CN106350826B - 一种铁路棚车轴承的清洗维护方法 - Google Patents
一种铁路棚车轴承的清洗维护方法 Download PDFInfo
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Abstract
本发明公开一种铁路棚车轴承的清洗维护方法，采用毛刷除杂、碱液清洗、水基清洗液超声波清洗、漂洗吹干、电镀修复、磷化处理等步骤对铁路棚车轴承进行清洗维护；其清洗液采用水基清洗液，克服传统采用石油类清洗溶剂造成环境污染的技术问题，并且在清洗过程中兼顾对轴承的磨损和缺陷进行修复，清洗效果良好，延长了轴承的使用寿命，并且节约成本。
Description
技术领域
本发明涉及轴承清洗技术领域，尤其涉及一种铁路棚车轴承的清洗维护方法。
背景技术
机械设备及各种车辆维修，尤其是铁路棚车（也叫铁路货车）检修中，轴承的清洗工作是检修的重要环节，而且工作量大，质量要求高。目前，铁路棚车轴承清洗的传统方法是使用石油类溶剂，用煤油、汽油来清洗，这不但存在石油原料的浪费和环境污染，而且石油类溶剂燃点低，易发生火灾。除此之外，清洗步骤也较为简单，一般采用1）热水或洗涤剂冲洗；2）煤油浸泡；3）手工擦拭的方法，清洗效果较差，并且不会对磨损的轴承修复，或者在后续工艺中再进行修复，增加了维护成本，且效果不理想。
有鉴于上述现有的棚车轴承清洗工艺存在的缺陷，本发明人基于从事此类产品设计制造多年丰富的实务经验及专业知识，并配合学理的运用，积极加以研究创新，以期创设一种铁路棚车轴承的清洗维护方法，提高铁路棚车轴承的清洗效果，并且在清洗铁路棚车轴承过程中对其进行修复，使其更具有实用性。
发明内容
本发明的主要目的在于，克服现有的铁路棚车轴承清洗效果差，清洗剂污染环境及清洗维护成本高的问题，提供一种铁路棚车轴承的清洗维护方法，提高其铁路棚车轴承的清洗维护效果、节约成本，从而更加适于实用，且具有产业上的利用价值。
本发明的目的及解决其技术问题是采用以下技术方案来实现的。依据本发明提出的一种铁路棚车轴承的清洗维护方法，包括如下步骤：
（1）将轴承拆下，目测轴承表面磨损和缺陷大小，若轴承磨损和缺陷量较多难以修复，则直接废弃；若轴承磨损和缺陷量较小可以修复，则采用硬质毛刷刷除轴承表面沾染的杂质；
（2）将经过步骤（1）毛刷处理后的轴承放入碱性溶液中进行浸泡清洗，所述的碱性溶液由双氧水H2O2、氨水NH3.H2O、氢氧化钠NaOH、碳酸氢钠NaHCO3和水组成；碱性溶液加热到40-60℃，轴承浸泡1-2h；
（3）经过步骤（2）处理后的轴承再进行水基清洗液浸泡超声波清洗，超声波清洗频率为25-40KHz，超声浸泡清洗0.5-1h；
（4）将步骤（3）处理后的轴承再进行纯水喷淋漂洗，喷淋过程中旋转轴承，使得轴承得到全方位的漂洗，轴承旋转喷淋3-5遍；
（5）将步骤（4）处理后的轴承进行高压氮气吹干；
（6）对吹干后的轴承进行检测，确定轴承的磨损和缺陷位置，并对磨损和缺陷位置进行电镀修复；
（7）将步骤（6）处理后的轴承进行纯水清洗和高压氮气吹干；
（8）将步骤（7）处理后的轴承进行磷化处理，磷化处理液的温度为60-80℃，处理时间为30-60min；
（9）将步骤（8）处理后的轴承浸泡防锈油，在50-70℃的条件下浸泡40-60min；
（10）将步骤（9）处理后的轴承进行纯水清洗和高压氮气吹干。
更进一步的，碱性溶液按如下质量比配置而成：
双氧水H2O2：氨水NH3.H2O：氢氧化钠NaOH：碳酸氢钠NaHCO3：水=3~5：1~2：2~4：1~2：20~30。
更进一步的，水基清洗液配方及重量百分比（wt.%）为：乳化剂2-4、三乙醇胺8-16、十二烷基苯磺酸钠7-15、乙二胺四乙酸钠10-20、苯并三氮唑0.1-0.5、亚硝酸钠5-6、消泡剂1-3 、PH调节剂1~3、去离子水45-60。
更进一步的，电镀处理后，轴承电镀层的主要成分为铁、锡、磷、镍、铬、铜。
更进一步的，磷化处理液采用质量百分比为8％-15％的磷酸二氢锌、0.5％-1％的磷酸、10%-20%的硝酸钙、0.1%-0.2%的亚硝酸钠、0.1%-0.2%的间硝苯磺酸钠和余量的去离子水混合而成。
更进一步的，防锈油采用质量百分比为环烷酸锌5%-8%、成膜剂2%-4%、石油磺酸钙6%-9%、失水山梨醇单油酸脂2%-5%、抗氧化剂0.5%-3%和余量的石蜡基油混合而成。
借由上述技术方案，本发明的铁路棚车轴承的清洗维护方法至少具有下列优点：采用毛刷除杂、碱液清洗、水基清洗液超声波清洗、漂洗吹干、电镀修复、磷化处理等步骤对铁路棚车轴承进行清洗维护；其清洗液采用水基清洗液，克服传统采用石油类清洗溶剂造成环境污染的技术问题，并且在清洗过程中兼顾对轴承的磨损和缺陷进行修复，清洗效果良好，延长了轴承的使用寿命，并且节约成本。
上述说明仅是本发明技术方案的概述，为了能够更清楚了解本发明的技术手段，并可依照说明书的内容予以实施，以下以本发明的较佳实施例详细说明如后。
具体实施方式
为更进一步阐述本发明为达成预定发明目的所采取的技术手段及功效,对依据本发明提出的棚车用墙板其具体实施方式、特征及其功效，详细说明如后。
实施例1
本发明的铁路棚车轴承的清洗维护方法，其特征在于，包括如下步骤：
（1）将轴承拆下，目测轴承表面磨损和缺陷大小，若轴承磨损和缺陷量较多难以修复，则直接废弃；若轴承磨损和缺陷量较小可以修复，则采用硬质毛刷刷除轴承表面沾染的杂质；
（2）将经过步骤（1）毛刷处理后的轴承放入碱性溶液中进行浸泡清洗，碱性溶液由双氧水H2O2、氨水NH3.H2O、氢氧化钠NaOH、碳酸氢钠NaHCO3和水组成；碱性溶液加热到45℃，轴承浸泡1.5h；各组分按如下质量比配置而成：双氧水H2O2：氨水NH3.H2O：氢氧化钠NaOH：碳酸氢钠NaHCO3：水=4：1.2：3.5：1.5：24；
（3）经过步骤（2）处理后的轴承再进行水基清洗液浸泡超声波清洗，超声波清洗频率为32KHz，超声浸泡清洗1h；水基清洗液配方及重量百分比（wt.%）为：乳化剂3、三乙醇胺12、十二烷基苯磺酸钠10、乙二胺四乙酸钠15、苯并三氮唑0.2、亚硝酸钠5、消泡剂2 、PH调节剂1.8、去离子水51。
（4）将步骤（3）处理后的轴承再进行纯水喷淋漂洗，喷淋过程中旋转轴承，使得轴承得到全方位的漂洗，轴承旋转喷淋5遍；
（5）将步骤（4）处理后的轴承进行高压氮气吹干，氮气压力为45MPa；
（6）对吹干后的轴承进行检测，确定轴承的磨损和缺陷位置，并对磨损和缺陷位置进行电镀修复；电镀处理后，轴承电镀层的主要成分为铁、锡、磷、镍、铬、铜；
（7）将步骤（6）处理后的轴承进行纯水清洗和高压氮气吹干，氮气压力为60MPa
（8）将步骤（7）处理后的轴承进行磷化处理，磷化处理液的温度为75℃，处理时间为40min；磷化处理液采用质量百分比为12％的磷酸二氢锌、0.6％的磷酸、16%的硝酸钙、0.2%的亚硝酸钠、0.1%的间硝苯磺酸钠和余量的去离子水混合而成；
（9）将步骤（8）处理后的轴承浸泡防锈油，在60℃的条件下浸泡40min；防锈油采用质量百分比为环烷酸锌6%、成膜剂3%、石油磺酸钙8%、失水山梨醇单油酸脂4%、抗氧化剂2%和余量的石蜡基油混合而成。
（10）将步骤（9）处理后的轴承进行纯水清洗和高压氮气吹干。
实施例2
本发明的铁路棚车轴承的清洗维护方法，其特征在于，包括如下步骤：
（1）将轴承拆下，目测轴承表面磨损和缺陷大小，若轴承磨损和缺陷量较多难以修复，则直接废弃；若轴承磨损和缺陷量较小可以修复，则采用硬质毛刷刷除轴承表面沾染的杂质；
（2）将经过步骤（1）毛刷处理后的轴承放入碱性溶液中进行浸泡清洗，碱性溶液由双氧水H2O2、氨水NH3.H2O、氢氧化钠NaOH、碳酸氢钠NaHCO3和水组成；碱性溶液加热到50℃，轴承浸泡1h；各组分按如下质量比配置而成：双氧水H2O2：氨水NH3.H2O：氢氧化钠NaOH：碳酸氢钠NaHCO3：水=5：2：4：1：28；
（3）经过步骤（2）处理后的轴承再进行水基清洗液浸泡超声波清洗，超声波清洗频率为40KHz，超声浸泡清洗0.5h；水基清洗液配方及重量百分比（wt.%）为：乳化剂4、三乙醇胺10、十二烷基苯磺酸钠12、乙二胺四乙酸钠14、苯并三氮唑0.2、亚硝酸钠6、消泡剂2.3 、PH调节剂1.5、去离子水50。
（4）将步骤（3）处理后的轴承再进行纯水喷淋漂洗，喷淋过程中旋转轴承，使得轴承得到全方位的漂洗，轴承旋转喷淋4遍；
（5）将步骤（4）处理后的轴承进行高压氮气吹干，氮气压力为45MPa；
（6）对吹干后的轴承进行检测，确定轴承的磨损和缺陷位置，并对磨损和缺陷位置进行电镀修复；电镀处理后，轴承电镀层的主要成分为铁、锡、磷、镍、铬、铜；
（7）将步骤（6）处理后的轴承进行纯水清洗和高压氮气吹干，氮气压力为60MPa；
（8）将步骤（7）处理后的轴承进行磷化处理，磷化处理液的温度为65℃，处理时间为50min；磷化处理液采用质量百分比为10％的磷酸二氢锌、0.8％的磷酸、18%的硝酸钙、0.15%的亚硝酸钠、0.2%的间硝苯磺酸钠和余量的去离子水混合而成；
（9）将步骤（8）处理后的轴承浸泡防锈油，在45℃的条件下浸泡60min；防锈油采用质量百分比为环烷酸锌8%、成膜剂4%、石油磺酸钙9%、失水山梨醇单油酸脂3%、抗氧化剂1.5%和余量的石蜡基油混合而成。
（10）将步骤（9）处理后的轴承进行纯水清洗和高压氮气吹干。
以上所述，仅是本发明的较佳实施例而已，并非对本发明作任何形式上的限制，虽然本发明已以较佳实施例揭露如上，然而并非用以限定本发明，任何熟悉本专业的技术人员，在不脱离本发明技术方案范围内，当可利用上述揭示的技术内容做出些许更动或修饰为等同变化的等效实施例，但凡是未脱离本发明技术方案的内容，依据本发明的技术实质对以上实施例所作的任何简单修改、等同变化与修饰，均仍属于本发明技术方案的范围内。
Claims (5)
1.一种铁路棚车轴承的清洗维护方法，包括如下步骤：
（1）将轴承拆下，目测轴承表面磨损和缺陷大小，若轴承磨损和缺陷量较多难以修复，则直接废弃；若轴承磨损和缺陷量较小可以修复，则采用硬质毛刷刷除轴承表面沾染的杂质；
（2）将经过步骤（1）毛刷处理后的轴承放入碱性溶液中进行浸泡清洗，所述的碱性溶液由双氧水H2O2、氨水NH3.H2O、氢氧化钠NaOH、碳酸氢钠NaHCO3和水组成；碱性溶液加热到40-60℃，轴承浸泡1-2h；
（3）经过步骤（2）处理后的轴承再进行水基清洗液浸泡超声波清洗，超声波清洗频率为25-40KHz，超声浸泡清洗0.5-1h；
（4）将步骤（3）处理后的轴承再进行纯水喷淋漂洗，喷淋过程中旋转轴承，使得轴承得到全方位的漂洗，轴承旋转喷淋3-5遍；
（5）将步骤（4）处理后的轴承进行高压氮气吹干；
（6）对吹干后的轴承进行检测，确定轴承的磨损和缺陷位置，并对磨损和缺陷位置进行电镀修复；
（7）将步骤（6）处理后的轴承进行纯水清洗和高压氮气吹干；
（8）将步骤（7）处理后的轴承进行磷化处理，磷化处理液的温度为60-80℃，处理时间为30-60min；
（9）将步骤（8）处理后的轴承浸泡防锈油，在50-70℃的条件下浸泡40-60min；
（10）将步骤（9）处理后的轴承进行纯水清洗和高压氮气吹干。
2.如权利要1所述的铁路棚车轴承的清洗维护方法，其特征在于，所述碱性溶液按如下质量比配置而成：
双氧水H2O2：氨水NH3.H2O：氢氧化钠NaOH：碳酸氢钠NaHCO3：水=3~5：1~2：2~4：1~2：20~30。
3.如权利要1所述的铁路棚车轴承的清洗维护方法，其特征在于，所述水基清洗液配方及重量百分比（wt.%）为：乳化剂2-4、三乙醇胺8-16、十二烷基苯磺酸钠7-15、乙二胺四乙酸钠10-20、苯并三氮唑0.1-0.5、亚硝酸钠5-6、消泡剂1-3 、PH调节剂1~3、去离子水45-60。
4.如权利要1所述的铁路棚车轴承的清洗维护方法，其特征在于，所述磷化处理液采用质量百分比为8％-15％的磷酸二氢锌、0.5％-1％的磷酸、10%-20%的硝酸钙、0.1%-0.2%的亚硝酸钠、0.1%-0.2%的间硝苯磺酸钠和余量的去离子水混合而成。
5.如权利要1所述的铁路棚车轴承的清洗维护方法，其特征在于，所述防锈油采用质量百分比为环烷酸锌5%-8%、成膜剂2%-4%、石油磺酸钙6%-9%、失水山梨醇单油酸脂2%-5%、抗氧化剂0.5%-3%和余量的石蜡基油混合而成。
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