Rolling bearing series standardized according to DIN ISO, the cross-section of thin-section bearings increases with increasing diameter, and all sizes of thin-section bearings in a series have the same cross-section. &#;There are several definitions of thin-section bearings in the industry, one of the most common is that a bearing is considered thin-section when the diameter is than 4 times greater than the radial cross-section. Cross-section dimensions can vary, but are typically ball Twice the diameter.&#; Typical applications for thin-section bearings are those critical applications where space is limited, weight must be minimized, absolute accuracy must be maintained and load and torque requirements still require the use of ball bearings. In such applications, thin section bearings help reduce costs compared to standard deep groove ball bearing sizes and have the advantage of using only one bearing with little impact on overall weight.
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Angular contact thin-section bearings are mainly used in harsh environments with high axial loads. It is generally not recommended to use a single A-type angular contact thin section bearing to support moment or reverse axial loads, but two A-type bearings as a duplex bearing pair can easily support such loads. The stability, load capacity and repeatability of A-type angular contact thin-section double bearing pairs are better than those of C-Type thin-section bearings.
Type C radial contact ball thin section bearings are designed so that the ball and ring contact in the center plane of the ball when only radial loads are applied. Although primarily designed for radial load applications, C-type bearings have no filled grooves and can handle some axial loads in either direction. The ability to withstand axial loads depends on the amount of clearance in the bearing after installation. By increasing the radial clearance above the standard value, C-type bearings can have a larger contact angle under axial load, resulting in greater axial load capacity. In this case, it is recommended to adjust the bearing against another bearing of similar construction to reduce axial movement under reverse axial loads. Used in this manner, the bearings are essentially angular contact ball bearings rather than radial contact ball bearings.
Unlike Type A and Type C thin section bearing designs, Type X four-point contact thin section bearings are made with Gothic archways that create four points of contact between the balls and raceways in the bearing. This design makes four-point contact thin section bearings a prime option for applications requiring sufficient torque or reverse axial loads in a small package. However, Type X four-point contact thin section bearings do have a lower ability to carry a wide range of radial loads than Type X thin section bearings. Type X four-point contact thin section bearings are not recommended as a replacement for type C or type A thin section bearings in environments intended for pure radial loads. It should be noted that the speed (rpm) of X-type four-point contact thin section bearings is a particular concern when combined with radial loads when applied with axial or moment loads.
Type C: The centers of the radii are located in the center plane of the ball.
Type A: The ferrule and the ball are in angular contact, and the groove radius center is offset by an equal amount on both sides of the ball center plane.
X-type: The grooves in each ring have two radii with their centers offset from the center plane of the ball.
Like C-type bearings, X-type bearings usually have radial clearance. However, the nominal contact angle and axial load capacity of type X bearings do not depend on the clearance. When the axial or moment load is considerable, the gap should be minimized to prevent the contact angle from being too large. The main thing to note is that it is recommended that the X-bearing be used alone. It is not recommended to use two X-bearings on a common shaft as this may lead to unacceptable frictional moments.
Bearings support shafts or housings, allowing them to run freely under load. Above we analyzed a variety of thin-section bearings that can withstand radial, axial and moment loads. Loads can be applied to thin-section bearings in one of two cardinal directions, where the resultant moment load (M) can be calculated as:
Axial loads (Fa) are parallel to the shaft (the axis of rotation of the bearing), while radial loads (F r ) are at right angles to the axis of rotation. When these loads deviate from the bearing axis (distance Sa) or the radial plane (distance Sr< /span>), a final moment load (M) is created. The use of computer software has made the method of determining bearing life complex and accurate than previous manual calculations. The actual load is applied to the bearing and the resultant load on each ball in that bearing is determined. From this calculation, the static safety factor and the basic rating life L10 can be determined.
Calculating the static safety factor or dynamic life requires the help of computer software to determine the individual ball loads throughout the bearing &#; using Reali-Design (for Reali-Slim inch bearings) or Reali-Design MM (for Reali-Slim metric bearings) software. Once these are calculated, the maximum load sphere is used to determine the maximum stress level and thus the static safety factor. All ball loads are used in a weighted analysis to determine the basic rating life, L10.
While it is not possible to set precise speed limits, practical applications and the experience of the AUB test laboratory provide a basis for setting general limits. Assume the bearings are installed correctly and have adequate heat dissipation. These limits are based on a full service life of 1 000 000 revolutions. Higher speeds can be tolerated if shorter lifetimes are acceptable. For speeds approaching or exceeding the limit calculated using the limit speed (n) formula, special attention must be paid to lubrication and heat:
&#;Grease should be specially designed for high speed bearings.
&#;The frequency of relubrication must be sufficient so that sufficient lubricant is always available.
&#;If oil is used, viscous drag should be minimized by controlling the level, using an oil slinger, and/or metering small amounts of liquid or mist.
&#;The effects of air turbulence at high speeds can make it very difficult to introduce oil to critical surfaces, so the design of the lubrication system becomes very important.
Once larger moment loads have been determined, AUB will recommend the use of X-pattern or 4-point contact ball bearing options. The design utilizes a &#;gothic arch&#; raceway to create four points of contact between the ball and raceway. Making it the perfect solution for reverse axial loads and ideal for moment loads. Although type X bearings may be used in other light load conditions, replacement of type C or A bearings under purely radial loads is not always encouraged.
As a standard rule, AUB recommends careful monitoring of application speed (RPM) when specifying X-type bearings for combinations of axial or moment loads and radial loads. AUB&#;s experienced team of engineers proved to be very supportive in this regard. They can provide and determine limiting speeds and combined loads based on statistics and research. They also added recommendations regarding the use of radial bearings with combined radial, axial or moment loads and limiting speed and separator selection.
Radial contact bearings, such as type C bearings, are suitable for radial loads. This is because their deep ball grooves provide the durability to withstand higher loads. Although this particular type of bearing is used in applications that carry primarily radial loads, Carter suggests that it can also effectively carry reverse axial loads, moderate axial loads and moment loads.
Thin-section bearings have been developed primarily for applications where space is limited, providing friction-free solutions for articulated components such as robot arms or other joints such as elbows. Different types of thin-section bearings are widely used in different institutions, including aerospace, medical imaging, robotics, semiconductors, data storage, machine tools, packaging equipment, packaging equipment, satellite systems, and optical and aiming systems.
AUB specializes in solutions regarding a full range of thin section bearings. Our well-equipped engineering team creates custom bearing designs by considering space, load, precision and reliability, and custom manufactures them to your application needs. AUB offers precision low-profile bearings in sizes from 1 in. ID (inner diameter) to 40 in. OD (outer diameter) for large turntables deployed in commercial and industrial applications.
In the world of engineering and design, where precision and efficiency are paramount, thin section bearings have emerged as a game-changing component. These unassuming but powerful bearings are the unsung heroes behind countless innovations in aerospace, robotics, medical equipment, and more. In this comprehensive guide, we will delve into the world of thin section bearings, exploring their types, applications, science, selection criteria, and much more.
Understand the materials and manufacturing processes that make thin section bearings robust and reliable.
Materials:
Manufacturing Processes:
These materials and manufacturing processes collectively contribute to the strength and reliability of thin-walled bearings across various applications.
Gain insights into the engineering principles that govern the performance of these bearings.
Geometry and Tolerance Control: Precise control of the bearing&#;s geometry and tolerances is crucial. Tight tolerances ensure proper fit and alignment, minimizing friction and wear.
Load Capacity Calculation: Calculating the expected loads and forces the bearing will encounter is essential for selecting the right bearing size and type to ensure it can handle the load effectively.
Lubrication and Sealing: Proper lubrication is critical for reducing friction and preventing premature wear. Effective sealing mechanisms maintain lubricant integrity and protect the bearing from contamination.
Material Selection: Choosing the right materials based on factors like load, temperature, and environmental conditions is fundamental. Materials impact strength, corrosion resistance, and overall performance.
Preload and Clearance: Setting the appropriate preload and clearance within the bearing is essential to control the axial and radial play, optimizing performance and minimizing vibration.
These engineering principles are integral to designing and using thin-section bearings effectively in various applications, ensuring their optimal performance and longevity.
Learn about the critical factors that influence the design of thin section bearings, including size, load capacity, and environmental conditions.
Size and Geometry: The size and shape of the bearing must be carefully considered to ensure it fits within the available space while maintaining proper clearance and alignment.
Load Capacity: Determining the expected load and load distribution is crucial. The bearing&#;s design must accommodate these loads while minimizing stress and ensuring durability.
Environmental Conditions: Consider the operating environment, including temperature, moisture, and contaminants. Bearings may require special materials or coatings to withstand harsh conditions.
Speed and Precision Requirements: The design should account for the required rotational speed and precision. High-speed applications or precision machinery may demand specific design features.
Lubrication and Maintenance: Selecting the right lubrication method and considering the need for maintenance or lubrication intervals is essential for long-term performance.
Mounting and Fit: Proper mounting and fit within the assembly are critical. The design must ensure the bearing aligns correctly with other components to minimize wear and friction.
These factors play a significant role in the design of thin-section bearings, as they impact their performance, reliability, and longevity in diverse applications.
Identify the key factors that should guide your choice of thin section bearings.
Load Type and Magnitude: Consider the type and magnitude of the loads the bearing will need to support, including axial, radial, or a combination of both.
Space Constraints: Evaluate the available space for the bearing, including the housing and clearance requirements, to ensure a proper fit.
Operating Environment: Take into account environmental factors such as temperature, humidity, and the presence of contaminants, which can impact material selection and sealing requirements.
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Rotational Speed: Determine the required speed of the bearing, as high-speed applications may require bearings designed for reduced friction and heat generation.
Precision Requirements: Assess the level of precision needed for your application, as some applications demand low runout and tight tolerances.
Maintenance and Lubrication: Consider the availability and frequency of maintenance, as well as the preferred lubrication method, to select a bearing that aligns with your maintenance strategy.
These factors will help you make an informed choice when selecting thin-section bearings, ensuring they meet the specific needs of your application for optimal performance and longevity.
Proper mounting of thin-section bearings is essential to ensure their optimal performance and longevity.
Clean and Lubricate: Before installation, ensure that the mounting surfaces and the bearing itself are clean and free from any contaminants. Apply the appropriate lubricant to reduce friction and protect against wear during initial operation.
Precision Fit: Ensure that the bearing is mounted with the correct interference or press fit. A proper fit minimizes radial and axial play, reducing the risk of misalignment and premature wear.
Even Distribution of Load: When pressing the bearing into place, distribute the load evenly across the bearing&#;s outer ring. Using a press tool with a flat surface or a fixture specifically designed for bearing installation can help achieve an even load distribution.
Avoid Overloading: Be cautious not to apply excessive force when mounting the bearing, as it can lead to deformation or damage. Follow the manufacturer&#;s guidelines for the maximum recommended press-in force.
Alignment and Positioning: Ensure that the bearing is accurately aligned with the shaft and housing. Misalignment can lead to increased stress and reduced bearing life. Precision instruments, such as dial indicators, can aid in achieving proper alignment.
Additionally, always refer to the manufacturer&#;s recommendations and guidelines for mounting and handling thin-section bearings. Proper mounting techniques are crucial to prevent damage during installation and to ensure the bearing operates as intended within your specific application.
Maintaining thin-section bearings is crucial to ensure their long-term performance and reliability.
Lubrication: Regularly inspect and maintain the lubrication of the bearings. Use the appropriate lubricant and follow the manufacturer&#;s recommendations for re-lubrication intervals. Proper lubrication minimizes friction and wear.
Sealing: Ensure that the bearing&#;s seals or shields are in good condition to prevent contamination from dust, dirt, or moisture. Replace damaged seals promptly to maintain a clean and protected bearing environment.
Monitoring: Implement a monitoring system to keep an eye on bearing performance, such as vibration analysis or temperature monitoring. Early detection of issues can prevent costly failures and downtime.
Proper Handling: During maintenance or replacement, handle the bearings with care. Avoid dropping or impacting them, and use appropriate tools and equipment to prevent damage during handling and installation.
Environment: Maintain a clean and controlled operating environment. Minimize exposure to harsh conditions, such as extreme temperatures, chemicals, or corrosive substances, to extend the bearing&#;s lifespan.
Regular maintenance and a proactive approach to addressing potential issues can significantly extend the life of thin-section bearings and ensure their reliable performance in various applications. Always consult the manufacturer&#;s guidelines for specific maintenance recommendations related to your bearings.
Judging the failure of thin-section bearings is crucial to prevent potential issues and ensure the continued performance of your equipment.
Unusual Noise or Vibration: Excessive noise or vibration during operation can be a clear indicator of bearing problems. If you notice unusual sounds or vibrations, it may signify a potential failure.
Increased Friction or Heat: If the bearing becomes hotter than usual or if you observe an increase in friction during operation, it could be a sign of a problem. Check for elevated temperatures and excessive heat generation.
Irregular Movement: Any irregularities in the smooth rotation of the bearing, such as sticking or uneven movement, suggest a potential failure. Monitor the bearing&#;s movement closely for signs of distress.
Visible Damage: Physically inspect the bearing for visible signs of damage, including cracks, pitting, spalling, or wear. These issues can indicate a failure or impending failure.
Abnormal Play or Clearance: Excessive axial or radial play in the bearing can lead to misalignment and reduced performance. Check for any abnormal play or clearance in the bearing during operation.
Regular inspections and vigilance for these signs are essential for identifying bearing failures promptly. Early detection can help prevent more significant damage and costly equipment downtime. If you notice any of these issues, it&#;s advisable to consult with bearing experts or manufacturers for a proper diagnosis and resolution.
Repairing common thin-section bearing faults can help extend their lifespan and maintain performance. However, some faults may require professional assistance to ensure proper repair and safety.
Repairing Common Thin-Section Bearing Faults:
Relubrication: If a bearing exhibits signs of insufficient lubrication, reapply the appropriate lubricant following the manufacturer&#;s recommendations to address dry or overheated bearings.
Cleaning: Removing contaminants, such as dirt or debris, can help restore proper function. Clean the bearing carefully and inspect seals and shields for damage.
Reassembly: In cases of dislodged or misaligned components, reassemble the bearing correctly and ensure that it maintains the proper fit and alignment.
Removal of Minor Damage: Minor surface damage, like light corrosion or small nicks, can sometimes be polished or smoothed out to restore functionality. However, be cautious with this approach, as it may not be suitable for all situations.
Retightening: Check for loose components or fasteners and tighten them as needed to ensure proper fit and alignment.
Faults Requiring Professional Help:
Severe Damage: If the bearing has extensive damage, such as deep pitting, cracks, or significant wear, it&#;s best to seek professional help as these issues may not be repairable.
Misalignment: Correcting misalignment issues can be complex and may require special tools or expertise. Seek professional assistance if you suspect a severe misalignment.
Bearing Cage Damage: If the bearing cage is damaged, it may result in erratic performance. Repairing or replacing the cage typically requires professional intervention.
Critical Applications: For bearings used in critical applications where downtime can have serious consequences, it&#;s advisable to consult experts to ensure a thorough and reliable repair.
Complex Machinery: In complex or specialized machinery, addressing bearing faults may require expertise beyond simple maintenance. Professionals can ensure proper repairs in such cases.
When in doubt, or when dealing with critical equipment, it&#;s generally safer to seek professional assistance to assess and repair thin-section bearing faults. Professional expertise can help prevent further damage and ensure the continued reliability of the equipment.
In conclusion, thin-section bearings play a critical role in many industries, and their proper selection and maintenance are essential for ensuring reliable and efficient operations.
By considering factors such as load capacity, size constraints, and environmental conditions, as well as proper maintenance, it is possible to extend the life of thin-section bearings and minimize downtime and repair costs.