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                Foshan Zhengda Mechanical & Electrical Bearing Co.,Ltd.

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                Case

                Cement Roller Press Bearings on improving the service life of the proposed
                 
                Roller Press is the core of key equipment for cement plants, of which bearing a reliable and stable operation of a direct impact on the continuity of cement production. 241/560 roller bearings that can line the use of a ~ 2 up to a longer overhaul cycles, is a key indicator of cement plant equipment operation. SKF combined experience in the cement industry, combined with SKF platform product features, make the following recommendations:

                1. Bearing Selection and Installation

                1. SKF Bearing Model: 241/560 ECK30J/C3W33

                EC said the two of them pressed steel window-type cage, inner ring without ribs, with an inner ring led by a guide roller ring and the enhanced group. None of this inner wall design, the following advantages: can reduce the stress concentration ribs, load evenly distributed so that it can withstand greater load, as shown below:
                 

                In addition, the bearing type (domestic) is 241/560 CAK30/C3W33, the CA-based design of the inner wall with a wall surface easily lead to wear and rolling body side stress concentration, cage guided on the rolling capacity of the body not as Window-type steel cage. Meanwhile, the development of spherical roller bearings, E design and CC design gradually replaced with ribs CA design, the relevant comparison as shown below.
                 


                2. Bearing Clearance, SKF recommended values are as follows:

                241/560 ECK30J/C3W33 the original clearance of 0.54 ~ 0.68 mm;

                Reduce the amount of radial clearance 0.24 ~ 0.32 mm;

                After installation to allow clearance for the remainder of 0.25 mm

                Among them, reduce the amount of radial clearance mainly affects the inner bearing journal on the cone to hold fast to power, bearing the original clearance if less, then reduce the amount of radial clearance can take the appropriate limit. Some customers bearing was installed after the clearance of 0.4 ~ 0.45mm, SKF think too much body roll clearance will be deterioration of operation, mainly: participation in load reduction in the number of rolling bodies, a small amount of rolling bodies prone to rub in the run-time slip, is not conducive to extended bearing life. The following icon:
                 


                In addition, taking into account the roller press is generally within the pass water-cooled rollers, bearing the actual operating temperature is not high, therefore, due to temperature changes resulting from reduction in the amount of clearance would be very small.

                Different clearance when the load distribution (left to a smaller clearance, right picture a larger clearance)

                3. Bearing Installation

                For the tapered bore of large bearings, hydraulic assembly method is the best assembly method, the hydraulic assembly can accurately control the axial bearing to promote, in turn, control the radial clearance (as icons).
                 


                2. SKF Sealing Solutions Roller Press

                 

                3. Roller Press Grease Solutions

                Taking into account the roller press for low overload conditions, and there is impact load, therefore, oil must be met: excellent abrasion resistance, good mechanical stability, high carrying capacity, extreme pressure additives, effective ultra-high
                Viscosity of base oil, corrosion resistance and so on.

                SKF grease recommended for: LGEV 2, technical parameters are as follows:

                SKF with a solid lubricant of high viscosity bearing grease LGEV 2 Technical Data

                - Soap / base oil type: Lithium - Calcium base / mineral oil

                - Operating temperature range, oC: -10 - +120

                - Drop point DIN ISO 2176, oC:> 180

                - Base oil viscosity of 40 oC, mm2 / s: 1020 (100 oc, mm2 / s: 58)

                4. Factors affecting bearing life

                ISO as well as the SKF bearing life calculation formula is:
                 


                Where a1: reliability coefficient; aSKF: life correction factor; p: life formula index (ball bearings for the 3; roller bearings for 10 / 3) Life aSKF correction factor is to consider the viscosity of oils and fats, and the impact of pollution on the bearing life factor This formula took into account the carrying capacity of bearings, bearing the actual load, external contamination, oil viscosity, the impact on bearing life. Therefore, to improve the roller press bearing life, except from the cement production process, that is, roll feed block is relatively stable, maintaining a relatively constant roll gap, but also must be integrated to improve the following aspects:

                1. Bearing: Using SKF Explorer spherical roller bearings 241/560 ECJ30K/C3W33

                2. Sealing: SKF with a Polytetrafluoroethylene HDSF2 dust lip oil seals (with wear-resistant bushing);

                3. Grease: high-performance rolling machine-specific oil LGEV 2


                Of course, roller press equipment monitoring and predictive maintenance, can greatly to avoid unplanned downtime of equipment testing in the state, SKF's rattlesnake-line condition monitoring and fault detection system is ideally suited for stick
                Press detection program. (Rattlesnake test program attached) In addition to on-line monitoring, the spectral analysis of vibration data, control equipment, vibration and bearing condition of the early damage is particularly important. SKF acceleration enveloping technology, based on data acquisition and spectrum analyzers Microlog CMXA70 can analyze vibration data can be screening out the harmonic vibration of the situation, in which high-frequency signal is to determine bearing an important basis for early damage.
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