Thin-Section Bearing Relubrication for Contamination-Prone Multiwire Machines
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Solution Overview
Problem
Existing thin section bearing units in multiwire machines require frequent maintenance due to high contamination and poor heat dissipation, leading to reduced service life and decreased production efficiency, as they need to be disassembled for thorough cleaning and reconditioning of lubricating grease.
Innovation Solution
A thin section bearing unit with a hydraulic network for distributing lubricating grease, allowing for relubrication without disassembly, featuring a combination of axial and radial ducts for uniform grease distribution and centring blind holes for alignment, enabling prolonged service life and reduced maintenance needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If bearing units are mounted close together as a set with large diameters and small axial thicknesses, then the tensioner pulleys can be axially mounted as close to one another as possible, but the high level of contamination and poor heat dissipation require frequent maintenance and deep cleaning
Solution Approach 1:
The bearing unit is divided into separable components: a stationary inner ring assembly and a rotatable outer ring assembly that can be independently removed. This segmentation allows the outer ring to be detached for maintenance without removing the entire bearing unit from the machine, enabling maintenance without shutdown and preserving productivity while extending service life through targeted refurbishment.
Solution Approach 2:
The bearing unit incorporates a self-lubrication system with a grease reservoir and distribution mechanism that automatically supplies lubricant to the rolling elements during operation. This self-service lubrication system reduces the frequency of manual maintenance interventions, extends service life, and eliminates the need for frequent shutdowns for grease reconditioning.
2Reliability
If frequent maintenance including thorough deep cleaning and reconditioning of lubricating grease is performed, then the service life of bearing units is prolonged, but the production efficiency of multiwire machines is reduced due to disassembly operations
Solution Approach 1:
The bearing unit is divided into separable components: a stationary inner ring assembly and a rotatable outer ring assembly that can be independently removed. This segmentation allows the outer ring to be detached for maintenance without removing the entire bearing unit from the machine, enabling maintenance without shutdown and preserving productivity while extending service life through targeted refurbishment.
Solution Approach 2:
The bearing unit incorporates a self-lubrication system with a grease reservoir and distribution mechanism that automatically supplies lubricant to the rolling elements during operation. This self-service lubrication system reduces the frequency of manual maintenance interventions, extends service life, and eliminates the need for frequent shutdowns for grease reconditioning.
3Reliability
If sealing shields are used to prevent contamination and grease dispersion, then the bearing units are protected, but frequent maintenance is still necessary due to poor heat dissipation and contamination in the working environment
Solution Approach 1:
The bearing unit incorporates a self-lubrication system with a grease reservoir and distribution mechanism that automatically supplies lubricant to the rolling elements during operation. This self-service lubrication system reduces the frequency of manual maintenance interventions, extends service life, and eliminates the need for frequent shutdowns for grease reconditioning.
Solution Approach 2:
The bearing unit is pre-filled with lubricating grease in a reservoir before installation, and the grease distribution channels are pre-configured to automatically deliver lubricant to critical surfaces. This preliminary preparation ensures continuous protection against contamination and adequate lubrication without requiring frequent maintenance interventions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables prolonged service life of the bearing units and reduces maintenance frequency, enhancing production efficiency by allowing relubrication without shutting down the multiwire machines, ensuring consistent performance and reduced contamination risks.
Implementation Method 1
a hydraulic network for distributing lubricating grease, featuring a combination of axial and radial ducts for uniform grease distribution
Data Source
AI summary
A thin section bearing unit (10) for multiwire machines. The bearing unit has a central axis (A) of rotation, an inner ring (20), and a flanged rotatable outer ring (30). Defined between the inner and outer rings is a cylindrical cavity (90) for respective rolling elements (40). The inner ring (20) has an outer raceway (22) with an intermediate circumferential groove (23) containing lubricating grease for keeping the raceway (22) lubricated. The bearing unit (10) also has a hydraulic network (60) for distributing the lubricating grease for lubricating the cavity (90). The hydraulic network (60) including at least one axial duct (61) passing through the inner ring (20) and a related radial duct (62) formed in the inner ring (20) between the duct (61) and the circumferential groove (23) of the outer raceway (22).