發(fā)電機(jī)組軸承異響是常見的機(jī)械故障，可能由潤滑不良、磨損、安裝不當(dāng)或異物侵入等原因引起。以下是針對軸承異響的維修步驟和注意事項(xiàng)：

　　Abnormal noise from generator set bearings is a common mechanical failure, which may be caused by poor lubrication, wear, improper installation, or foreign object intrusion. The following are the maintenance steps and precautions for bearing abnormal noise:

　　一、故障診斷與檢查

　　1、 Fault diagnosis and inspection

　　異響特征判斷

　　Identification of abnormal noise characteristics

　　金屬摩擦聲：可能因潤滑不足或油質(zhì)劣化導(dǎo)致干摩擦。

　　Metal friction sound: Dry friction may be caused by insufficient lubrication or deterioration of oil quality.

　　規(guī)律性敲擊聲：軸承滾道或滾動體磨損、剝落。

　　Regular knocking sound: wear and peeling of bearing raceway or rolling elements.

　　尖銳嘯叫：游隙過小或軸承安裝不當(dāng)（如過緊）。

　　Sharp whistling: Insufficient clearance or improper installation of bearings (such as too tight).

　　斷續(xù)異響：可能混入異物（沙粒、金屬屑等）。

　　Intermittent abnormal noise: may contain foreign objects (such as sand particles, metal shavings, etc.).

　　停機(jī)檢查

　　Shutdown inspection

　　手動盤車：感受軸承轉(zhuǎn)動是否順暢，有無卡滯或阻力。

　　Manual turning: Check whether the bearing rotates smoothly, whether there is any jamming or resistance.

　　溫度檢測：用紅外測溫儀檢查軸承溫度，異常高溫（超過80℃）可能預(yù)示潤滑或磨損問題。

　　Temperature detection: Use an infrared thermometer to check the bearing temperature. Abnormal high temperatures (over 80 ℃) may indicate lubrication or wear issues.

　　目視檢查：拆解后觀察軸承內(nèi)外圈、滾動體、保持架是否破損、銹蝕或變形。

　　Visual inspection: After disassembly, observe whether the inner and outer rings, rolling elements, and cage of the bearing are damaged, corroded, or deformed.

　　游隙測量：使用塞尺或千分表檢測軸承徑向/軸向游隙，對比標(biāo)準(zhǔn)值判斷是否超限。

　　Clearance measurement: Use a feeler gauge or micrometer to check the radial/axial clearance of the bearing, and compare it with the standard value to determine if it exceeds the limit.

　　二、常見原因及處理措施

　　2、 Common causes and solutions

　　1. 潤滑不良

　　1. Poor lubrication

　　癥狀：軸承溫度高、異響伴隨焦糊味。

　　Symptoms: High bearing temperature, abnormal noise accompanied by burnt smell.

　　處理：

　　handle:

　　清理舊油脂，用煤油或?qū)Ｓ们逑磩氐浊鍧嵼S承及油道。

　　Clean old grease and thoroughly clean bearings and oil passages with kerosene or specialized cleaning agents.

　　更換符合規(guī)格的潤滑脂（如鋰基脂、高溫潤滑脂），注脂量占軸承腔的1/3~1/2。

　　Replace the lubricating grease that meets the specifications (such as lithium based grease, high-temperature lubricating grease), with a grease injection amount of 1/3 to 1/2 of the bearing chamber.

　　檢查潤滑系統(tǒng)（如自動注油器）是否堵塞或失效。

　　Check if the lubrication system (such as the automatic oiler) is blocked or malfunctioning.

　　2. 軸承磨損或損壞

　　2. Bearing wear or damage

　　癥狀：滾動體或滾道表面剝落、點(diǎn)蝕，保持架斷裂。

　　Symptoms: Peeling and pitting of rolling elements or raceway surfaces, and fracture of retaining frames.

　　處理：

　　handle:

　　更換同型號新軸承（注意品牌精度等級，如SKF、NSK）。

　　Replace with a new bearing of the same model (pay attention to the brand accuracy level, such as SKF, NSK).

　　檢查軸頸和軸承座尺寸公差，避免因配合不當(dāng)導(dǎo)致二次損壞。

　　Check the dimensional tolerances of the journal and bearing seat to avoid secondary damage caused by improper fit.

　　使用熱裝法安裝時，加熱溫度不超過120℃（避免軸承退火）。

　　When using the hot installation method, the heating temperature should not exceed 120 ℃ (to avoid bearing annealing).

　　3. 安裝問題

　　3. Installation issues

　　癥狀：軸承游隙異常（過緊或過松），軸向/徑向跳動超標(biāo)。

　　Symptoms: Abnormal bearing clearance (too tight or too loose), excessive axial/radial runout.

　　處理：

　　handle:

　　重新安裝，確保軸與軸承座同心，使用液壓工具或銅棒均勻敲擊。

　　Reinstall, ensure that the shaft is concentric with the bearing seat, and use hydraulic tools or copper rods to strike evenly.

　　檢查軸肩、鎖緊螺母是否到位，防止軸向竄動。

　　Check if the shoulder and locking nut are in place to prevent axial movement.

　　對非定位端軸承保留適當(dāng)熱膨脹間隙。

　　Leave appropriate thermal expansion clearance for non positioning end bearings.

　　4. 異物侵入

　　4. Foreign object intrusion

　　癥狀：軸承內(nèi)部可見顆粒物，滾道劃痕明顯。

　　Symptoms: Particles can be seen inside the bearing, and there are obvious scratches on the raceway.

　　處理：

　　handle:

　　清潔軸承座密封結(jié)構(gòu)，更換失效的油封或迷宮式密封件。

　　Clean the sealing structure of the bearing seat and replace any failed oil seals or labyrinth seals.

　　檢查機(jī)組進(jìn)氣過濾系統(tǒng)，防止灰塵進(jìn)入（尤其適用于戶外或粉塵環(huán)境）。

　　Check the intake filtration system of the unit to prevent dust from entering (especially suitable for outdoor or dusty environments).

　　5. 負(fù)載異常

　　5. Abnormal load

　　癥狀：軸承異常磨損集中在局部，伴隨機(jī)組振動超標(biāo)。

　　Symptom: Abnormal bearing wear is concentrated locally, accompanied by excessive vibration of the unit.

　　處理：

　　handle:

　　檢查聯(lián)軸器對中誤差（激光對中儀校準(zhǔn)，偏差≤0.05mm）。

　　Check the alignment error of the coupling (laser alignment instrument calibration, deviation ≤ 0.05mm).

　　排查發(fā)電機(jī)負(fù)載是否超限或存在不平衡電流。

　　Check whether the generator load exceeds the limit or there is unbalanced current.

　　檢查基礎(chǔ)螺栓是否松動，設(shè)備底座是否水平。

　　Check if the foundation bolts are loose and if the equipment base is level.

　　三、維修后測試

　　3、 Post repair testing

　　空載試運(yùn)行：啟動后監(jiān)聽異響是否消失，監(jiān)測軸承溫度（≤70℃為正常）。

　　No load test run: Monitor whether the abnormal noise disappears after starting, and monitor the bearing temperature (≤ 70 ℃ is normal).

　　振動檢測：使用振動分析儀檢測軸承部位振動值（ISO 10816標(biāo)準(zhǔn)）。

　　Vibration detection: Use a vibration analyzer to detect the vibration value of the bearing part (ISO 10816 standard).

　　負(fù)載測試：逐步增加負(fù)載至額定值，觀察運(yùn)行穩(wěn)定性。

　　Load test: Gradually increase the load to the rated value and observe the stability of operation.

　　四、預(yù)防措施

　　4、 Preventive measures

　　定期維護(hù)：按手冊周期更換潤滑脂（一般每運(yùn)行2000~5000小時）。

　　Regular maintenance: Replace lubricating grease according to the manual cycle (usually every 2000-5000 hours of operation).

　　狀態(tài)監(jiān)測：采用在線振動監(jiān)測系統(tǒng)或定期采集油樣進(jìn)行鐵譜分析。

　　Condition monitoring: Use online vibration monitoring system or regularly collect oil samples for iron spectrum analysis.

　　環(huán)境控制：保持機(jī)房清潔干燥，避免潮濕或腐蝕性氣體。

　　Environmental control: Keep the computer room clean and dry, avoid moisture or corrosive gases.

　　備件管理：使用原廠或高精度替代軸承，避免劣質(zhì)配件。

　　Spare parts management: Use original or high-precision replacement bearings to avoid inferior parts.

　　注意事項(xiàng)

　　Precautions

　　拆卸軸承時禁止直接錘擊，需使用專用拉拔器。

　　When disassembling bearings, direct hammering is prohibited and a specialized puller must be used.

　　若軸承與軸頸粘連，可采用加熱法（感應(yīng)加熱器）輔助拆卸。

　　If the bearing is adhered to the journal, heating method (induction heater) can be used to assist in disassembly.

　　對于大型發(fā)電機(jī)組（如船用或電站機(jī)組），建議聯(lián)系專業(yè)維修團(tuán)隊(duì)處理。

　　For large generator sets (such as marine or power plant units), it is recommended to contact a professional maintenance team for handling.

　　通過系統(tǒng)排查和規(guī)范維修，可有效解決軸承異響問題，延長機(jī)組使用壽命。若異響反復(fù)出現(xiàn)，需進(jìn)一步檢查發(fā)電機(jī)轉(zhuǎn)子動平衡或傳動系統(tǒng)匹配性。

　　Through system troubleshooting and standardized maintenance, the problem of bearing abnormal noise can be effectively solved, and the service life of the unit can be extended. If abnormal noise occurs repeatedly, further check the dynamic balance of the generator rotor or the matching of the transmission system.

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