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Locomotive rolling bearings are critical components that ensure the safe operation of trains, especially in traction motors and axle box bearings. Any failure in these bearings can lead to serious consequences, including train stoppages, which is particularly dangerous for passenger services. A faulty bearing not only disrupts operations but also poses a significant risk to safety. Therefore, it's essential to detect potential issues before installation and ensure that only qualified bearings are used on the locomotives.
Bearing failures often result from multiple factors rather than a single cause. Poor operating conditions can create a vicious cycle, leading to severe damage such as overheating or burning. This makes it challenging to identify the root cause after an incident, complicating the process of drawing conclusions and implementing preventive measures. In this article, we will explore various factors that contribute to bearing problems.
One common issue arises when the bearing is not installed according to the required specifications. For example, using a copper hammer to strike the bearing can cause deformation of the cage, while incorrect installation of the inner and outer rings may lead to axial movement loss and excessive pressure on the shaft.
Improper assembly clearance can also lead to bearing problems. If the clearance is too small, it may cause friction between the rollers and raceway, leading to heat generation. As the temperature rises, different parts of the bearing expand at varying rates, further reducing the clearance and increasing internal stress. This can lead to uneven load distribution, causing some rollers to bear excessive loads and potentially fail.
Another important factor is the interference fit between the bearing’s inner ring and the shaft. Excessive interference can cause tensile stress, leading to cracks in the inner ring. On the other hand, insufficient interference may result in poor contact and instability.
Wear and tear over time can also lead to bearing faults. As the bearing operates, defects and scratches may appear on the inner ring, rolling elements, cage, and raceway, affecting smoothness and generating heat. Prolonged heat can cause lubricant breakdown, leading to increased friction and further damage. If a bearing becomes excessively hot and smokes, it should not be stopped immediately, as cooling could make it impossible to restart, potentially blocking the track.
Proper lubrication is crucial for maintaining bearing performance. Both under-lubrication and over-lubrication can cause problems. Insufficient oil leads to friction and overheating, while excess oil can mix with the lubricant and cause overheating as well. Maintaining clean and high-quality grease is also essential, as contaminants or moisture can affect the oil film and clearance.
Over time, bearings can exceed their service life, leading to material fatigue. Combined with impact forces, this can cause peeling of the roller and raceway surfaces, resulting in reduced smoothness and increased vibration.
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Analysis of the diagnosis method and fault of locomotive rolling bearing
Source: Bearing Network | Time: April 11, 2013