the ceramic rolling elements account for a significant portion of the final cost of hybrid bearings.
[0003] There is a ongoing need for continuous improvement in the financial costs, energy consumption, and / or environmental impact of manufacturing ceramic rolling elements used in hybrid bearings. Currently, there is no method for recycling ceramic rolling elements as raw materials, unlike steel components which can be remelted. Therefore, ceramic rolling elements are typically wasted at the end of the hybrid bearing's service life.
[0004] The current “production-consumption-waste” value chain problem of ceramic rolling elements remains unresolved, even though ceramic rolling elements account for up to 80% of the final cost of hybrid bearings.
[0005] Therefore, the object of the present invention is to provide a method for manufacturing hybrid bearings that allows for reductions in the financial cost, energy consumption, and / or environmental impact of ceramic rolling elements used in hybrid bearings. Summary of the Invention
[0006] This task is solved by the method for manufacturing hybrid rolling bearings according to claim 1.
[0007] The following describes a method for manufacturing a hybrid rolling bearing. The hybrid rolling bearing includes at least one set of ceramic rolling elements, at least one inner ring made of bearing steel, and at least one outer ring made of bearing steel. The ceramic rolling elements may be made of silicon nitride (Si3N4). Furthermore, the inner ring may be provided with an inner raceway and / or the outer ring may be provided with an outer raceway, on which the rolling elements roll. The rolling elements may be balls, cylindrical rollers, tapered rollers, needle rollers, etc. For example, the hybrid rolling bearing may be a hybrid ball bearing. Furthermore, the rolling elements may be held in a cage, wherein the cage is configured to space the rolling elements apart from each other in the circumferential direction.
[0008] A method for manufacturing hybrid rolling bearings includes the following steps:
[0009] Disassemble a used hybrid bearing having at least one set of ceramic rolling elements, at least one inner ring made of bearing steel, and at least one outer ring made of bearing steel.
[0010] Collect at least one ceramic rolling element from the set of ceramic rolling elements.
[0011] Clean the collected ceramic rolling elements.
[0012] Provide at least one cast inner ring made of bearing steel and / or at least one cast outer ring made of bearing steel.
[0013] Select at least one of the cleaned ceramic rolling elements, and
[0014] The new hybrid bearing is assembled using the at least one selected ceramic rolling element and the at least one cast inner ring made of bearing steel and / or the at least one outer ring made of bearing steel.
[0015] It has been found that rolling elements may experience more or less wear depending on the type used in the bearing. For example, in ball bearings, balls experience less excessive rolling fatigue than rings due to the random excessive rolling direction and spin of the balls. Furthermore, it has been found that ceramic rolling elements, such as silicon nitride (Si3N4) rolling elements, can have very high fatigue limits, preventing fatigue accumulation in the material under most standard operating conditions, thus preventing fatigue of the subsurface material, and allowing the ceramic rolling elements used to retain their initial material grade. In other words, new bearings can consist of new steel rings in a new or unused condition, as well as used and reworked ceramic rolling elements.
[0016] In addition, collecting at least one ceramic rolling element may include collecting one ceramic rolling element from a set of ceramic rolling elements, a portion of at least one set of ceramic rolling elements from a used bearing, or the entire set of ceramic rolling elements. If the mixed bearing used includes more than one set of ceramic rolling elements, it may also be possible to collect only a portion of two sets of ceramic rolling elements, or only a complete set of ceramic rolling elements, and only a portion of another set of ceramic rolling elements, or both.
[0017] Furthermore, the method may also include the step of providing a cast cage configured to retain the ceramic rolling element. Specifically, all worn steel components and / or parts (such as seals) can be replaced with new components and / or parts in new condition.
[0018] Therefore, the above-described method for manufacturing hybrid rolling bearings has the following advantages: it avoids wasting ceramic rolling elements at the end of the service life of the hybrid bearing simply because the steel components have worn out.
[0019] Reusing ceramic rolling elements offers several advantages: the financial costs, energy consumption, and / or environmental impact of ceramic rolling elements used in hybrid bearings can be reduced, as the largest portion of these impacts is caused by the production of ceramic rolling elements. More specifically, the "production-consumption-waste" value chain problem associated with ceramic rolling elements can be overcome by introducing roundness into the rolling elements.
[0020] As used herein, the term "used bearing" may refer to a bearing that has previously been used in a machine or application. In particular, a used bearing may have reached the end of its service life and may have been removed from the machine due to planned and / or unplanned maintenance work. In addition, at least one steel component of the used bearing, such as the inner ring, the inner raceway disposed on the inner ring, the outer ring, and / or the outer raceway, may be worn.
[0021] As used herein, the term "new bearing" can mean a bearing that has not yet been used in a machine or application. In particular, a new bearing may be at the beginning of its service life and may be incorporated into a machine, for example, to replace a worn bearing. Furthermore, at least one steel component of the new bearing (e.g., the inner ring, the inner raceway disposed on the inner ring, the outer ring, and / or the outer raceway) may be in a cast state.
[0022] The method of the present invention includes several steps. These steps may be performed sequentially. The term "performed sequentially" may mean that the steps are performed in the order they are listed. However, the term "performed sequentially" may also cover the option of including further steps before, after, or between any of the listed steps.
[0023] According to another embodiment, cleaning the collected ceramic rolling elements includes removing lubricant and / or other particles that may adhere to the surfaces of the collected ceramic rolling elements and / or may have accumulated on the surfaces of the ceramic rolling elements. For example, the lubricant may be grease, oil, lubricating coolant, and / or mixtures thereof. Preferably, cleaning the collected ceramic rolling elements includes chemical cleaning, which may include the use of a chemical cleaner configured to remove lubricant and / or other particles.
[0024] Furthermore, the method may include a step of repolishing the collected and / or cleaned ceramic rolling elements. Repolishing can also be performed using abrasive media such as diamond, and / or silica, and / or alumina or other oxide-based compounds. Repolishing ceramic rolling elements can have the advantages of effectively removing accumulated particles and / or other media such as lubricants.
[0025] Preferably, the method further includes the step of inspecting the surface of the ceramic rolling element to determine a surface appearance grade. For example, the surface of the ceramic rolling element can be inspected using similar techniques also applied to new rolling elements. In particular, the surface of the ceramic rolling element can be inspected using optical methods, such as white light inspection and / or fluorescent penetrant inspection. This has the advantage of being able to determine the surface appearance grade of the ceramic rolling element used. Additionally, the determined surface appearance grade of the ceramic rolling element used can be compared with the previous surface appearance grade of the ceramic rolling element in its cast state. This allows for the determination of whether the surface of the ceramic rolling element has been damaged.
[0026] Furthermore, after inspecting the surface of the ceramic rolling element to determine its surface appearance category, the ceramic rolling elements can be sorted based on the determined surface appearance category. Alternatively or alternatively, based on surface performance knowledge and / or specifications, the suitability of the rolling element surface can be evaluated using inspection standards already applicable to new parts. For example, interferometry, digital holographic microscopy, X-ray tomography, etc., can be used to inspect ceramic parts. Advantageously, due to hardness, stiffness, and / or primary elastic response, the surface of the ceramic rolling element may tend to remain intact or nearly "new," thus maintaining or nearly maintaining its initial surface appearance grade and its diameter tolerance grade.
[0027] According to another embodiment, the method further includes a step of evaluating the ceramic rolling element based on at least one predetermined criterion. Preferably, the at least one predetermined criterion is the diameter of the ceramic rolling element and / or a quantity indicating surface properties. The quantity indicating surface properties may be surface roughness and / or surface quality, such as surface errors, cavities, etc. Furthermore, the method may also include a step of sorting the ceramic rolling elements based on the predetermined criterion. For example, the ceramic rolling elements may be classified based on their diameter. This allows the ceramic rolling elements to be classified into groups of rolling elements with the same diameter.
[0028] Preferably, new ceramic rolling elements are selected based on at least one predetermined criterion. Specifically, if a ceramic rolling element passes the required surface appearance grade inspection and / or dimensional requirements, it is shaped to extend its service life or is effectively used for a second service life. More specifically, the readjustment process (e.g., the aforementioned cleaning and / or repolishing process) for passing the appearance grade inspection consumes at least five times less time and energy compared to producing new ceramic rolling elements from Si3N4 powder and sintering additives. This can be recycled to ensure lower costs and a lower environmental footprint by reducing raw material extraction, manufacturing energy, the amount of toxic waste, waste materials, transportation costs, end-of-life waste, and / or water consumption.
[0029] Preferably, the selected new set of ceramic rolling elements is the same as or equal to at least one set of ceramic rolling elements collected from the hybrid bearings used. More specifically, this set of ceramic rolling elements can be retained when disassembling the used hybrid bearings. This has the advantage that the step of sorting the ceramic rolling elements based on at least one predetermined criterion can be omitted. That is, due to hardness, stiffness, and / or primary elastic response, the surface of the ceramic rolling elements tends to remain intact or nearly "new," thus maintaining or nearly maintaining their initial surface appearance grade and diameter tolerance grade when retained as a kit from the bearing.
[0030] According to another aspect, a hybrid rolling bearing is provided. The hybrid rolling bearing includes at least one set of ceramic rolling elements, at least one inner ring made of bearing steel, and at least one outer ring made of bearing steel, wherein the hybrid rolling bearing is manufactured according to the method described above. Preferably, at least one inner ring and / or at least one outer ring made of bearing steel are in a cast state. Furthermore, the hybrid bearing may also include a cage configured to retain the ceramic rolling elements, wherein the cage is in a cast state.
[0031] Further preferred embodiments are defined in the dependent claims, as well as in the specification and drawings. Thus, elements described or shown in conjunction with other elements may exist alone or in combination with other elements without departing from the scope of protection. Attached Figure Description
[0032] In the following description, preferred embodiments of the invention are illustrated in the accompanying drawings, which are merely exemplary and not intended to limit the scope of protection. The scope of protection is defined only by the appended claims.
[0033] The diagram shows:
[0034] Figure 1 A schematic diagram of a method for manufacturing a hybrid rolling bearing according to an embodiment. Detailed Implementation
[0035] In the following text, the same or similar functional elements are indicated by the same reference numerals.
[0036] Figure 1 A schematic illustration of a method for manufacturing a hybrid rolling bearing 1 according to an embodiment is shown. The hybrid rolling bearing 1 includes at least one set of ceramic rolling elements 2, at least one inner ring and an outer ring 8 made of bearing steel. The ceramic rolling elements are balls made of silicon nitride (Si3N4). Alternatively, the rolling elements may be cylindrical rollers, tapered rollers, needle rollers, etc.
[0037] In the first step S1, customer A collects six hybrid rolling bearings 1 from machine 2 at the end of their respective service lives. Then, in step S2, the bearings 1 can be sent to a repair center. In the next step S3, the hybrid bearings 1 are disassembled, the silicon nitride (Si3N4) balls 4 are retained in groups, and the worn inner and outer rings 8 are recycled.
[0038] After disassembling the hybrid bearing 1 and collecting the ceramic balls 4, the ceramic balls 4 are cleaned in step S4. Cleaning includes chemical cleaning using chemical cleaners to remove old lubricant. After cleaning S4, the ceramic balls 4 are repolished using abrasive media (e.g., diamond and / or silica and / or alumina or other oxide-based compounds) to remove any particles that may have accumulated on the surface of the ceramic balls 4.
[0039] Then, in step S5, the cleaned and repolished ceramic ball 4 is inspected and / or evaluated based on predetermined criteria. These criteria may be surface appearance category and / or diameter tolerance grade. For example, techniques also applied to new rolling elements can be used to inspect the surface of the ceramic ball 4. For instance, the surface of the ceramic ball 4 can be inspected using optical methods, such as white light inspection and / or fluorescent penetrant inspection. Alternatively, interferometry, digital holographic microscopy, X-ray tomography, etc., can be used to inspect the ceramic ball 4.
[0040] In step S6, ceramic balls 4 are selected based on at least one predetermined standard (e.g., the desired surface appearance grade and / or diameter tolerance grade) and paired with cast inner and outer rings 10 made of bearing steel in step S7 to assemble a new hybrid bearing 1, which is then sold to customer A or B.
[0041] In summary, the described method for manufacturing hybrid rolling bearings addresses the "production-consumption-waste" value chain problem of ceramic rolling elements by introducing a recycling process. By reusing already used ceramic rolling elements of known material grades, which again meet the surface appearance and / or dimensional requirements for producing new hybrid bearings, the financial costs, energy consumption, and / or environmental impact of ceramic rolling elements used in hybrid bearings can be reduced.
[0042] In particular, the described method consumes at least five times less time and energy compared to producing new ceramic rolling elements from Si3N4 powder and sintering additives. This can be ensured through recycling due to less raw material extraction, less manufacturing energy and toxic waste, less waste material, less transportation, less scrapping, and / or less water consumption, resulting in lower costs and a much lower environmental footprint.
[0043] Therefore, reusing ceramic rolling elements has the following advantages: the financial cost, energy consumption and / or environmental impact of ceramic rolling elements used in hybrid bearings can be reduced, since the largest part of the cost of hybrid bearings is caused by the production of ceramic rolling elements.
[0044] Figure Labels
[0045] 1. Hybrid rolling bearing
[0046] 2 machines
[0047] 4 rolling elements
[0048] 6 rolling element groups
[0049] 8,10 bearing rings
[0050] S1-S7 Method Steps
Claims
1. A method for manufacturing a hybrid rolling bearing (1), wherein the hybrid rolling bearing (1) comprises at least one set (6) of ceramic rolling elements (4), at least one inner ring (10) made of bearing steel and at least one outer ring (10) made of bearing steel, wherein the method comprises the following steps Disassemble (S3) the used hybrid bearing (1), which has at least one set (6) of ceramic rolling elements (4), at least one inner ring (8) and at least one outer ring (8). At least one ceramic rolling element (4) is collected from the set (6) of ceramic rolling elements (4). Clean (S4) the collected ceramic rolling elements (4). Provide at least one cast inner ring (10) made of bearing steel and / or at least one outer ring made of bearing steel (10), Select (S6) at least one of the cleaned ceramic rolling elements (4). (S7) A new hybrid rolling bearing (1) is assembled using at least one selected ceramic rolling element (4) and at least one cast inner ring (10) made of bearing steel and / or at least one outer ring (10) made of bearing steel.
2. The method according to claim 1, wherein the ceramic rolling element (4) collected by cleaning (S4) includes chemical cleaning.
3. The method according to claim 1 or 2, wherein the method further comprises a step of repolishing the collected ceramic rolling element (4).
4. The method according to any one of the preceding claims, wherein the method further comprises the step of inspecting (S5) the surface of the ceramic rolling element (4) to determine the surface appearance grade.
5. The method according to any one of the preceding claims, wherein the method further comprises the step of evaluating the ceramic rolling element (4) based on at least one predetermined criterion.
6. The method according to claim 5, wherein the at least one predetermined criterion is the diameter of the ceramic rolling element (4) and / or a quantity representing surface properties.
7. The method according to claim 6, wherein the new ceramic rolling element (4) is selected based on the at least one predetermined criterion.
8. The method according to any one of the preceding claims, wherein, The method further includes the step of providing a cast cage configured to hold the ceramic rolling element (4).
9. The method according to any one of the preceding claims, wherein the selected new set of ceramic rolling elements is the same as at least one set of ceramic rolling elements collected for the hybrid rolling bearing used.
10. A hybrid rolling bearing (1) comprising at least one set of ceramic rolling elements (4), at least one inner ring (10) made of bearing steel and at least one outer ring (10) made of bearing steel, wherein the hybrid rolling bearing is manufactured according to any one of the preceding claims.
11. The hybrid rolling bearing (1) according to claim 10, wherein, At least one inner ring (10) made of bearing steel and / or at least one outer ring (10) made of bearing steel are in the casting state.
12. The hybrid rolling bearing (1) according to claim 10 or 11, wherein, The hybrid rolling bearing (1) further includes a cage configured to hold the ceramic rolling element (4), wherein the cage is in a cast state.