How to judge the damage of car ball cage bearings

The daily maintenance of the high-speed polyester elastic machine (one-step false twisting machine) with a guide wheel needs to be carried out around the five core modules of the guide wheel system, stretching system, false twisting system, shaping system, and winding system, and managed by shift, week, and month. Please provide a detailed explanation of each item below.

1. Daily maintenance for each shift (before startup, during operation, and after shutdown)

1. Pre startup inspection (about 10 to 15 minutes)

Inspection of guide wire disc (the most critical component):

Check if there are scratches, pits, or rust on the chrome plating layer on the guide wire disc surface, as any damage can directly cause the wire to rub and fuzz.

. If damage is found, it must be replaced and cannot be continued to be used after sanding with sandpaper.

Check the dynamic balance status of the guide wire disc: Gently turn the guide wire disc by hand and feel if there is any obvious vibration or eccentricity. If there is any abnormality, dynamic balance correction is required.

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Check the fit between the guide wire disc and the dragon belt (drive belt): The dragon belt cannot be pressed against one side of the belt disc to operate, otherwise the edge will be worn and cause uneven rotation speed of the ingot group;

; The surface of the dragon belt cannot tilt, otherwise the transmission wheel will slip and the speed will decrease; The tension of the dragon belt should be maintained appropriately - based on 1 meter on each side of the belt, with an optimal elongation of about 1.8%. When the dragon belt is loose, the tension must be adjusted, and those with severe injuries must be replaced.

Synchronous belt inspection (daily mandatory):

Check all synchronous belts for looseness, missing teeth, and friction between synchronous belts.

. The synchronous belt is the power transmission lifeline of the high-speed loading machine. Once the belt breaks or the teeth jump, the entire vehicle immediately becomes paralyzed.

Feeding and stretching roller inspection:

Check whether there are scratches, oil stains, burrs on the surface of the first, second, and third roller (leather ring), and whether the shaft is wrapped with waste wire.

. The waste wire wrapped around the shaft and continuing to operate can cause poor rotation, local heating, and damage to the bearings, which must be removed every time the machine is stopped. Measure the contact pressure of the roller using a spring scale, with a requirement of 5 ± 0.5kg, and make a record. Low pressure and insufficient grip force cause fluctuations in false twisting tension, while high pressure exacerbates wear and shortens lifespan. The shafts of the upper and lower rollers must be kept completely parallel, otherwise poor grip can cause uneven curling, uneven dyeing, and breakage.

False Twister Inspection:

Timely remove the waste threads wrapped around the friction spindle shaft and the "snowflakes" (polymer deposits) on the friction disc.

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Use a flash speedometer to measure the speed of the friction disc. If any abnormalities are found, check the cause: incorrect position of the dragon belt, tilt of the dragon belt, abnormal tension of the dragon belt, etc.

Check if there is peeling, scratching, or roughness on the surface of the friction disc. If there is, it must be replaced.

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Check whether the small bearings of the false twisting device are damaged, whether they rotate flexibly, and whether the small toothed belts that drive the three spindle shafts are stretched or worn.

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Safety device confirmation:

Test the emergency stop buttons (on both sides of the console and at both ends of the equipment) one by one, and confirm that they can immediately cut off all power when pressed.

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Whether the protective cover is completely fixed and has no gap with the moving parts.

. Whether the installation height and sensitivity of the photoelectric protection device are normal, and whether it can immediately trigger shutdown when obstructed.

2. During operation inspection (every 30 to 60 minutes)

Listen for sound and observe vibration:

Check if the sound of the transmission parts in the front and rear transmission boxes is normal, and if there are any abnormal impact or friction sounds.

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Check if the bearings of each roller component, friction roller component, guide wire, and transmission component are heating up and vibrating - lightly touch the bearing seat with the back of your hand, if it is hot, it will be abnormal.

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Check if there is any jamming in the rotating parts such as feeding roller, stretching roller, and false twisting device.

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Check the status of the wire:

Check if the wire is running normally in the guide, and if there is any deviation, jumping, or entanglement.

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Whether the wire breakage detector (wire detector) is sensitive and whether the wire cutter can operate in a timely manner after the wire breakage.

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Check if the trajectory of the lateral guide wire is correct and does not come into contact with the winding roller or winding tube, otherwise it will produce fuzz.

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Check the winding forming:

Check if there are any forming defects such as convex edges, spider webs, collapsed edges, and large differences in surface hardness on the winding tube.

. If there is any, it is necessary to check whether the winding system and the cylinder are jumping, and whether the trajectory of the lateral guide wire is correct.

Check the process parameters:

Record once per hour: vehicle speed, first hot box temperature, second hot box temperature, false twist tension, winding tension.

. If the temperature deviation exceeds ± 2 ℃, immediate adjustment is required.

3. Maintenance after shutdown (about 15 to 20 minutes)

This is the most easily overlooked but crucial step:

First, clean up the debris and dust (which must be done every day).

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Use a brush or specialized cleaning tool to clean the entire machine, removing cotton wool, dust, and oil stains from the surface of the machine.

. Dust entering the interior of the equipment can affect operational accuracy, and more importantly, starch/polyester dust poses a risk of combustion in high-temperature areas. It is strictly prohibited to blow electrical components and sensors directly with compressed air to prevent dust from entering the control cabinet. Secondly, check the elastic coupling (which must be checked every time the machine is stopped).

Check whether the elastic couplings of each part are loose or worn. If they are loose, they must be tightened, and if they are worn, they must be replaced.

. Coupling failure can lead to transmission shock, damaging the roller and false twisting device. Thirdly, clean the wire guide and false twisting device.

If the installation of the wire guide is not consistent, it will cause differences in the running angle, vibration, and gas coil state of the wire.

. Remove the oil, monomer, and polymer powder attached to the guide wire, and grind or replace it if there are wear and tear marks.

The waste threads on the spindle of the false twisting machine and the "snowflakes" on the friction disc must be thoroughly removed.

. Fourth, clean the hot box.

Check daily whether the hot box wire path is normal and whether the wire strip deviates from the wire path.

. Deviation of the wire strip from the hot box wire path can cause the finished wire to become stiff.

2. Weekly maintenance (once a week, about 1 to 2 hours)

Maintenance itemsSpecific contentJudgment criteria

Comprehensive inspection of synchronous beltsCheck the operation of all synchronous belts, observe whether there is looseness, missing teeth, or mutual frictionReplace immediately if there is any abnormality

Leather roller/leather ring polishingRe ">First and second rollers should be polished once after using them for 1 to 3 months, and third rollers should be polished once after using them for about 6 monthsDuring polishing, check whether the bearing rotates flexibly

Dynamic balance check of the guide wire discUse a testing instrument to check the dynamic balance of the guide wire discVibration values exceeding the standard must be recalibrated

Friction disc inspectionCheck for peeling, scratches, and roughness on the surfaceReplace if necessary

Tooth belt tension inspectionCheck the tension of the small tooth belt of the transmission false twisting deviceAdjust or replace if it is too large or too small

Cooling system inspectionCheck the cooling water flow rate and water temperature (not exceeding 40 ℃)High water temperature affects the shaping effect

Lubrication system checkCheck if the oil level of each bearing and gear is within the specified range (at 1/2 to 2/3 of the gearbox oil level)Supplement if insufficient, replace if deteriorated

3. Monthly maintenance (once every 2 to 3 months, about half a day)

1. Hot box guide tube cleaning (core project)

This is the key to affecting the heating effect of the filament - the spinning oil agent on the filament is heated and evaporated in the heat pipe, and low boiling point components remain in the pipe, coking and affecting the heating effect, resulting in a decrease in DTY quality.

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First hot box cleaning (every 2 to 3 months):

Pull out the wire guide tube from above, immerse it in 15% to 20% alkaline solution, and heat it up.

. After cooling, take it out, wash it with hot water, and then dry it with compressed air. Check if the dirt inside the tube has been thoroughly cleaned.

Caution: Do not make the pipe mouth or inner wall rough or deflate, in order to prevent the damaged pipe from rubbing against the processed thread.

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Cleaning of the second hot box (every 2 to 3 months):

Rotate the hot box to an inclined position, extract the tube from above, and soak it in 15% to 20% alkali solution for heating and cleaning.

. After cooling, rinse with hot water, blow dry with compressed air, and inspect.

2. Inspection of spindle accuracy

Use a dial gauge to measure the radial runout (should be ≤ 0.002 to 0.003mm) and axial displacement (should be ≤ 0.001 to 0.002mm) at the end of the spindle.

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Exceeding the tolerance indicates that the spindle bearing is worn and must be replaced.

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3. Inspection of lead screw and nut

Use a dial gauge to measure the radial runout and axial clearance of the lead screw.

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Check if the preload force of the ball screw nut has decreased, as it may cause inaccurate feed of the worktable.

4. Inspection of winding head

Measure the vibration value of the winding head, and repair if it exceeds the tolerance.

. Check the function of the tube clamp and brake. Check the sensitivity and accuracy of the operating linkage and brake slider.

Fourth, quarterly maintenance (medium maintenance level, about 1 to 2 days)

ProjectContent

Worm gear reducerExchange oil, inspect the steering joint

Upper oil panDisassemble, clean, straighten, and inject lubricating grease into the rotating shaft bearing

Winding headDisassemble, inspect, and perform dynamic balance verification

Disassembly, maintenance, and dynamic balance verification

Sliding pressure mechanismDisassembly, maintenance, and selective replacement of bearings

Wire suction device, waste wire box, and compressed air systemDisassembly, inspection, cleaning, selective replacement

Full oil tankCheck and clean

Grounding resistance and insulation resistanceGrounding resistance<4 ohms, insulation resistance>2 megohms

Whole machine accuracy testingUse a laser interferometer to test the positioning accuracy and repeatability accuracy of each axis

Fifth, key precautions in maintenance

First, the wire guide is the "heart" of this machine.

. The independent micro motor control of the guide wire disc structure is the core feature of high-speed loading machines, and the synchronization consistency of the three roller guide wire discs directly determines the uniformity of the stretching. Once the chrome plating layer on the surface of the guide wire disc is damaged, it is not a problem of polishing, but a problem that must be replaced - the uneven micro roughness of the polished surface can become a source of fuzzing during high-speed operation.

Secondly, the maintenance frequency of the false twisting device is the highest.

. The "snowflakes" on the friction disc and the waste wires on the spindle shaft are the most common sources of faults, which must be cleaned every shift. Before using the friction disc, clean the surface with gasoline or alcohol and blow dry for 30 minutes. All ceramic discs should be protected from falling and collisions, sudden cooling, and contact with corrosive chemicals.

Thirdly, the tension of the dragon belt (transmission belt) is an invisible killer.

. Loosening of dragon belt → Decrease in spindle rotation speed → Uneven curling and abnormal staining of deformed wire; Tight dragon belt → accelerates wear and shortens lifespan. It is necessary to maintain a 1-meter extension of approximately 1.8% on both sides and conduct regular inspections and adjustments.

Fourthly, the elastic coupling must be checked every time it stops.

. Loosening can cause transmission impact, and wear can lead to belt breakage. This is the cheapest part and also the most easily overlooked part. Once there is a problem, it will also damage the roller and false twisting device.

Fifth, the temperature of the hot box must be calibrated regularly.

. Use a scanning temperature monitor to check the temperature of each hot box one by one. The temperature deviation of the first hot box should not exceed ± 1 ℃, and the temperature deviation of the second hot box should not exceed ± 2 ℃. Inaccurate temperature directly leads to substandard curl and elasticity.

Summary sentence

The daily maintenance of the high-speed polyester elastic machine with a guide wire disc can be summarized as follows: "Clean the thread debris and check the coupling in each shift, check the synchronous belt with the circumferential measuring dragon belt, clean the friction disc in the monthly washing and heating box, and perform dynamic balance with seasonal calibration accuracy." Among them, the surface condition of the guide wire disc, the tension of the dragon belt, and the cleanliness of the false twisting device are the three most prone to problems and have the greatest impact on product quality. By grasping these three points, daily maintenance can grasp 80% of the key.