Подшипник качения

22 июля 2015г. - 16:34 9913 просмотров


Подшипник каченияОсновные особенности и устройство

Подшипник качения (жирный) используется в качестве опоры вращающихся частей механизмов или машин.

Конструкция этого типа подшипника включает в себя два кольца – внутреннее, которое надевается на цапфу вала, и наружное,  тела качения и сепаратор, который разделяет между собой тела качения и направляет их движение.

По форме тел качения, которые  применяются, подшипник качения (жирный) может быть шариковым или роликовым.

Подшипники качения и скольжения имеют между собой принципиальное различие: в подшипнике качения (жирный) (см. рис. 1) работа происходит  в условиях трения качения, а  в подшипнике скольжения преобладающим видом трения является трение скольжения.

 


Рис. 1. Подшипник качения (жирный)

Рис. 1. Подшипник качения (жирный)

 

На наружной стороне внутреннего кольца и на внутренней стороне наружного кольца выполнены дорожки качения, при этом их геометрическая форма зависит от типа тел качения, применяемых в данном подшипнике. В некоторых случаях подшипник изготавливается с использованием одного кольца, тогда дорожка качения находится прямо на валу или на поверхности детали.  Иногда конструкция подшипников качения не предусматривает наличия сепаратора.  Применение подшипников качения без сепаратора  (см. рис. 2) предпочтительно в тех случая, когда необходимы малые радиальные габариты.

 

 

 Рис 2. Подшипник качения (жирный) без сепаратора.

Рис 2. Подшипник качения (жирный) без сепаратора.

Такие подшипники имеют большее количество тел качения, за счёт этого сила трения увеличивается, таким образом, происходит снижение предельной частоты  вращения  и обеспечивается большая грузоподъёмность подшипника качения.

Назначение по типу нагрузки

В зависимости от назначения подшипники качения подразделяются на четыре группы. Подбор подшипников качения должен происходить  с учётом типа нагрузки. Радиальные однорядные подшипники используются для восприятия радиальных осевых нагрузок. Радиально-упорные используются в случае комбинированных нагрузок, т. е. радиальных и осевых. Упорно-радиальные используются в тех случаях, когда преобладают в основном осевые нагрузки и присутствуют незначительные радиальные.

Этот вид подшипника качения используется сравнительно редко.  Упорный подшипник качения (жирный) применяется только для осевых нагрузок.

Выбор подшипников качения должен проводиться с учётом множества параметров, в числе которых – точность подшипника качения, величина fnp, долговечность и статическая грузоподъёмность.

Наряду со многими другими характеристиками, грузоподъёмность подшипника качения, пожалуй, один из наиболее важных параметров.  При выборе подшипников инженерные работники руководствуются обычно специальными изданиями, например, очень полная номенклатура с указанием особенностей применения, множеством характеристик приведена в издании «Подшипники качения. Справочник», издательство «Металлург», год 1984.

Есть ещё один очень хороший каталог подшипников качения  авторов Черменского и Федотова. Здесь рассмотрено все характеристики подшипников качения,  маркировка подшипников качения, рассмотрены тела качения, особенности проектирования подшипникового узла, рекомендации по выбору подшипника качения,  приведены таблицы условных обозначений подшипников качения, рассмотрены новые перспективные направления в разработке, вопросы выбора посадки подшипников качения, в том числе подшипники  качения бейзельман.  В общем, книга является неоценимым пособием, как для инженеров, так и для тех, перед кем встала необходимость подобрать подшипники качения.

Смазочные материалы

Очень важно учитывать такой момент, как смазка подшипников качения. Недостаточная смазка, или смазка некачественным смазочным материалом может стать причиной того, что любой подшипник качения выйдет из строя очень скоро.

В настоящее время существует очень большой ассортимент смазок для самых разных типов подшипников качения. Применяются как жидкие, так и твёрдые и пластичные смазочные материалы, но наиболее широко применяются пластичные, так как они обеспечивают наиболее благоприятные возможности для работы механизма.

Существуют разные смазки для различных условий работы подшипников:

  • Смазки универсальные пластичные;
  • Смазки для высоких и экстремально высоких температур;
  • Смазки пластичные для низких температур;
  • Смазки пластичные для высокооборотных подшипников;
  • Смазки, предназначенные для подшипников, работающих в условиях высоких и экстремально высоких нагрузок;
  • Смазки для пищевой промышленности;
  • Смазки специально для химически агрессивной среды;
  • Смазки пластичные противошумные;

Использование правильно подобранных масел обеспечивает хорошее отведение тепла, стабильность работы, способствует очищению подшипника качения (жирный) от продуктов, образующихся в процессе износа.

Классификация

Классификация подшипников качения по точности регламентируется классами. Во всех  странах мира для обозначения  класса точности подшипников качения используется единый стандарт, при этом класс указывают слева через тире.

Разработанный в нашей стране на подшипники качения ГОСТ 3395 обозначает типы подшипников качения и их конструктивные особенности.

По техническим требованиям роликовые и шариковые подшипники качения должны соответствовать ГОСТу 520.

Допуски и посадки подшипников качения  должны соответствовать ГОСТ 3325-85

Таблица 1.

Поля допуска на диаметры отверстий корпусов подшипников качения и посадочных валов

Квалитеты Поля допусков для отклонений
e f g H J s j K m n p r
Для вала
3 H 3 J s 3
4 g4 H 4 J s4 k4 m4 n4
5 G*5 H*5 J s5 (j*5) K*5 M*5 N*5 p5
6 f6 G 6 H 6 J s6 (j*6) K6 M6 N6 P*6 R*6
7 f7 H*7 r7
8 e8 f8 h8
9 (e9) f9 h9
10 (h10)

 

 

Квалитеты Поля допусков для отклонений
e f g H J s j K m n p
Для отверстия корпуса
3    
4 g4 H 4 J s4 K*4 M*4  
5 G*5 H *5 Js5 K*5 M*5 n5
6 F*6 G 6 H 6 Js 6 (j6) k6 m6 N6 P*6
7 F7 G7 h7 Js 7 (j*7) K7 M7 N7 P*7
8 E* 8 H*8
9 (e 9) H*9
10

Диагностика и ремонт

В роторных механизмах подшипники качения (жирный) являются одним из самых уязвимых механизмов (см. рис. 3). Подшипник осуществляет пространственную фиксацию ротора,  соответственно, большая часть нагрузок, возникающих  в механизме, как статических, так и динамических, воспринимается именно подшипником, поэтому диагностика подшипников качения должна проводиться своевременно, чтобы не допускать снижения работоспособности механизма.

Рис 3. Дефекты подшипника качения.

Рис 3. Дефекты подшипника качения.

Оценка технического состояния проводится с помощью нескольких методов:

  •  Метод ПИК-фактора; данный метод заключается в измерении уровня вибрации с помощью виброметра, затем вычисляются значения  пиковой амплитуды вибрации и среднеквадратичное значение (СКВ). После вычисляется отношение этих двух значений. Достоинство данного метода заключается в его простоте, недостаток – в необходимости частых измерений в процессе эксплуатации.
  • Контроль подшипников качения методом анализа спектра вибросигнала. Данный метод обладает высокой помехозащищённостью, так как маловероятно, что  в механизме могут присутствовать источники, создающие вибрации той же частоты, что и дефекты подшипника качения. С помощью спектрального анализа можно диагностировать детали подшипника качения, а не только весь его целиком, так как кольца, тела вращения и сепаратор имеют свои частоты;
  • Метод анализа спектра огибающей. Сложный и дорогостоящий метод, основанный на анализе модулирующих низких частот и высокочастотной составляющей. В случае, когда имеется дефект, даже зарождающийся, высокочастотная составляющая будет модулироваться низкочастотным сигналом. Таким образом, осуществляется более своевременный контроль, чем при использовании других методов, и можно вовремя выявить необходимость  ремонта подшипника качения.
  • Метод измерения ударных импульсов, для которого применяется пьезоэлектрический датчик, основан на измерении и анализе затухающего колебания. Достоинство  метода в том, что он не зависит от внешних помех. Подшипниковые узлы после соударения дефектов испускают излучение определённой частоты, которое быстро затухает, на осциллографе колебания выглядят как импульсы, что и дало название методу. Существует один недостаток метода, связанный с особенностями конструкции подшипника качения: необходимо, чтобы между  датчиком и наружным кольцом подшипника качения (жирный) присутствовал массив металла.
  • Контроль подшипников качения  проводится также методом прослушивания. Подшипник, находящийся в идеальном состоянии, обычно издаёт еле слышное жужжание. При наличии инородных частиц в дорожке наружного кольца может возникнуть неравномерный вибрирующий звук. Недостаточный зазор подшипника качения также может вызвать звенящий металлический шум. Причиной шума могут стать и усталостные раковины, и повреждения, возникшие во время монтажа, и недостаточная смазка подшипника качения. В каждом случае звук имеет особый характер, от стучащего или вибрирующего до громкого гула. Метод доступный и простой, но недостаток его  в том, что повреждение выявляется слишком поздно, обычно уже тогда, когда требуется не ремонт подшипника качения, а его замена.


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