How can wear and tear on the belt pulley bearing cause problems
The roller is the part of the belt conveyor that transmits power and supports the belt, and at the same time has the role of reversing and tensioning, and is the main stressed part of the belt conveyor. Once the bearing position of the roller shaft of the belt conveyor is worn, it will seriously affect the normal operation of the belt and cause economic losses to production. The bearing of the belt roller shaft is prone to the following problems in long-term operation: due to the metal characteristics, the bearing is prone to metal fatigue, resulting in the fit of the inner ring of the bearing and the shaft from interference fit to clearance fit, if it is not found in time, it will lead to the relative displacement of the inner ring of the bearing and the shaft, and then lead to the aggravation of wear on the bearing surface.
Insufficient lubrication or foreign matter during bearing operation is also one of the main reasons for bearing wear, especially for the roller shaft bearing, its working environment is very harsh, and if the bearing seal is damaged, it is easy to cause foreign matter to carry out the bearing. There are many factors that cause bearing damage, once the bearing has a problem, it is bound to cause the relative movement of the bearing and the shaft or sinter together to cause damage to the shaft, if not dealt with in time, it will cause downtime and affect production.
In December 2023, Fushilan technicians went to a large cement plant in Shandong to repair the wear of the belt drum shaft bearing, the equipment company had used this technology to repair, the operation has been very stable, due to bearing damage caused by wear and tear again, the company has always trusted the composite material technology, when the wear problem immediately contacted our company, Fushilan arranged technicians to repair it in time and resume the production of the enterprise.
On-site inspection of equipment condition and formulation of maintenance plan
The bearing diameter of the equipment is 160mm, the width is 80mm, and the maximum unilateral wear is 6-7mm, for this problem, if the enterprise adopts traditional repair methods such as machining, thermal spraying and brush plating to repair, it takes a long time and there are certain drawbacks, whether it is machining after surfacing welding or thermal spraying, it can not avoid the phenomenon that thermal stress cannot be eliminated, which is easy to cause material damage, resulting in bending or fracture of components. The brush plating is limited by the thickness of the coating, easy to peel off, and the above methods are to repair the metal with metal, can not change the "hard to hard" coordination relationship, under the comprehensive action of various forces, it will still cause re-wear, and the long repair time can not meet the first demand of the enterprise for rapid repair. The use of our polymer composite material repair can not only buffer and resist the comprehensive mechanical force during mechanical operation, but also better ensure the 100% surface fit between the bearing position and the bearing, and can be repaired on the spot, greatly shortening the repair time.
Schematic diagram of mold method restoration.
On-site repair of roller bearing wear steps
1.Surface treatment: Use oxygen acetylene flame to burn the surface to be repaired for oil treatment and use a grinder to polish the bearing surface until the original color of the metal is exposed, so as to ensure that the surface to be repaired is clean, dry and strong.
2. Air test mold: on-site measurement and check the mold size and shoulder positioning size, air test mold to ensure that each part is matched accurately.
3. Apply Fushilan 803 release agent: clean the inner surface of the mold with anhydrous ethanol, and then apply the release agent to dry it for later use.
4. Blend Fushilan 2211F materials: Mix the appropriate amount of Fushilan 2211F high-resolution composite materials in strict proportion until there is no uniform color difference. The blended material should be spread out in thin sheets on the blending board and applied immediately to prevent the material from curing prematurely.
5. Apply the material and install the mold: first apply a thin layer and scrape repeatedly to ensure that the material is pressed into every microhole on the surface, and then increase the thickness layer by layer, the thickness of the material is slightly greater than the wear size of the shaft, and then quickly install the mold and tighten the bolts, and the excess material will be discharged from the discharge groove.
6. Curing: Sufficient curing time is carried out, and the specific curing time is determined according to the on-site temperature and referring to the material technical data sheet. The curing time can be shortened by heating with iodine-tungsten lamp or hot air blower, and it is important not to use an open flame to directly contact the material, and the heating temperature must not exceed the maximum temperature of the material.
7. Remove excess materials: After the material is cured, disassemble the mold and use grinders, files, sandpaper and other tools to remove excess materials, and never allow knocking on the material.
8. Installation: Use sandpaper to polish the glaze of the material and clean it with absolute ethanol. Mix a small amount of material again and apply a thin layer to quickly heat assemble the bearing.