Search Results (18)

The intelligent bearing with an embedded sensor is a key technology to realize the running state monitoring of railway locomotive axle box bearings at the source end. To investigate the mechanical properties of axle box bearings with embedded sensor slots, based on nonlinear Hertzian contact theory and the bearing fatigue life theory, a mechanical equivalent analysis model with a virtual mandrel is established for double-row tapered roller bearings used in axle boxes with sensor-embedded slots, which integrally considers the effects of external forces. After verifying the mesh independence before and after embedding the sensor slots, the contact load of tapered rollers calculated by the mechanical model is compared with the theoretical solution based on Hertz contact which verifies the validity of the model from the perspective of contact load. The results show that adjusting the grooving depth and axial position has a significant effect on the local stress peak, and an excessive grooving depth or inappropriate axial position will trigger fatigue damage. This study provides a theoretical basis for analyzing the mechanical characteristics of sensor-embedded slots used in railway locomotive axle box bearings. Full article

The key to exploring the behavior of bearings through dynamic methods lies in establishing an accurate model for calculating the contact load between the roller and the raceway. Based on the half-space theory of Boussinesq, this study developed a full-order model for calculating the contact load of the finite line contact roller. The model adopted an iterative procedure to calculate the contact load of each roller slice according to deformations. According to the comparisons between the contact loads obtained by the proposed model and those obtained by FEA, the average error for a cylindrical roller was approximately 2%, while that for a tapered roller was approximately 17%. By neglecting the influences of inter-slice contact stresses on the deformation of local roller slice, a fast-calculating method for the full-order model was developed, thereby reducing the calculation time by approximately 77%. By integrating the fast method with the Dowson–Higginson’s formula, another model was developed to calculate the contact load under lubrication conditions. The proposed models were utilized to investigate the dynamic characteristics of a double-row tapered roller bearing, and the results were validated through experiments. The proposed method could be utilized to assess dynamic performances of bearings across different operating scenarios. Full article

Double-row spherical roller bearings are frequently employed as supporting components in mining machinery. In practice, these bearings are lubricated manually, and the bearing chamber is filled with grease, which can lead to issues such as grease wastage and increased bearing temperatures. Additionally, factors such as load and speed also influence the bearing temperature, collectively contributing to inadequate lubrication and potential bearing failure. Consequently, it is essential to investigate the temperature of the bearing under operating conditions. Utilizing tribology theory and the principles of bearing heat generation, a numerical model of fluid–structure interaction heat transmission within the bearing was developed, and finite element analysis was conducted through the ANSYS-Fluent module. The model was verified, and the temperature field of the bearing under varying operating conditions was studied. The findings of this research are as follows: (1) The numerical model demonstrates high accuracy, with a relative error of less than 5% when comparing the experimental temperature values of the jaw crusher bearing to the simulated values. (2) Under diverse operating conditions, the inner ring of the bearing has the highest temperature of all parts of the bearing, while the bearing cavity’s flow field has the lowest temperature. (3) The average temperature amplitude across different areas of the bearing system will rise as a result of increases in radial load or the bearing rotational speed. (4) When the grease filling volume increases from minimal to maximal, the average temperature in each bearing area initially decreases before subsequently rising, with the optimal grease filling amount identified as 60%. In operational scenarios, if the bearing temperature exceeds 70 °C, it is imperative to shut down the machine immediately to avert bearing failure. This study on bearing lubrication has practical guiding significance. Full article

A steady-state thermal model of double-row tapered roller bearings (DTRB) with grease lubrication under a combined load is established in this paper. The influence of the internal load distribution on the temperature allotment of bearings in the circumferential, axial, and radial directions is considered. Firstly, the local heat generation of the bearing is calculated based on the kinematic relationship inside the bearing, the internal load distribution, and the rheological properties of the grease. Then, combined with the heat dissipation analysis of the bearing, the three-dimensional steady-state temperature field of the DTRB is obtained. Ultimately, an analysis is conducted to examine how working conditions, including radial load, axial load, and rotational speed, impact the allotment of temperature fields in a DTRB along its circumferential, axial, and radial directions. The theoretical analysis outcome agrees with the experimental test outcome, providing theoretical guidance for the analysis of the bearing’s three-dimensional temperature field. Full article

High-quality data samples are essential for the early detection of bearing failures and the analysis of bearing behavior. The accurate simulation of bearing fault conditions can provide valuable insights into understanding failure mechanisms. This paper establishes a new numerical simulation method for double-row cylindrical roller bearing (DCRB) faults based on the augmented Lagrange dynamics method, overcoming the limitations of previous models by incorporating fault conditions related to cage fracture. This method accounts for the dynamic behavior of the rollers during the motion cycle and their interactions with other DCRB components. By comparing the characteristic frequencies of the fault components, the model not only replicates the dynamic behavior of faulty DCRBs more accurately but also offers a deeper understanding of fault-induced dynamics. This advancement provides a more comprehensive and realistic tool for bearing fault analysis. Full article

This article presents a method for identifying the cause of damage to a rotary air preheater on one of the fluidized bed boilers operating in a power plant. The bearing in question operates under harsh conditions with the exhaust gas temperature reaching 287 °C and causing its casing to heat up intensively. It is therefore important to ensure that the bearing is constantly cooled by water, which lowers the operating temperature and thus extends its service life. Unfortunately, after a short period of operation, the upper double-row spherical roller bearing was damaged, and the tests presented in the assessment method helped to determine the cause of damage to its casing. Full article

In this study, a deep transfer learning model was developed using ResNet-101 architecture to diagnose double roller bearing defects. Vibration data were collected for three different load scenarios, including conditions without load, and for five different rotational speeds, ranging from 500 to 2500 RPM. Significantly, the speed condition of 2500 RPM has not previously been investigated, therefore offering a potential avenue for future investigations. This study offers a thorough examination of bearing conditions using multidirectional vibration data collected from accelerometers positioned in both vertical and horizontal orientations. In addition to transfer learning using ResNet-101, four additional models (VGG-16, VGG19, ResNet-18, and ResNet-50) were trained. Transfer learning using ResNet-101 consistently achieved the highest accuracy in all scenarios, with accuracy rates ranging from 90.78% to 99%. Scattergram Filter Bank 1 was used as the image input for training as a preprocessing method to enhance feature extraction. Research has effectively applied transfer learning to improve fault diagnosis accuracy, especially in limited data scenarios. This shows the capability of the method to differentiate between normal and faulty bearing conditions using signal-to-image transformation, emphasizing the potential of transfer learning to augment diagnostic performance in scenarios with limited training data. Full article

The Double-Disk Straight Groove Lapping (DDSGL) technique, a novel approach to batch processing of bearing rollers, achieves high dimensional consistency by removing material through size comparison between multiple rollers in the processing area. To avoid collision between the rollers, the prevalent practice in DDSGL involves circulating the rollers in fixed linear sequences, an approach that impedes comprehensive size comparison throughout the entire batch of rollers. To counter this, we introduce a Dual-Channel Mixing Scheduling (DCMS) strategy that disrupts the roller sequence without triggering collisions. This strategy promotes extensive size comparison and enhances batch size consistency. To elucidate the operational principles of DCMS, we have developed a computational model grounded in DDSGL, designed simulation test plans under different mixing parameters, and summarized the number of direct comparisons, total comparisons, and differences in roller cycle times to determine the optimal combination of mixing parameters. Finally, structural modifications were made in the DDSGL system for validation studies under different mixing parameters. The test results show that the use of DCHS can reduce processing time by up to 50%, and the batch diameter change of the rollers can converge from 1.15 μm to as low as 0.76 μm. The industrial relevance of this research is significant; these improvements can lead to higher efficiency in the manufacturing process and improved quality of bearing rollers. Full article

In recent years, with the development of robot transmission technology, the market demand for high-performance actuators, which can be applied to lower limb exoskeleton assist robots, is increasing. These robots help achieve human–robot interaction through rigid and flexible coupling, and they can ensure the flexibility of the elderly or patients in daily walking and rehabilitation training. A novel actuator with a double-roller gear drive structure is proposed with high bearing capability and high transmission efficiency due to multi-tooth rolling contact with small tooth difference such that friction is greatly reduced in the transmission process compared to what occurs in involute planetary transmission. The bearing capacity of the tooth surface was analyzed by using the loaded contact analysis method. Finally, a prototype was manufactured with the 3D printer, and the maximum output torque of the developed actuator was tested with an experimental setup. The results show that this novel actuator, with its double-roller gear drive, has huge potential for use in the hip joint of an exoskeleton robot. Full article

Double-row tapered roller bearings have been widely used in various equipment recently due to their compact structure and ability to withstand large loads. The dynamic stiffness is composed of contact stiffness, oil film stiffness and support stiffness, and the contact stiffness has the most significant influence on the dynamic performance of the bearing. There are few studies on the contact stiffness of double-row tapered roller bearings. Firstly, the contact mechanics calculation model of double-row tapered roller bearing under composite loads has been established. On this basis, the influence of load distribution of double-row tapered roller bearing is analyzed, and the calculation model of contact stiffness of double-row tapered roller bearing is obtained according to the relationship between overall stiffness and local stiffness of bearing. Based on the established stiffness model, the influence of different working conditions on the contact stiffness of the bearing is simulated and analyzed, and the effects of radial load, axial load, bending moment load, speed, preload, and deflection angle on the contact stiffness of double row tapered roller bearings have been revealed. Finally, by comparing the results with Adams simulation results, the error is within 8%, which verifies the validity and accuracy of the proposed model and method. The research content of this paper provides theoretical support for the design of double-row tapered roller bearings and the identification of bearing performance parameters under complex loads. Full article

Spherical roller bearings (SRBs) are widely used under self-aligning operating conditions, such as rotor bending or an angular misalignment between inner and outer rings due to their self-aligning function. However, the characterization of SRBs’ self-aligning function is often ignored in the present models. The reason for this is that the self-aligning condition is essentially a fault condition, and many scholars have assumed SRBs are in an ideal operating condition. Although there is nothing wrong with this analysis theoretically, it is incapable of characterizing SRBs’ service behavior comprehensively. In this work, the Lagrange equation was introduced to model the relationship among the rollers and the inner and outer rings. The contact region in particular was characterized in detail in order to solve the problems of undetermined contact status (UCS) and the varying law of the self-aligning contact angle (SAC angle). For the experiment, a novel SRBs pedestal with a self-aligning operating condition was designed, and the relevant self-aligning function testing was carried out. A good agreement was shown between the theoretical and experimental results. The results pointed out that, if taking no account of the self-aligning function, SRBs can be regarded as angular contact ball bearings or cylinder roller bearings. The amplitude of the inner-ring motion orbit is determined by the external load, but the shape is influenced by the direction and magnitude of the SAC angle. In the example of this paper, the values of the main frequency equal 136.8 Hz. Some additional frequencies are clearly aroused under the self-aligning operating condition, whose value is approximately equal to 8.3 Hz or its integer multiples. The dynamic performance of SRBs will be substantially improved by a light axial load plus an anticlockwise self-aligning contact angle rather than a large axial preload. Full article

The overrunning clutch, or freewheel, is a kind of universal part with a one-way drive character, and is widely used in machinery. Typical roller overrunning clutches and sprag overrunning clutches have shortcomings such as low load bearing capacity, low torsional stiffness, and short life. For these reasons, studies on high-performance overrunning clutches have always been the focus of researchers. In this paper, a new type of double arc sprag overrunning clutch is proposed that overcomes the disadvantages of poor transmission capacity and low rigidity found in traditional overrunning clutches. The mechanical model of the double arc sprag overrunning clutch is established, the calculation formulas of the overrunning clutch engagement conditions and overrunning conditions are deduced, and the forces of the outer ring, roller, and inner star wheel of the overrunning clutch are also deduced. The contact stress and transmission torque of the overrunning clutch are compared with those of the roller overrunning clutch and the sprag overrunning clutch. The results show that the proposed overrunning clutch has the largest load capacity, which is 5.75 times that of the roller type overrunning clutch, and 2.1 times that of the sprag type overrunning clutch. The experiment shows that the proposed overrunning clutch has reliable bonding conditions in the oil-free and oil-immersed state, and the overrunning condition is sensitive, which indicates the effectiveness of the double arc sprag overrunning clutch. The roller overrunning clutch and double arc sprag overrunning clutch with the same geometric parameters are designed and manufactured, and the torsional stiffness test of the three types of overrunning clutches is carried out. The results show that the torsional stiffness of the double arc sprag overrunning clutch is the largest, which is 4.6 times of the roller overrunning clutch and 6.2 times of the sprag overrunning clutch. Full article

A three-dimensional vehicle-axle box bearing coupling model is established. The model can calculate the contact force in three directions and obtain the dynamic response of axle box bearing under the real vehicle running environment. The load distribution on the double row tapered roller bearing and the vehicle is analyzed, and the co-simulation is conducted by comprehensively considering the force transmission between vehicle and bearing. Taking into account the great impact of defects on the bearing, three different types of bearing defects are added into the model, respectively. The simulation results verify the effectiveness of the model. The model is also verified by using the rolling and vibrating test rig of single wheelset. It is concluded that the simulation results show good agreement with experimental results. The influence of track irregularity on the system motion state is studied by using axis trajectory and vibration RMS (Root Mean Square value). The results show that the influence of track irregularity and wheel flat scar on axle box bearing cannot be ignored. The RMS of acceleration will change greatly due to the existence of defects. Wheel flat scar will greatly interfere with the extraction of bearing defect, but it can be selected at high speed and low frequency to monitor the existence of wheel flat scar, and select low speed and high frequency to monitor the existence of bearing defect. The research results are helpful to the detection of wheel flat scar and axle box bearing defect. Full article

The research on the thermal characteristics of railway double-row tapered roller bearing is of great significance for its structural design and operation monitoring. We established the quasi-static mechanical model of the bearing according to the test conditions, and we obtained the load distribution and kinematic parameters of the bearing. We studied the temperature distribution of railway double-row tapered roller bearing under test conditions through finite element analysis, which was consistent with the test results. We built a bearing testbed to study the effects of different rotating speeds on the temperature distribution of the bearing inner ring, outer ring, and roller. The results show that the speed dramatically affects the bearing inner ring. With the rate increase, the temperature difference between the inner and outer rings decreases gradually, and the temperature at the large end of the roller is the highest. Full article

With the continuous improvement of train speeds, it is necessary to find the possible problems of bearings in time, otherwise they will cause serious consequences. Aiming at the characteristics of rapid temperature change of bearings, a thin film thermocouple temperature sensor was developed to measure the real-time temperature of the bearing’s rolling elements during train operation. Using dc pulse magnetron sputtering technology, Al₂O₃ film, NiCr film, NiSi film, and SiO₂ film were successively deposited on an aluminum alloy substrate. We studied their microstructure, static characteristics, dynamic characteristics, and repeatability. Finally, we installed an adaptive film temperature sensor on the bearing testing machine to measure the temperature of the rolling elements. The results show that the developed temperature sensor has good linearity in the range of 30~180 ℃. The Seebeck coefficient is 40.69 μV/℃, the nonlinear fitting error is less than 0.29%, the maximum repeatability error is less than 4.55%, and the dynamic response time is 1.42 μs. The temperature of the measured rolling elements is 6~10 ℃ higher than that of the outer ring, which can reflect the actual temperature of the bearing operation. Full article