A bearing heat treatment system and method for improved extreme service performance

Abstract

The application relates to the technical field of bearing heat treatment, in particular to a bearing heat treatment system and method for improving limit service performance, which comprises a composite rotating unit, a plurality of auxiliary rotating discs are arranged on a main rotating disc, and clamping areas are arranged on the auxiliary rotating discs; an intelligent spraying unit comprises a plurality of sprayers, temperature controllers are arranged at the spray nozzles of the sprayers; a state sensing unit comprises a controller and an infrared thermal imager array; the controller is configured to calculate the cooling rate of each feature area based on bearing ring surface temperature field data and compare the cooling rate with an ideal cooling curve; when it is identified that the cooling rate deviates from the ideal range, the controller synchronously adjusts at least two parameters, namely, the rotating speed of the auxiliary rotating disc of the feature area, the spraying parameter of the sprayer of the feature area and the power of the corresponding temperature controller. The application can realize the synchronism and uniformity of the bearing ring bainite phase change, so that the limit service performance of the bearing is significantly improved.

Description

Technical Field

[0001] This application relates to the technical field of bearing heat treatment, and in particular to a bearing heat treatment system and method for improving ultimate service performance. Background Technology

[0002] During continuous high-speed operation, the critical transmission bearings of rhinestone-making machinery must withstand high-frequency rotational and vibration loads. The working environment is often contaminated with dust, fine particles, and other impurities, placing extremely high demands on the bearings' precision retention, wear resistance, and fatigue life. Currently, bearings used in this type of machinery commonly suffer from significant temperature rise, increased noise, rapid precision decay, and insufficient service life during high-speed operation. Inadequate heat treatment processes are one of the key factors leading to early bearing failure. Traditional oil-immersion quenching processes easily cause decarburization of the bearing rings, uneven microstructure, and excessive quenching deformation, severely affecting the reliability and durability of the bearings under high-speed precision machining conditions.

[0003] Chinese Patent Publication No. CN116694919B discloses an optimization method and system for the bainitic heat treatment process of bearings. This technology determines the optimal static process parameters by constructing a bearing processing expert database and iteratively optimizing isothermal temperature and time based on a neural network model. The contribution of this technology lies in improving the rationality of process parameter settings through post-analysis driven by historical data, thereby enhancing the quality consistency of batch-produced products to a certain extent.

[0004] While existing technologies have theoretically improved the rationality of bainitic heat treatment processes through static parameter optimization, their solutions are severely inadequate for the specific scenario of bainitic phase transformation in bearing races. Bainitic phase transformation is a typical temperature-time sensitive diffusion-type phase transformation process, with the core process requirement being that all parts of the race enter and stabilize at the bainitic transformation temperature window at similar cooling rates. However, in actual quenching environments, due to the inherent non-uniform flow field of fixed spray systems and the obstruction of equipment structures, specific cooling priority zones and cooling lag zones are formed along the circumference of the race. This orientation-locked cooling non-uniformity directly leads to asynchronous bainitic phase transformation. Specifically, while the cooling priority zone has entered the bainitic transformation stage, the cooling lag zone remains in the austenitic state. This difference in phase transformation process generates a non-uniform structural stress distribution within the race, and the release of this stress further leads to uncontrollable elliptical deformation of the race. More importantly, the stress-deformation coupling effect during the bainitic phase transformation creates a positive feedback loop: geometric deformation alters the relative positional relationship between the bearing ring and the spray medium, further exacerbating the existing uneven cooling pattern and amplifying the asynchronous phase transformation problem throughout the process. Existing static optimization methods are completely inadequate to handle this dynamic evolution. Their post-hoc parameter adjustments based on historical data cannot detect the spatial distribution differences in the bainitic phase transformation process in real time, nor can they break this orientation-locked uneven cooling pattern through dynamic control. This technical deficiency is particularly problematic when dealing with products like bearings used in water-drilling machinery, which require extremely high uniformity of microstructure, dimensional stability, and smooth high-speed operation. This directly leads to significant fluctuations in the bainitic microstructure grade and elliptic deformation exceeding allowable tolerances, severely impacting the bearing's performance in high-speed precision machining and the overall machining quality of the equipment. Summary of the Invention

[0005] In order to achieve the synchronization of bainitic phase transformation and uniformity of microstructure in bearing rings, thereby significantly improving the ultimate service performance of bearings, this application provides a bearing heat treatment system and method for improving ultimate service performance.

[0006] In a first aspect, this application provides a bearing heat treatment system for improving ultimate service performance, employing the following technical solution: A bearing heat treatment system for improving ultimate service performance, comprising: A composite rotating unit includes a main rotating disk that can rotate about its vertical axis and several auxiliary rotating disks arranged circumferentially about the axis of the main rotating disk and that can rotate about its vertical axis. The auxiliary rotating disks are provided with clamping areas for clamping bearing rings. The intelligent spraying unit includes several sprayers arranged circumferentially around the axis of the main rotating disk. The sprayers are used to spray quenching medium onto the bearing rings located in the clamping area, and the nozzles of the sprayers are equipped with temperature controllers for adjusting the temperature of the quenching medium. The state sensing unit includes a controller and an infrared thermal imager array. The controller has a built-in bainitic phase transformation dynamics model and is electrically connected to the infrared thermal imager array, the main rotating disk, the secondary rotating disk, the sprayer, and the temperature controller. The controller is configured to: Based on the real-time temperature field data of the bearing ring surface acquired by the infrared thermal imager array, the real-time cooling rate of each characteristic region of the bearing ring is calculated and compared in real-time with the ideal cooling curve preset in the bainitic phase transformation dynamics model. When the cooling rate of any characteristic region deviates from the ideal range, the controller synchronously adjusts at least two of the following parameters: Adjust the rotational speed of the secondary rotating disk corresponding to this feature area; Adjust the spray parameters of the sprayer that is about to reach the characteristic area; Adjust the power of the temperature controller set in the sprayer.

[0007] Optionally, the state sensing unit further includes a laser displacement sensor, and the controller is electrically connected to the laser displacement sensor; The measuring beam of the laser displacement sensor is directed to the end face or radial surface of the bearing ring, and is used to collect the geometric dimensional changes of the bearing ring in real time during the quenching process. The controller is further configured to: The geometric dimension change is fused with the temperature field data and then input into the bainitic phase transformation dynamics model. Based on the output of the bainitic phase transformation kinetic model, determine whether the bearing ring has undergone abnormal deformation. When the change in geometric dimensions exceeds a preset safety threshold, parameter adjustment for the corresponding feature area is initiated. The parameter adjustment includes at least two of the following: adjusting the rotational speed of the secondary rotating disk, adjusting the spray parameters of the sprayer, and adjusting the power of the temperature controller.

[0008] Optionally, a position encoder is provided on the main rotary disk, and the position encoder is electrically connected to the controller; The controller is further configured to: Based on the angle signal of the main rotating disk fed back by the position encoder, a real-time position mapping of each bearing ring in the revolution motion is established. Based on the real-time position mapping, it is determined whether a specific area on each bearing ring is within the effective coverage range of the corresponding sprayer. When it is determined that the specific area has entered the effective coverage range, the corresponding sprinkler is activated to spray. When it is determined that the specific area has left the effective coverage area or the gap area between the bearing rings has passed, the corresponding sprayer is turned off.

[0009] Optionally, the sprayer is equipped with a high-frequency pulse valve and a temperature controller connected in series along the direction of medium flow; The controller is further configured to: Based on the real-time location mapping, when it is determined that the specific area has entered the effective coverage range of the corresponding sprayer, the opening duration and / or pulse frequency of the high-frequency pulse valve are controlled according to the real-time cooling requirements of the specific area, and the power of the temperature controller is adjusted synchronously. The real-time cooling requirement is determined by comparing the real-time cooling rate of the feature region with the ideal cooling curve in the bainitic phase transformation kinetic model.

[0010] Optionally, the controller is further configured to: When the cooling rate of a certain characteristic region is found to be lower than the ideal range based on the comparison results of the bainitic phase transformation dynamics model, the rotation speed of the secondary rotating disk corresponding to that region is increased, and the following operations are performed simultaneously: increasing the opening duration and / or pulse frequency of the high-frequency pulse valve in the sprayer that will be subsequently reached by that region; and reducing the set temperature of the temperature controller. When the cooling rate of a certain characteristic area is detected to be higher than the ideal range, the rotation speed of the secondary rotating disk corresponding to that area is reduced, and the following operations are performed simultaneously: reducing the opening duration and / or pulse frequency of the high-frequency pulse valve in the sprayer that will subsequently reach that area; increasing the set temperature of the temperature controller.

[0011] Optionally, the high-frequency pulse valve and the temperature controller are connected in series via an eddy current generator, and the eddy current generator has a spiral flow channel inside; The pulse flow generated by the high-frequency pulse valve is transformed into a vortex jet with three-dimensional rotational momentum through the spiral flow channel. This vortex jet and the medium whose temperature has been adjusted by the temperature controller together form a composite cooling field acting on the surface of the bearing ring.

[0012] Optionally, the infrared thermal imager array includes multiple high-resolution infrared temperature sensors, which are non-uniformly distributed. Specifically, the number of infrared temperature sensors arranged in the detection orientation directly facing the inner and outer raceway surfaces of the bearing rings is greater than in other orientations.

[0013] Secondly, this application provides a bearing heat treatment method for a bearing heat treatment system to improve ultimate service performance, which adopts the following technical solution: A bearing heat treatment method for a bearing heat treatment system to improve ultimate service performance includes the following steps: The bearing ring is clamped in the clamping area; Start the composite rotating unit so that the main rotating disk drives the bearing ring to revolve around the center, while each of the auxiliary rotating disks drives the corresponding bearing ring to rotate on its own axis. The infrared thermal imager array is used to collect temperature field data on the surface of the bearing rings in real time. Based on the temperature field data, the real-time cooling rate of each characteristic region of the bearing ring is calculated by the controller and compared in real time with the ideal cooling curve in the bainitic phase transformation dynamics model. When the cooling rate of any characteristic region deviates from the ideal range, the controller synchronously adjusts at least two of the following parameters: Adjust the rotational speed of the secondary rotating disk corresponding to the feature region; Adjust the spray parameters of the sprayer that is about to reach the characteristic area; Adjust the power of the temperature controller set in the sprayer.

[0014] In summary, this application includes the following beneficial technical effects: 1. The composite rotating unit in this application relies on the main rotating disk to drive the bearing ring to revolve around the center and the auxiliary rotating disk to drive the bearing ring to rotate on its own axis, fundamentally eliminating the uneven cooling mode of the fixed spray system; the intelligent spray unit provides an adjustable quenching medium through circumferentially arranged sprayers; the controller of the state sensing unit compares the cooling rate of each characteristic region in real time based on the temperature field data collected by the infrared thermal imager array and the built-in bainitic phase transformation dynamics model. Once it detects a deviation from the ideal range, it synchronously adjusts the rotation speed of the auxiliary rotating disk, the spray parameters of the sprayers, and the power of the temperature controller, actively constraining the cooling process of each region to the ideal path of bainitic phase transformation, effectively avoiding the positive feedback loop of stress deformation, and ultimately achieving the synchronization and uniformity of the bainitic phase transformation of the bearing ring, significantly improving the ultimate service performance of the bearing; 2. The intelligent spray unit's sprayer is connected in series with a high-frequency pulse valve, an eddy current generator, and a temperature controller. The controller relies on the angle signal fed back by the position encoder on the main rotating disk to establish a real-time position mapping of the bearing ring. It can accurately determine whether a specific area of ​​the ring is within the effective coverage range of the sprayer. Then, based on the real-time cooling needs of that area, it adjusts the opening duration and pulse frequency of the high-frequency pulse valve and synchronously adjusts the power of the temperature controller. At the same time, the eddy current generator converts the pulse flow into a vortex jet to enhance the coverage and penetration of the medium. This control method can increase the cooling intensity for heat accumulation areas such as the bearing ring flange and slow down the cooling rate for areas with faster heat dissipation such as the ring end face. It can accurately adapt to the heat exchange needs of different structural areas of the ring, avoid the local formation of martensite or phase transformation lag, and further ensure the consistency of bainitic phase transformation in each area. 3. The clamping area of ​​the secondary rotating disk of the composite rotating unit adopts a vertical rod structure with a flow groove. In conjunction with the rotation of the bearing ring driven by the secondary rotating disk and the vortex jet of the intelligent spray unit, the quenching medium can penetrate to the inner wall of the bearing ring through the flow groove. The vortex jet can also enhance the coverage and penetration of the quenching medium on the surface of the bearing ring, completely solving the problem that traditional fixed fixtures and direct jets cannot cover the inner wall of the bearing ring and the microscopic dead corners such as the raceway root. This ensures that the inner and outer surfaces of the bearing ring and key microscopic areas are uniformly cooled, avoiding local unevenness of structure and dimensional deformation caused by cooling dead corners, and improving the overall quality of the bearing ring. 4. The state sensing unit uses only two laser displacement sensors to monitor the end face and radial surface of the bearing rings respectively. It achieves dynamic scanning coverage of multiple bearing rings by relying on the revolution of the main rotating disk. Combined with the real-time position mapping of the position encoder, it accurately associates the dimensional change and temperature field data of each bearing ring. While ensuring measurement accuracy, it greatly simplifies the multi-sensor monitoring structure, reduces signal interference and data processing load, enables the controller to achieve millisecond-level response, avoids untimely control due to data processing delay, and ensures the timeliness and accuracy of parameter control during heat treatment. 5. The infrared thermal imager array of the state sensing unit adopts non-uniformly distributed high-resolution infrared temperature sensors. More sensors are arranged in the detection direction facing the inner and outer raceway surfaces of the bearing raceways. Since the raceway surface is a critical area of ​​bearing stress, the setting of more sensors ensures the temperature monitoring accuracy of this area, provides accurate data support for accurately calculating the cooling rate of each characteristic area, ensures the accuracy of the controller's parameter adjustment based on the cooling rate comparison results, and further ensures the uniformity of the structure and the stability of the performance of the critical stress area of ​​the bearing. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the bearing heat treatment system according to an embodiment of this application; Figure 2 This is a schematic diagram of the structure of the sealed chamber in an embodiment of this application; Figure 3 This is a cross-sectional structural schematic diagram of the bearing heat treatment system according to an embodiment of this application; Figure 4 This is a schematic diagram of the internal structure of the sealed room in an embodiment of this application; Figure 5 This is a cross-sectional structural schematic diagram of the sealed chamber according to an embodiment of this application; Figure 6 This is a schematic diagram of the structure of the composite rotating unit in an embodiment of this application; Figure 7 This is a schematic diagram of the structure of the secondary rotating disk in an embodiment of this application.

[0016] Reference numerals: 1. Sealed chamber; 11. Base; 111. Flow channel; 112. Oil outlet; 113. Filter screen; 12. Protective frame; 121. Sealing groove; 122. Sealing gasket; 13. Sealing cover; 131. Observation window; 14. Oil storage tank; 2. Composite rotating unit; 21. Main rotating disk; 211. First servo motor; 212. Main disk body; 213. Recovery tank; 214. Flow guide hole; 22. Secondary rotating disk; 221. Second servo motor; 222, auxiliary disk; 223, clamping area; 224, vertical rod; 225, positioning step; 226, flow channel; 23, position encoder; 3, intelligent spray unit; 31, sprayer; 32, high-frequency pulse valve; 33, eddy current generator; 34, temperature controller; 35, annular header; 36, circulating pump; 4, status sensing unit; 41, controller; 42, infrared thermal imager array; 43, laser displacement sensor. Detailed Implementation

[0017] The following is in conjunction with the appendix Figure 1-7 This application will be described in further detail.

[0018] This application discloses a bearing heat treatment system for improving ultimate service performance. For example... Figure 1 and Figure 2 As shown, a bearing heat treatment system for improving extreme service performance includes a sealed chamber 1, a composite rotating unit 2, an intelligent spraying unit 3, and a status sensing unit 4.

[0019] The sealed chamber 1 provides a stable quenching environment for the bearing heat treatment system. It includes a base 11, on which a vertical protective frame 12 is bolted to the upper surface of the base 11, and a sealing cover 13 is fastened to the top of the protective frame 12.

[0020] The base 11 is made of Q235 steel. The base 11 has a pre-set circular flow channel 111 made of 304 stainless steel. One end of the flow channel 111 extends to the upper surface of the base 11, and the other end passes through the side of the base 11 and connects to the external oil tank 14, so as to recover the quenching medium flowing to the upper surface of the base 11.

[0021] The protective frame 12 is made of 304 stainless steel. The top of the protective frame 12 is provided with an annular sealing groove 121. A thick nitrile rubber sealing gasket 122 is embedded in the sealing groove 121. The sealing gasket 122 can fit tightly with the sealing cover 13 to ensure sealing.

[0022] The sealing cover 13 is made of 304 stainless steel. When closed, it forms a sealed space. The center of the sealing cover 13 is provided with a high-temperature resistant quartz glass observation window 131, which facilitates observation of the internal condition of the protective frame 12 without damaging the sealed environment. This sealed structure effectively prevents harmful gases generated by the volatilization of the quenching medium from polluting the environment, avoids external dust and impurities from mixing into the medium and affecting the cooling effect, and maintains the stability of the cooling field inside the protective frame 12, avoiding local cooling deviations caused by airflow interference, thus laying an environmental foundation for the subsequent collaborative work of various units.

[0023] like Figures 2 to 4 As shown, the composite rotating unit 2 includes a main rotating disk 21 and several auxiliary rotating disks 22. The main rotating disk 21 includes a first servo motor 211 mounted on the upper surface of the base 11. The output shaft of the first servo motor 211 is vertically arranged and coaxially connected to the main disk body 212 through a coupling. The first servo motor 211 is used to drive the main disk body 212 to rotate. Several auxiliary rotating disks 22 are arranged circumferentially around the axis of the main disk body 212. Each auxiliary rotating disk 22 includes a second servo motor 221 mounted on the upper surface of the main disk body 212. The output shaft of the second servo motor 221 is vertically arranged and coaxially connected to the auxiliary disk body 222 through a coupling. The second servo motor 221 is used to drive the auxiliary disk body 222 to rotate around its own vertical axis.

[0024] A ring-shaped recovery groove 213 is opened circumferentially on the upper surface of the main disk 212. The recovery groove 213 is located on the outside of all the sub-disks 222. Multiple guide holes 214 are evenly opened at the bottom of the recovery groove 213. The guide holes 214 vertically penetrate the main disk 212. The inner wall of the recovery groove 213 is polished and the surface roughness Ra≤0.8μm is reduced to reduce the residue of quenching medium in the groove and ensure that the medium can flow smoothly into the guide holes 214.

[0025] like Figures 5 to 7 As shown, the upper surface of the sub-disc 222 is provided with a clamping area 223, and a vertical rod 224 structure is installed at the clamping area 223. The vertical rod 224 is vertically fixed to the center of the upper surface of the sub-disc 222. The vertical rod 224 is made of 45 steel (the same material as the main disc 212 and the sub-disc 222, with a thermal conductivity close to that of the GCr15SiMn steel used in the bearing rings, to avoid temperature deviation caused by differences in heat conduction in the contact area). For self-aligning roller bearing rings used in water drilling machinery with a diameter of 200-500mm, the diameter of the vertical rod 224 is adapted to the inner diameter of the ring (when the inner diameter of the ring is 180-480mm, the diameter of the vertical rod 224 is set to 180-480mm), and the vertical rod 224 and the inner diameter of the ring adopt a transition fit (fit clearance 0.02-0.05mm), which avoids pre-deformation caused by interference fit and prevents the ring from shaking during rotation due to excessive clearance.

[0026] The top of the vertical rod 224 is provided with a positioning step 225, the height of which is 1 / 3 to 1 / 2 of the height of the bearing ring. Radial positioning is achieved only by the contact between the end face of the step and the edge of the inner wall of the bearing ring, reducing the contact area and thus reducing the stress effect. Multiple wide flow grooves 226 are evenly opened along the axial direction of the vertical rod 224 to ensure that the quenching medium can penetrate into the inner wall of the bearing ring through the flow grooves 226, avoiding the formation of cooling dead zones.

[0027] The composite rotating unit 2 drives the main disk 212 to revolve the auxiliary disk 222 and the bearing ring, and the auxiliary disk 222 drives the bearing ring to rotate on its own axis. This fundamentally solves the problem of uneven cooling in existing fixed spray systems. The revolving motion causes the outer surface of the bearing ring to periodically traverse all the sprayers 31 of the intelligent spray unit 3, ensuring that the total cooling energy received by each area in the circumferential direction of the bearing ring tends to be consistent. The rotational motion causes the azimuth and impact angles of the micro-regions of the bearing ring (such as the raceway root and the cage guide surface) relative to the fixed sprayer 31 to continuously change, completely breaking the stable vapor film that hinders heat conduction. At the same time, the flow groove 226 structure of the vertical rod 224 cooperates with the rotation, allowing the quenching medium to penetrate into the inner wall and dead corners of the bearing ring from multiple directions, including the normal and tangential directions.

[0028] like Figure 1 and Figure 3 As shown, a position encoder 23 is installed on the edge of the main disc 212. The position encoder 23 is electrically connected to the controller 41 in the state sensing unit 4, thereby providing real-time feedback of the angle signal of the main disc 212. Based on this signal, the controller 41 establishes a real-time position mapping of each bearing ring in the revolution motion, providing a precise motion reference for the "target tracking spray" of the intelligent spray unit 3, and avoiding the energy waste of "air spray" or "missed spray" in the prior art.

[0029] like Figure 3 and Figure 4 As shown, the intelligent spray unit 3 includes multiple sprayers 31 evenly arranged around the axis of the main rotating disk 21. Each sprayer 31 is fixed to the inner wall of the protective frame 12, and the nozzle of the sprayer 31 faces the center of the main rotating disk 21 to ensure that the bearing ring is covered.

[0030] The sprayer 31 is connected in series with a high-frequency pulse valve 32, a vortex generator 33, and a temperature controller 34 along the direction of medium flow. The high-frequency pulse valve 32 is a millisecond-level response valve with an opening duration adjustable range of 10-1000ms and a pulse frequency of 1-10Hz. Its on / off state can be precisely controlled by the controller 41. The vortex generator 33 has a spiral flow channel inside, which can convert the pulse flow generated by the high-frequency pulse valve 32 into a vortex jet with three-dimensional rotational momentum, enhancing the coverage and penetration of the quenching medium on the bearing ring surface and solving the problem that traditional direct jet cannot fully cover complex curved surfaces. The temperature controller 34 adopts a Peltier semiconductor temperature controller 34 with a temperature control accuracy of ±1℃ and an adjustment range of 20-80℃. It can adjust the temperature of the quenching medium in real time to meet the cooling needs of different areas.

[0031] like Figure 1 and Figure 2 As shown, all sprayers 31 are connected to the annular header 35 through pipes. The annular header 35 is installed on the outside of the protective frame 12 and is connected to the oil storage tank 14 through the circulating pump 36 to form a circulation path for the quenching medium.

[0032] Based on the real-time position mapping of the position encoder 23, the controller 41 determines whether a specific area of ​​the bearing ring enters the effective coverage range of the sprayer 31. When the specific area enters, the controller 41 immediately controls the sprayer 31 to start. When the specific area leaves or the gap area between the bearings passes through, the controller 41 immediately controls the sprayer 31 to shut down, thereby realizing dynamic tracking, improving the utilization rate of the quenching medium, and eliminating ineffective spraying.

[0033] The controller 41 can adjust the spray volume through the high-frequency pulse valve 32, enhance the coverage of the eddy current generator 33, and adjust the temperature of the temperature controller 34 according to the cooling requirements of different structural areas of the bearing ring, forming an adjustable cooling mode: For the bearing ring flange area (or the area near the raceway) where there is a lot of heat accumulation and a slow heat dissipation rate due to local structural protrusions, the opening time and pulse frequency of the high-frequency pulse valve 32 in the corresponding spray assembly can be increased, while the set temperature of the temperature controller 34 of the spray assembly can be reduced to form "concentrated" cooling, enhance the heat exchange efficiency of the area, and avoid phase transformation lag due to insufficient heat dissipation; For the area near the end face of the bearing ring where the structure is relatively thin, the heat capacity is small, and the heat dissipation rate is fast, the opening time and pulse frequency of the high-frequency pulse valve 32 in the corresponding spray assembly can be reduced, while the set temperature of the temperature controller 34 of the spray assembly can be increased to slow down the cooling rate of the area and avoid the formation of martensite due to excessive cooling. This precise control capability based on the actual structural differences of the bearing rings is something that existing static spray systems cannot achieve at all. Existing static spray systems can only spray with fixed parameters and cannot adjust the cooling intensity according to the heat dissipation differences of different structural areas of the rings. However, the control method of this system can adapt to the heat exchange needs of various parts of the annular bearing rings, providing precise energy guarantee for all structural areas of the bearing rings to enter the bainitic phase transformation window simultaneously, ensuring that the phase transformation process is uniform and consistent, and avoiding structural stress and dimensional deformation caused by asynchronous local phase transformation.

[0034] like Figure 1 , Figure 4 and Figure 5 As shown, the state sensing unit 4 includes a controller 41 with a built-in bainitic phase transformation dynamics model, an infrared thermal imager array 42, and a laser displacement sensor 43. The controller 41 is electrically connected to the infrared thermal imager array 42, the laser displacement sensor 43, the first servo motor 211, the second servo motor 221, the sprayer 31, the high-frequency pulse valve 32, and the temperature controller 34. The infrared thermal imager array 42 includes multiple high-resolution infrared temperature sensors with a resolution of 640×512 pixels, a temperature measurement range of 0-1000℃, and a sampling frequency of 50Hz. The infrared temperature sensors are non-uniformly distributed, with most of them... Fixed to the inner wall of the protective frame 12, directly facing the inner and outer raceway surfaces of the bearing raceway, with a few fixed to the top inner side of the protective frame 12, directly facing the end face of the bearing raceway. As the raceway surface is a critical area for bearing stress, the arrangement of more sensors ensures the accuracy of temperature monitoring in this area, providing accurate data for subsequent cooling rate calculation; there are two laser displacement sensors 43 fixed to the inner wall of the protective frame 12, with the two laser displacement sensors 43 pointing to the end face of the raceway and the radial surface respectively, with a measurement range of 50-500mm, a measurement accuracy of ±0.01mm, and a sampling frequency of 100Hz, which can collect the changes in the geometric dimensions of the bearing raceway in real time.

[0035] The state sensing unit 4, composite rotation unit 2, and intelligent spraying unit 3 form a closed-loop collaborative system. Infrared thermal imager array 42 collects real-time temperature field data on the bearing ring surface. Controller 41 calculates the real-time cooling rate of each characteristic region based on the temperature field data and compares it in real-time with the ideal cooling curve in the bainitic phase transformation kinetic model. Laser displacement sensor 43 collects real-time geometric dimensional changes of the bearing ring during the quenching process. The geometric dimensional changes are fused with the temperature field data and input into the bainitic phase transformation kinetic model. Controller 41 outputs a judgment based on the bainitic phase transformation kinetic model to determine whether abnormal deformation has occurred. When the cooling rate deviates from the ideal range or the dimensions exceed limits, controller 41 simultaneously adjusts at least two parameters, such as... When the cooling rate of a certain characteristic area is lower than the ideal range, the controller 41 increases the rotation speed of the corresponding auxiliary rotating disk 22 (increasing the relative flow rate between the bearing ring and the quenching medium), and at the same time increases the opening duration and frequency of the high-frequency pulse valve 32 in the sprayer 31 that the characteristic area is about to reach (increasing the spray volume of the quenching medium), and decreases the set temperature of the temperature controller 34 (enhancing the cooling effect). When the cooling rate is higher than the ideal range, the rotation speed of the auxiliary rotating disk 22 is reduced, the pulse parameters are reduced, and the temperature of the temperature controller 34 is increased. This joint regulation actively constrains the phase transformation process of the bearing ring on the ideal process path, avoids the positive feedback loop of stress-deformation, and realizes a qualitative change from "passive response" to "actively guiding the transformation of microstructure".

[0036] In addition, after the intelligent spray unit 3 sprays the quenching medium, the unabsorbed quenching medium flows down the surface of the bearing ring to the recovery tank 213 of the main rotating disk 21. It then flows into the guide channel 111 of the base 11 through the guide hole 214 at the bottom of the recovery tank 213, and is then transported to the oil outlet 112 on the side of the base 11. A stainless steel filter screen 113 with a 0.1mm aperture is installed at the oil outlet 112 to filter impurities in the quenching medium, preventing the circulating quenching medium from clogging the spray nozzle of the sprayer 31 or affecting the operation of the temperature controller 34. The filtered medium flows into the 304 stainless steel oil storage tank 14. The oil storage tank 14 is connected to the annular header 35 of the intelligent spray unit 3 through the circulation pump 36, realizing the recycling of the medium, significantly reducing production costs, meeting the requirements of green production, and at the same time, the purity of the filtered medium is higher, further ensuring the stability of the cooling effect.

[0037] The implementation principle of a bearing heat treatment system for improving ultimate service performance in this application embodiment is as follows: This application completely eliminates the inherent cooling priority zone and cooling lag zone of the existing fixed spray system by coordinating the revolution and rotation of the composite rotating unit 2, so that the total cooling energy received by each area in the circumferential direction of the bearing ring tends to be consistent. At the same time, the flow groove 226 of the vertical rod 224, together with the vortex jet generated by the vortex generator 33, solves the problem that the existing fixed fixtures and direct jet cannot cover the microscopic dead corners such as the inner wall of the bearing ring and the root of the raceway, and realizes the penetration of the quenching medium from the normal and tangential directions. In view of the problems that the multi-sensor monitoring scheme in the prior art is prone to structural complexity, signal interference and data processing delay, this application uses two laser displacement sensors 43 to realize the monitoring of multiple bearing rings by relying on the revolution of the main rotating disk 21. The dynamic scanning coverage of the bearing rings, combined with the real-time position mapping of the position encoder 23, accurately associates the size and temperature data of each bearing ring. While ensuring measurement accuracy, it greatly simplifies the structure and reduces the data processing load, ensuring the millisecond-level response efficiency of the controller 41. In view of the shortcomings of the static parameter optimization in the prior art, which cannot control the phase transformation process in real time, the controller 41 of this application adjusts the rotation speed of the auxiliary rotating disk 22, the spray parameters of the sprayer 31, and the power of the temperature controller 34 based on the real-time data of the state sensing unit 4. It actively constrains the cooling process of each characteristic area of ​​the bearing rings on the ideal path of bainitic phase transformation, avoids the formation of stress deformation positive feedback loop, and solves the problem that the prior art cannot take into account the uniformity of bearing structure, dimensional stability and process economy, so as to significantly improve the ultimate service performance of the bearing.

[0038] This application discloses a bearing heat treatment method for improving the ultimate service performance of a bearing heat treatment system. The bearing heat treatment method for improving the ultimate service performance of a bearing heat treatment system includes the following steps: S1. The operator opens the top sealing cover 13 of the protective frame 12, checks whether the guide channel 111 of the base 11 is unobstructed, whether the filter screen 113 is clean, and whether the quenching medium in the oil tank 14 is sufficient. After confirming that everything is correct, the operator starts the circulation pump 36 to allow the quenching medium to circulate for 10 minutes to expel air from the pipeline. Then, the operator turns off the circulation pump 36 and places the water drill special self-aligning roller bearing ring to be processed onto the vertical rod 224 of the auxiliary rotating disk 22, ensuring that the bearing ring is firmly fixed and without pre-deformation. Then, the operator closes the sealing cover 13 to form a sealed space.

[0039] S2, the controller 41 sends a start signal to the first servo motor 211 and the second servo motor 221, causing the main rotating disk 21 to drive the bearing rings to revolve around the center, and the auxiliary rotating disk 22 to drive the corresponding bearing rings to rotate on their own axis. At the same time, the position encoder 23 on the main rotating disk 21 feeds back the angle signal to the controller 41 in real time. The controller 41 establishes a real-time position mapping of each bearing ring in the revolution motion based on the signal.

[0040] S3, Controller 41 starts the infrared thermal imager array 42 and the laser displacement sensor 43. The infrared thermal imager array 42 collects the surface temperature field data of the bearing ring in real time, focusing on monitoring the temperature changes in key areas such as the raceway surface. The laser displacement sensor 43 collects the end face and radial geometric dimension changes of the bearing ring in real time. All data are transmitted to the controller 41 in real time through a high-speed industrial network.

[0041] S4. Based on the temperature field data collected in step S3, the controller 41 calculates the real-time cooling rate of each characteristic region of the bearing ring (by dividing the temperature difference between two consecutive sampling times by the time interval, and then smoothing the data using a moving average algorithm). The real-time cooling rate is then compared in real time with the ideal cooling curve in the bainitic phase transformation dynamics model. At the same time, the geometric dimension change collected by the laser displacement sensor 43 is fused with the temperature field data and input into the bainitic phase transformation dynamics model to determine whether the bearing ring has undergone abnormal deformation.

[0042] S5. When the controller 41 identifies, based on the data collected by the state sensing unit 4, that the cooling rate of any characteristic area of ​​the bearing ring (such as the ring flange area, where the structure protrudes, resulting in more heat accumulation and a slower heat dissipation rate; or the area near the ring end face, where the structure is relatively thin, the heat capacity is small, and the heat dissipation rate is fast) deviates from the ideal range in the bainitic phase transformation dynamics model, or when the geometric dimension change collected by the laser displacement sensor 43 exceeds the preset safety threshold, it will synchronously adjust at least two of the following core parameters according to the actual working conditions of the characteristic area: If the cooling rate of the flange portion is detected to be below the ideal range, the controller 41 will first adjust the rotation speed of the auxiliary rotating disk 22 corresponding to that flange portion, i.e., increase the rotation speed of the auxiliary rotating disk 22. By increasing the relative flow velocity between the flange portion and the quenching medium, the convective heat transfer efficiency of the surface in that area is enhanced, breaking the local low temperature gradient formed by heat accumulation. At the same time, the controller 41 will synchronously adjust the spray parameters of the spray assembly that the flange portion is about to reach, i.e., increase the opening duration and pulse frequency of the high-frequency pulse valve 32. By increasing the spray volume and impact frequency of the quenching medium, the cooling energy for the flange portion is supplemented. If further enhancement of the cooling effect is required, the power of the temperature controller 34 set in the spray assembly will also be adjusted synchronously, i.e., reduce the set temperature of the temperature controller 34. By reducing the temperature of the quenching medium, the cooling capacity per unit volume of medium is increased, ensuring that the cooling rate of the flange portion quickly returns to the ideal range.

[0043] If the controller 41 detects that the cooling rate in the area near the end face of the ring is higher than the ideal range, it will adjust the relevant parameters in the opposite direction: First, it will reduce the rotation speed of the secondary rotating disk 22 corresponding to the area near the end face, thereby reducing the relative flow rate between the end face and the quenching medium and slowing down the convective heat transfer rate in the area to avoid over-cooling; at the same time, it will simultaneously reduce the opening duration and pulse frequency of the high-frequency pulse valve 32 in the spray assembly that the end face is about to reach, thereby reducing the amount of quenching medium sprayed and reducing the cooling intensity on the end face; in addition, it will simultaneously increase the set temperature of the spray assembly temperature controller 34, thereby increasing the temperature of the quenching medium and weakening the cooling capacity of the medium to prevent the end face from generating martensitic structure due to excessive cooling.

[0044] S6. After completing the synchronous adjustment of at least two of the above parameters, the controller 41 will continuously monitor the cooling rate changes of each characteristic area of ​​the bearing ring through the infrared thermal imager array 42 and track the geometric stability through the laser displacement sensor 43 until the infrared thermal imager array 42 detects that the overall temperature of the ring has dropped to the bainitic phase transformation termination temperature (300℃), and the fluctuation of the dimensional change collected by the laser displacement sensor 43 for three consecutive times is less than 0.05mm (indicating that the dimensions have stabilized). At this time, the controller 41 will sequentially close the high-frequency pulse valve 32 and the temperature controller 34 of the intelligent spray unit 3, the circulation pump 36, and finally close the first servo motor 211 and the second servo motor 221 of the composite rotation unit 2. The operator then opens the sealing cover 13 on the top of the protective frame 12 and takes out the processed bearing ring; the quenching medium remaining in the annular recovery tank 213 of the main rotating disk 21 will flow into the guide channel 111 in the base 11 through the guide hole 214 at the bottom of the recovery tank 213, and after being filtered by the stainless steel filter screen 113 at the oil outlet 112, it will flow into the external oil storage tank 14, waiting for the next cycle.

[0045] The implementation principle of the bearing heat treatment method of the bearing heat treatment system for improving ultimate service performance disclosed in this application embodiment is as follows: This application completely eliminates the cooling priority zone and lag zone of the fixed spray system by coordinating the revolution and rotation of the composite rotating unit 2. This application solves the cooling problem of microscopic dead corners such as the inner wall of the bearing ring and the root of the raceway by cooperating with the vertical rod 224, the flow groove 226 and the vortex jet of the sprayer 31. In view of the problems of complex structure, signal interference and data processing delay of the existing multi-sensor monitoring scheme, this application relies on the revolution of the main rotating disk 21 and the positioning of the position encoder 23 to make the two laser displacement transmission Sensor 43 achieves dynamic scanning coverage of multiple bearing races, accurately associating the temperature and size data of each bearing race, ensuring monitoring accuracy while simplifying the structure and improving the response efficiency of controller 41; addressing the shortcomings of existing static optimization that cannot control the phase transformation process in real time, this application uses controller 41 to synchronously adjust mechanical motion parameters and thermal management parameters, actively constraining the cooling process of the bearing races to the ideal bainitic phase transformation path, avoiding stress deformation positive feedback loop, solving the problem that existing technologies cannot simultaneously achieve microstructure uniformity, dimensional stability and process economy, thus significantly improving the ultimate service performance of bearings.

[0046] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A bearing heat treatment system for improving ultimate service performance, characterized in that: include: A composite rotating unit includes a main rotating disk that can rotate about its vertical axis and several auxiliary rotating disks arranged circumferentially about the axis of the main rotating disk and that can rotate about its vertical axis. The auxiliary rotating disks are provided with clamping areas for clamping bearing rings. The intelligent spraying unit includes several sprayers arranged circumferentially around the axis of the main rotating disk. The sprayers are used to spray quenching medium onto the bearing rings located in the clamping area, and the nozzles of the sprayers are equipped with temperature controllers for adjusting the temperature of the quenching medium. The state sensing unit includes a controller and an infrared thermal imager array. The controller has a built-in bainitic phase transformation dynamics model and is electrically connected to the infrared thermal imager array, the main rotating disk, the secondary rotating disk, the sprayer, and the temperature controller. The controller is configured to: Based on the real-time temperature field data of the bearing ring surface acquired by the infrared thermal imager array, the real-time cooling rate of each characteristic region of the bearing ring is calculated and compared in real-time with the ideal cooling curve preset in the bainitic phase transformation dynamics model. When the cooling rate of any characteristic region deviates from the ideal range, the controller synchronously adjusts at least two of the following parameters: Adjust the rotational speed of the secondary rotating disk corresponding to this feature area; Adjust the spray parameters of the sprayer that is about to reach the characteristic area; Adjust the power of the temperature controller set in the sprayer.

2. The system according to claim 1, characterized in that: The state sensing unit further includes a laser displacement sensor, and the controller is electrically connected to the laser displacement sensor; The measuring beam of the laser displacement sensor is directed to the end face or radial surface of the bearing ring, and is used to collect the geometric dimensional changes of the bearing ring in real time during the quenching process. The controller is further configured to: The geometric dimension change is fused with the temperature field data and then input into the bainitic phase transformation dynamics model. Based on the output of the bainitic phase transformation kinetic model, determine whether the bearing ring has undergone abnormal deformation. When the change in geometric dimensions exceeds a preset safety threshold, parameter adjustment for the corresponding feature area is initiated. The parameter adjustment includes at least two of the following: adjusting the rotational speed of the secondary rotating disk, adjusting the spray parameters of the sprayer, and adjusting the power of the temperature controller.

3. The system according to claim 1, characterized in that: A position encoder is provided on the main rotating disk, and the position encoder is electrically connected to the controller; The controller is further configured to: Based on the angle signal of the main rotating disk fed back by the position encoder, a real-time position mapping of each bearing ring in the revolution motion is established. Based on the real-time position mapping, it is determined whether a specific area on each bearing ring is within the effective coverage range of the corresponding sprayer. When it is determined that the specific area has entered the effective coverage range, the corresponding sprinkler is activated to spray. When it is determined that the specific area has left the effective coverage area or the gap area between the bearing rings has passed, the corresponding sprayer is turned off.

4. The system according to claim 3, characterized in that: The sprayer is equipped with a high-frequency pulse valve and a temperature controller connected in series along the direction of medium flow. The controller is further configured to: Based on the real-time location mapping, when it is determined that the specific area has entered the effective coverage range of the corresponding sprayer, the opening duration and / or pulse frequency of the high-frequency pulse valve are controlled according to the real-time cooling requirements of the specific area, and the power of the temperature controller is adjusted synchronously. The real-time cooling requirement is determined by comparing the real-time cooling rate of the feature region with the ideal cooling curve in the bainitic phase transformation kinetic model.

5. The system according to claim 4, characterized in that: The controller is further configured to: When the cooling rate of a certain characteristic region is found to be lower than the ideal range based on the comparison results of the bainitic phase transformation dynamics model, the rotation speed of the secondary rotating disk corresponding to that region is increased, and the following operations are performed simultaneously: increasing the opening duration and / or pulse frequency of the high-frequency pulse valve in the sprayer that will be subsequently reached by that region; and reducing the set temperature of the temperature controller. When the cooling rate of a certain characteristic area is detected to be higher than the ideal range, the rotation speed of the secondary rotating disk corresponding to that area is reduced, and the following operations are performed simultaneously: reducing the opening duration and / or pulse frequency of the high-frequency pulse valve in the sprayer that will subsequently reach that area; increasing the set temperature of the temperature controller.

6. The system according to claim 4, characterized in that: The high-frequency pulse valve and the temperature controller are connected in series via an eddy current generator, and the eddy current generator has a spiral flow channel inside; The pulse flow generated by the high-frequency pulse valve is transformed into a vortex jet with three-dimensional rotational momentum through the spiral flow channel. This vortex jet and the medium whose temperature has been adjusted by the temperature controller together form a composite cooling field acting on the surface of the bearing ring.

7. The system according to claim 1, characterized in that: The infrared thermal imager array includes multiple high-resolution infrared temperature sensors, which are non-uniformly distributed. Specifically, the number of infrared temperature sensors arranged in the detection orientation directly facing the inner and outer raceway surfaces of the bearing rings is greater than in other orientations.

8. A bearing heat treatment method using the system according to any one of claims 1-7, characterized in that, Includes the following steps: The bearing ring is clamped in the clamping area; Start the composite rotating unit so that the main rotating disk drives the bearing ring to revolve around the center, while each of the auxiliary rotating disks drives the corresponding bearing ring to rotate on its own axis. The infrared thermal imager array is used to collect temperature field data on the surface of the bearing rings in real time. Based on the temperature field data, the real-time cooling rate of each characteristic region of the bearing ring is calculated by the controller and compared in real time with the ideal cooling curve in the bainitic phase transformation dynamics model. When the cooling rate of any characteristic region deviates from the ideal range, the controller synchronously adjusts at least two of the following parameters: Adjust the rotational speed of the secondary rotating disk corresponding to the feature region; Adjust the spray parameters of the sprayer that is about to reach the characteristic area; Adjust the power of the temperature controller set in the sprayer.

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