CN112524151A - 用于制冷剂压缩机的滚动轴承,特别是混合滚动轴承 - Google Patents
用于制冷剂压缩机的滚动轴承,特别是混合滚动轴承 Download PDFInfo
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- CN112524151A CN112524151A CN202010962352.0A CN202010962352A CN112524151A CN 112524151 A CN112524151 A CN 112524151A CN 202010962352 A CN202010962352 A CN 202010962352A CN 112524151 A CN112524151 A CN 112524151A
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- Prior art keywords
- rolling bearing
- bearing
- rolling
- hybrid
- raceway
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Abstract
一种具有内滚道和外滚道以及配置在所述内滚道与所述外滚道之间的多个滚动元件的滚动轴承。所述滚动轴承是介质润滑的或无油润滑的。润滑剂在所述滚动元件与滚道之间形成弹性流体动力润滑剂膜。在首次使用所述滚动轴承时,利用保护流体涂覆所述滚动轴承的至少一个表面,优选地,所述保护流体是油基防腐流体。此外,一种具有这种滚动轴承的制冷剂压缩机。
Description
技术领域
本发明涉及一种根据本专利权利要求1的前序部分的滚动轴承,特别是混合滚动轴承,并且涉及一种包括这种混合滚动轴承的制冷剂压缩机。
背景技术
滚动轴承并且特别是混合滚动轴承通常用于非常苛刻(demanding)的环境中,例如,用于润滑状况降低的应用中和/或用于高速和/或高温的应用中。在混合滚子轴承中,轴承圈和滚子元件由不同的材料制成。通常,(轴承)圈由钢制成,滚动元件由陶瓷材料制成。在工作状况(/工作条件)的严重性(/严格性)(severity)的增大的情况下(例如,较重的负载结合较高的温度、较薄的润滑膜和/或不良(/较差)的润滑状况),轴承组件可能遭受表面引发疲劳(surface initiated fatigue),即所谓的微点蚀(micropitting)。即使微点蚀不一定是主要故障(/失效)(failure)模式,它也可能会促进/加速其他故障(如凹痕(/压痕/凹口/缺口)(indentation)、表面引发剥落和咬死(seizure))的出现。
因此,微点蚀是导致寿命受限的轴承磨损的机制之一。减轻微点蚀影响的一种方法是确保轴承中的滚动接触表面始终被足够厚度的润滑膜分隔开。
这在超薄润滑膜厚度(UTFT)应用中是不可行的。滚动轴承中的UTFT应用是指当通过润滑膜分隔表面时受以下因素影响(compromised)的状况:
润滑剂的低粘度,即流体的动力粘度(/动态粘度)(dynamic viscosity)的量级为1cSt(厘斯)及以下(低于1cSt),和/或
润滑剂不足(starvation),即滚动接触入口(/进口)(inlet)中的可用润滑剂层无法保证轴承中的完全浸没(fully flooded)状态的状况。
在这两种状况下,接触表面处的总润滑剂层厚度被限制到300nm或更小。这之所以可能发生,是因为:轴承利用油脂来润滑(润滑剂的释放有限),或者润滑剂在到达接触之前蒸发(挥发性流体),或者由润滑系统供应的润滑剂有限。
此外,这些UFT应用中的许多应用使用介质润滑(如纯制冷剂润滑、油-制冷剂混合物润滑、燃料(煤油、柴油、汽油、天然气、醇类)润滑)和/或结合介质的油脂。排除了水润滑。对于纯制冷剂润滑,所得的润滑剂膜厚度甚至显著小于300nm,更多的时候小于100nm,通常在30nm的范围内。
这些滚动轴承的主要故障模式是由腐蚀导致(assisted)的磨损。磨损(因被腐蚀而增强的固体对固体接触)可以改变滚道轮廓,增大间隙(/游隙),并且使可以形成(develop)剥落的局部应力集中。这些轴承的另一重要故障模式是固体污染。由于这些应用在非常薄的膜厚度(例如,小于300nm至200nm)下工作,任何固体颗粒(碎屑、沙子、油烟(oilsoot)等)即使是非常小的固体颗粒,也会产生(/引起)接触表面的损坏并且会改变形貌(topography),扰乱(/破坏)(disrupting)原始表面的膜建立能力。过度污染还可能会产生将阻碍/阻挡轴承旋转的高摩擦力,并且可能会在保持架中产生断裂(fracture)或者在滚道和滚动元件中产生咬死(/卡住)。
因此,在现有技术中,已经提出采用表面工程技术并且提供尽可能相等的轴承圈的滚道的粗糙度和滚动元件的粗糙度,以便减少微点蚀并且改善轴承的磨损和疲劳寿命。这是基于以下理解:在存在滑动且不存在全膜润滑(full-film lubrication)的情况下,较粗糙的滚动接触表面将在较平滑的相对滚动接触表面上施加负载微循环(load microcycles)。不利的是,实际上,即使在普通的钢-钢轴承中,轴承的滚道通常也比滚动元件粗糙一些。在混合滚动轴承中,粗糙度之间的差异甚至更大。
为了提供一种即使在磨合(running-in)之后也具有延长的使用寿命以及改善的耐腐蚀性和抗微点蚀性的混合滚动轴承,还提出了使混合滚动轴承的滚动元件中的至少一个具有增大的表面RMS粗糙度Rq2,N,所述RMS粗糙度Rq2,N显著高于其余滚动元件的RMS粗糙度Rq2,i。当具有增大的粗糙度的至少一个滚动元件接触滚道时,所述至少一个滚动元件的较高的粗糙度值Rq2,N允许(/使得)磨损增加。即使通常应避免增加磨损,但根据本发明的预期磨损也使滚道中的(在轴承的使用寿命期间出现的)凹痕(/压痕/凹口/缺口)平滑。这反而减少了混合轴承的总体腐蚀,并且延长了轴承的使用寿命。
然而,已经证明不利的是,在滚动轴承的运输或安装期间,由于例如误操作或腐蚀影响,可能损坏精密加工的表面和/或可能使表面的有意设计的粗糙度劣化。这继而使轴承的耐腐蚀性和抗微点蚀性劣化,并且最终使其使用寿命劣化。
因此,本发明的目的是提供一种可用于超薄润滑膜厚度应用(特别是用于制冷剂压缩机装置)并且具有改善和受保护的耐腐蚀性和抗微点蚀性的滚动轴承(特别是混合滚动轴承)。
发明内容
该目的通过根据专利技术方案1所述的混合滚动轴承和包括这种轴承的制冷剂压缩机来解决。
在下文中,提出了一种滚动轴承,特别是混合滚动轴承,所述滚动轴承包括内滚道和外滚道以及配置在它们之间的多个滚动元件。所述滚动轴承可以是将球作为滚动元件的混合球轴承或将滚子作为滚动元件的混合滚子轴承,其中,混合滚动轴承具有由轴承钢制成的外滚道和内滚道以及由陶瓷材料制成的滚动元件(球或滚子)。
为了提供一种即使在磨合之后也具有延长的使用寿命和改善的耐腐蚀性和抗微点蚀性的滚动轴承,本发明人发现了,对于在使用时介质润滑的或无油润滑的滚动轴承(其中,润滑剂在滚动元件与滚道之间形成弹性流体动力润滑膜)而言,即使在首次使用之前,避免对滚动轴承的任何劣化影响也是至关重要的。因此,提出了一种滚动轴承,其中,在首次使用所述滚动轴承时,利用保护流体涂覆所述滚动轴承的至少一个表面,所述保护流体优选为油基防腐流体。保护流体覆盖轴承的功能表面中的至少一个并且保护轴承免受任何化学侵蚀。由此,保护流体确保了轴承的表面在轴承首次被使用之前尽可能不被损坏。
由此,特别有利的是,如果保护流体涂层是防水/防湿的(water/humidityrepellent),或者甚至是疏水性的,则水分/湿气不会与用于润滑的介质接触。通常,润滑剂用于介质润滑的轴承应用中,其在与水分/湿气接触时具有甚至更高的腐蚀影响。因此,应避免任何水分/湿气暴露,这可以通过利用防水或疏水性的涂层流体涂覆轴承来实现。
根据另一优选实施方式,介质润滑的轴承通过纯制冷剂或制冷剂油混合物来润滑。制冷剂和制冷剂-油混合物可以是侵蚀性的和/或容易分解并且形成酸。与水分/湿气结合时,这种制冷剂物质甚至更具侵蚀性。因此,在制冷剂润滑的环境中操作的轴承需要被额外保护,这通过附加保护流体涂层来完成。在安装或运输期间对表面的任何细微的损坏都可能导致寿命缩短。即使在制冷剂润滑的环境中,保护流体涂层也可以避免这样的损坏,从而增加轴承的使用寿命。通常,可以使用诸如R134a、R1233zd、R1234ze或R515B的制冷剂。
介质润滑的轴承的另一挑战是介质通常仅提供不足的润滑膜。因此,对于借助于配置在滚动元件与滚道之间的超薄润滑膜(其中,润滑膜厚度小于300nm,优选小于100nm,最优选小于30nm)来润滑的滚动轴承(特别是混合滚动轴承)而言,附加保护流体涂层是有利的。
有利的是,具有防腐蚀添加剂的保护流体涂层因物质不与介质(润滑剂/制冷剂)反应而在使用时留在轴承上。而且,保护流体涂层可以通过在轴承表面上保持附加保护涂层来保护轴承表面免受介质(润滑剂/制冷剂)的腐蚀影响,这进而提高了轴承性能。另一优点是,附加涂层可以增加超薄润滑膜应用中的润滑膜的厚度和/或连续性。
根据另一优选实施方式,保护流体是具有防腐蚀添加剂的防腐流体。防腐蚀添加剂物理地或化学地结合到轴承表面,并且保护轴承免受诸如化学侵蚀的劣化影响。
这种防腐蚀添加剂或保护流体本身可以是具有极性头部和非极性尾部的极性物质(/极性基质)(polar substrate),其中,极性头部适于(/被适配成)结合到轴承表面,并且非极性尾部防止元素(elements)与轴承表面接触。极性物质的另一优点是,极性物质的物理和化学性质支持在涂层一定程度上从轴承洗掉(washed off)的情况下重新建立保护流体涂层。
总体上,这些防腐蚀添加剂的机理相对简单。防腐蚀添加剂是可以吸附在金属表面上形成密集堆积的疏水层的具有长烷基链和极性基团(polar group)的分子。吸附机理可以基于极性防腐蚀添加剂与金属表面的物理或化学相互作用。
有利的是,极性物质是清净剂(/去垢剂)(detergent)、分散剂(dispersant)或抑制剂(inhibitor),其中,防腐流体优选包括高碱性磺酸盐、酰胺、酰亚胺和/或环烷酸锌(Zinc naphthenates)。
已知使用例如石油磺酸盐,石油磺酸盐是通过利用发烟硫酸(oleum)处理生产白油时的副产物。所得的酸焦油(acid tar)包含可以用碱液中和的长链烷基芳基磺酸(longchain alkylarylsulfonic acids)。在水基金属工作流体、发动机油和防锈剂中,通常将具有低分子量(低于约450)的磺酸钠用作具有附加防腐蚀性质的低价乳化剂和清净剂。具有较高分子量的磺酸盐以高效腐蚀抑制剂闻名,尤其是基于二价阳离子(如钙、镁和钡)时。由于毒理学(toxicological)和生态毒理学(ecotoxicological)的考虑,钡化合物的重要性不断降低。
此外,复合烷基苯磺酸盐(/合成烷基苯磺酸盐)(synthetic alkylbenzenesulfonates)由于它们较高且较恒定的质量而可以被优选使用。它们是专门设计的单烷基苯磺酸(monoalkylbenzenesulfonic acids)(通常为C24烷基(alkyl groups))和二烷基苯磺酸(通常为两个C12烷基)与碱金属氢氧化物和碱土金属氢氧化物的反应产物。
一类特殊的复合磺酸盐的组(group of synthetic sulfonates)是二壬基萘磺酸盐(dinonylnaphthenesulfonates)。
除了中性或仅轻微碱性的磺酸盐之外,具有高碱贮量(alkaline reserve)(TBN(总碱值,Total Base Number)100-400mg KOH/g)的高碱性磺酸盐也起到重要作用。它们表现出清净剂性质,并且能够中和酸性氧化产物。
此外,可以使用许多不同的长链羧酸衍生物,其中,羧基充当可以容易地吸附在金属表面上的极性部分。
示例是最常见与磺酸盐或氧化链烷烃(/氧化石蜡)结合的例如羊毛脂(羊毛脂肪)和羊毛脂脂肪酸的盐,其因高含量的羟基和氧代羧酸而具有高极性。
环烷酸锌可特别用于润滑脂(/润滑油脂)中。
烷基化琥珀酸、其偏酯(partial esters)和半酰胺也被认为是高效的,即使在0.01%至0.05%的非常低的处理率下也不会乳化防腐蚀添加剂。
4-壬基苯氧基乙酸及其衍生物具有类似的性能。
另一种广泛分布的基团是酰胺和酰亚胺,酰胺和酰亚胺是饱和脂肪酸和不饱和脂肪酸与烷基胺和烷醇胺的反应产物。最广为人知的这种类型的产物是表现出与咪唑啉衍生物的强协同作用(synergistic effect)的N-酰基肌氨酸。此外,这些添加剂具有良好的驱水性质。
此外,一些单烷基磷酸偏酯或二烷基磷酸偏酯的特殊胺盐除了其高效的抗磨(/耐磨)(antiwear)性质之外,还表现出优异的抗腐蚀性质。
作为另一种选择或另外地,可以使用气相腐蚀抑制剂(/气相缓蚀剂)(VCI),特别是对于封闭系统,可以使用气相腐蚀抑制剂。这些物质具有对金属表面的高亲和力以及相对高的蒸汽压,以保证它们在与润滑剂不稳定地直接接触的部件上的可用性。用于该应用的最常用的产物族是胺。已证明吗啉、二环己基胺和二乙醇胺对于该目的是非常有效的。由于主要涉及仲胺(/二级胺)的亚硝胺形成潜力的毒理学问题,这些产物部分将被叔胺(/三级胺)(如二乙醇甲胺)和类似产物取代。另一组油溶性VCI是低分子量碳酸(n-C8至n-C10)。
根据另一优选实施方式,轴承是接触角在10°与40°之间的角接触球轴承,特别是接触角在15°与30°之间的角接触球轴承。
轴承还可以包括多于一列的滚动元件,或者可以成组配置,例如:背对背配置或面对面配置的成对轴承。在轴承也是角接触球轴承的情况下,进一步优选的是,接触角是相同的。作为另一种选择,接触角也可以是不同的,其中特别地,两个球轴承中的第一球轴承的接触角在10°至20°之间,两个球轴承中的第二球轴承的接触角在21°至35°之间。
如果轴承成对配置,则进一步优选的是,两个轴承被构造为提供具有零测量载荷和零安装载荷的轴向间隙,其中,如果内圈的内径小于或等于80mm,则轴向间隙在-5μm与40μm之间;如果(内圈的)内径大于80mm且小于或等于180mm,则轴向间隙在-5μm与50μm之间;并且如果(内圈的)内径大于180mm,则轴向间隙在-5μm与70μm之间。作为另一种选择,轴向间隙可以基于滚动元件的节圆直径来限定,使得:如果两个轴承中的一个轴承的节圆直径小于或等于100mm,则轴向间隙在-5μm与40μm之间;如果两个轴承中的一个轴承的节圆直径大于100mm且小于或等于200mm,则轴向间隙在-5μm与50μm之间;并且如果两个轴承中的一个轴承的节圆直径大于200mm,则轴向间隙在-5μm与70μm之间。
由此,在首次使用轴承之前确定了间隙。进一步优选的是,两个滚动轴承成对形成同步组(synchronized set)。
根据另一优选实施方式,滚动轴承被构造用于2500rpm至25000rpm之间的高转速或500000/60s至1500000mm/60s之间的ndm值,其中,ndm值是转速与节圆直径的乘积结果。
在滚子轴承是混合滚子轴承的情况下,进一步优选的是,混合滚动轴承的滚动元件中的至少一个滚动元件具有增大的表面RMS粗糙度Rq2,N,所述RMS粗糙度Rq2,N显著高于其余滚动元件的RMS粗糙度Rq2,i。当具有增大的粗糙度的至少一个滚动元件接触滚道时,所述至少一个滚动元件的较高的粗糙度值Rq2,N允许(/使得)磨损增加。即使通常应避免增加磨损,但根据本发明的预期磨损也使滚道中的(在轴承的使用寿命期间出现的)凹痕(/压痕/凹口/缺口)平滑。这反而减少了混合轴承的总体腐蚀,并且延长了轴承的使用寿命。
具有增大的粗糙度的至少一个滚动元件的另一优点是,污染颗粒可以被接纳在所述至少一个滚动元件的粗糙表面内。由此,可以滤除已知会损坏圈的滚道和/或滚动元件的污染颗粒,这也增加了轴承的耐磨性和耐腐蚀性。
从而证明了,如果至少一个滚动元件的增大的RMS粗糙度Rq2,N比其余滚动元件的RMS粗糙度Rq2,i高10倍至25倍,则是有利的。这种高粗糙度允许(得到)优异的平滑结果。
根据另一优选实施方式,至少一个滚动元件的增大的粗糙度Rq2,N高于滚道的粗糙度Rq1。进一步优选的是,其余滚动元件的粗糙度低于滚道的粗糙度,其中,混合球轴承的滚道的粗糙度Rq1比其余球的粗糙度Rq2高2倍至5倍,优选2.5倍至4倍,和/或混合滚子轴承的滚道的粗糙度Rq1比其余滚子的粗糙度Rq2高1.2倍至4倍,优选1.5倍至3倍。
与提供具有基本上相同的滚道粗糙度值和滚动元件粗糙度值的混合滚动轴承的最新努力相反,本发明人惊奇地发现,如果将混合滚动轴承的接触表面的粗糙度(特别是在崭新状况下)工程设计为在上面提及的预定义边界之内,则可以显著减少混合滚动轴承的微点蚀和腐蚀引起的磨损。
通过提供被工程设计为具有上面限定参数的混合滚动轴承,陶瓷滚动元件减少了边界摩擦并优化了磨合(running-in)。此外,在不良润滑和污染状况下,所提出的陶瓷滚动元件抑制了损坏机制。此外,对构成的粗糙度的严格控制有助于润滑膜的建立和磨合的改善以及保护流体涂层的建立。
根据另一优选实施方式,滚动轴承具有在1.02与1.1之间的范围内的密切度Φ,其中,Φ被定义为其中ri,e是内滚道或外滚道的滚道半径,Dw是滚动元件的直径。所提出的密切度在表面处的低摩擦力与高接触应力之间取得了平衡,因此优化了轴承寿命。
进一步有利的是,所提出的滚动轴承的至少一个组件(例如,滚道和/或滚动元件)由硬化的耐腐蚀钢制成,所述硬化的耐腐蚀钢的耐腐蚀性的点蚀电势比根据ASTM G61-86的不锈钢基准(AISI 440C)高至少25mV。另外地或作为另一种选择,所使用的钢具有≥58HRC的热处理后硬度和/或至少14MPa m1/2的断裂韧性(参见ASTM-E399-12)。
在滚动轴承是混合滚动轴承的情况下,优选的是,混合滚动轴承的至少一个滚动元件由氮化硅(Si3N4)制成。这与上面所提到的钢的所选择的耐腐蚀性质相结合,允许在混合滚动轴承中产生(develop)低磨损,这是因为在这种情况下磨损取决于钢硬度和环境的化学侵蚀性(腐蚀辅助磨损(corrosion assisted wear))。
根据另一优选实施方式,所提出的滚动轴承的滚动元件借助于保持架引导,所述保持架优选由纤维增强材料制成,所述保持架优选由玻璃纤维增强PEEK或碳纤维材料制成。保持架的纤维增强材料防止保持架在重污染环境中断裂。
优选地,保持架具有至少一个保持架腔格,所述至少一个保持架腔格适于容纳至少一个滚动元件,其中,所述至少一个保持架腔格具有环形形状。保持架腔格的环形形状可以在不良润滑状况下支持轴承的性能。
即使在超薄润滑膜厚度状况的特定状况下,所有这些特征单独地或组合地确保滚动轴承(特别是混合滚动轴承)的长持续时间。在没有上述特征的情况下,这是无法实现的。
本发明的另一方面涉及一种制冷剂压缩机,所述制冷剂压缩机包括至少一个如上所述的滚动轴承。
在权利要求书、说明书和附图中公开了另外的优点和优选实施方式。还应注意的是,本领域技术人员可以在不扩展本发明的范围的情况下以不同于所指示的方式对所呈现的特征进行组合。
附图说明
在下文中,将通过附图中所示的实施方式来描述本发明。所示实施方式仅是示例性的,并不用于限制保护范围。保护范围仅由所附权利要求限定。
附图示出了:
图1:根据优选实施方式的包括混合滚子轴承的制冷剂压缩机的示意图。
1 制冷剂压缩机
2 电动马达
4 压缩机轴
10 混合滚子轴承
12 混合滚子轴承的内圈
13 混合滚子轴承的内圈的滚道
14 混合滚子轴承的外圈
15 混合滚子轴承的外圈的滚道
16 混合滚子轴承的滚子
17 混合滚子轴承的滚子的滚道
18 混合滚子轴承的保持架
20 混合球轴承
22 混合球轴承的内圈
23 混合球轴承的内圈的滚道
24 混合球轴承的外圈
25 混合球轴承的外圈的滚道
26 混合球轴承的球
27 混合球轴承的球的表面
28 混合球轴承的保持架
30、32 润滑部件
具体实施方式
在下文中,相同或相似的功能元件用相同的附图标记表示。
图1示出了制冷剂压缩机(refrigerant compressor)1的截面图,制冷剂压缩机1具有驱动轴4的电动马达2。轴4在径向上由配置在马达2的两侧的一组滚子轴承(特别是混合滚子轴承)10-1、10-2支撑。此外,轴4在轴向上和在径向上由多个球轴承(特别是混合球轴承)20-1、20-2、20-3支撑。球轴承20优选为能够支撑轴向力和/或径向力的角接触球轴承,但是可以是任何其他类型的球轴承。滚子轴承10可以是任何类型的滚子轴承,例如,圆柱滚子轴承、球面滚子轴承、圆锥滚子轴承、圆环滚子轴承(toroidal roller bearing)或它们的组合。
每个滚子轴承10包括:内圈12,具有滚道13;外圈14,具有滚道15;以及滚子16,具有滚道17且配置在内圈12与外圈14之间。滚子16还借助于保持架18引导,保持架18优选由玻璃纤维增强PEEK(聚醚醚酮)材料制成。然而,任何其他纤维增强材料(例如,碳纤维材料)可以用于该保持架。
类似地,每个球轴承20包括:内圈22,具有滚道23;外圈24,具有滚道25;以及球26,具有表面27且配置在内圈22与外圈24之间。此外,球26借助于保持架28引导,保持架28优选由玻璃纤维增强PEEK材料制成。然而,任何其他纤维增强材料(例如,碳纤维材料)可以用于该保持架。
此外,应注意的是,图1中所示的球轴承具有25°至30°的接触角,但是也可以使用接触角在0°至45°范围的球轴承。可选择的是,球轴承20具有范围在1.02与1.1之间的密切度(/密合度)(osculation)Φ,其中,Φ被定义为其中,ri,e是内滚道或外滚道的滚道半径,Dw是球的直径。所提出的密切度在表面处的低摩擦力与高接触应力之间取得了平衡,因此优化了轴承寿命。
还如图1中所示,滚动轴承10、20通过润滑部件30、32润滑,润滑部件30、32适于(/被适配为)将润滑剂提供到滚动轴承10、20。由于图1中所示的装置是制冷剂压缩机,因此优选使用制冷剂本身或制冷剂/油混合物作为润滑剂。这已经证明改善了冷凝器和蒸发器热交换器中的热传递。消除油润滑剂还消除了对油维护和油成本的需求。
不幸的是,所使用的制冷剂(例如,R134a、R1233zd、R1234ze或R515B)产生非常侵蚀性(aggressive)的环境,这导致轴承的腐蚀风险增加。因此,即使在首次使用之前,也要避免对滚动轴承的任何劣化影响。因此,在首次使用滚动轴承之前,利用保护流体(protective fluid)涂覆滚动轴承的至少一个表面,保护流体优选为油基防腐流体(preservative fluid)。保护流体覆盖轴承的功能表面中的至少一个,并且保护轴承免受任何劣化影响和化学侵蚀。由此,保护流体确保了轴承的表面在轴承首次被使用之前尽可能不被损坏。
水分(water)/湿气(humidity)是腐蚀(/侵蚀)的主要原因之一。在与所使用的制冷剂结合时,水分/湿气可能产生腐蚀性元素或增加腐蚀风险的其他物质。因此,保护流体涂层可以是防水/防/湿的,或者甚至是疏水性的,使得水分或湿气不会与用于润滑的介质接触。
保护流体本身是具有防腐蚀添加剂的防腐流体。防腐蚀添加剂或保护流体优选为具有极性头部(polar head)和非极性尾部(non-polar tail)的极性物质(/极性基质),其中,极性头部适于结合到(bond to)轴承表面,非极性尾部防止(腐蚀性)元素与轴承表面接触。极性物质的另一优点是,极性物质的物理性质和化学性质支持在涂层一定程度上从轴承洗掉的情况下重新建立保护流体涂层。
此外,由于制冷剂提供厚度小于200nm(优选小于100nm,最优选小于30nm)的弹性流体动力(elasto-hydrodynamic)润滑膜,使用纯制冷剂和/或制冷剂/油混合物作为润滑剂导致了超薄润滑膜厚度(UTFT)的状况。由于这些应用在非常薄的膜厚度(例如,小于200nm)下工作,因此任何固体颗粒(碎屑、沙子、油烟(oil soot)等)即使是非常小的固体颗粒,也可能会产生(/引起)接触表面的损坏,并且会改变形貌(topography),扰乱(/破坏)(disrupting)原始表面的膜建立能力(film build-up capability)。制冷剂润滑的滚动轴承中的另一问题是,过度污染还可能会产生将阻碍/阻挡轴承旋转的高摩擦力,并且会在保持架中产生断裂(fracture),或者在滚道和滚动元件中产生咬死(/卡住)(seizure)。
有利的是,具有防腐蚀添加剂的保护流体涂层因物质不与介质(润滑剂/制冷剂)反应而在使用时留在轴承上。而且,保护流体涂层可以通过在轴承表面上保持附加保护涂层来保护轴承表面免受制冷剂的腐蚀影响,这继而提高了轴承性能。另一优点是,附加涂层可以增加超薄润滑膜应用中的润滑层的厚度和/或连续性。
此外,为了改善用于制冷剂压缩机中的滚动轴承的磨损和疲劳寿命(fatiguelife),公知的是将硬化的高氮不锈钢(例如,VC444钢)和氮化硅的滚动元件用于混合滚动轴承。
此外,如果至少一个滚动元件的粗糙度显著高于其余滚动元件的粗糙度,则混合滚动轴承的微点蚀(micropitting)和腐蚀引起的磨损可以显著减少。当具有增大的粗糙度的至少一个滚动元件接触滚道时,至少一个滚动元件的较高的粗糙度值Rq2,N允许(/使得)磨损增加。即使通常应避免增加磨损,但预期的磨损也使滚道中的(在轴承的使用寿命期间出现的)凹痕(/缺口/凹口/凹陷)(indentation)平滑。这也减少了轴承的总体腐蚀,并且延长了轴承的使用寿命。
用于圈和滚道的钢优选为硬化的耐腐蚀钢,例如VC444钢,另一示例是DINX30CrMoN15-1(AMS 5898)。通常,用于UTFT状况的硬化的耐腐蚀轴承钢是指热处理后的硬度≥HRC 58和/或断裂韧性(fracture toughness)为至少14MPa m1/2的轴承钢(ASTM-E399-12)。如果耐腐蚀性的点蚀电位(pitting potential)比根据ASTM G61-86的不锈钢基准(AISI 440C)高大于或等于+25mV,则是进一步优选的。在热处理之后,圈的滚道13、15、23、25被加工成一定尺寸,并且调节所期望的粗糙度。热处理通常包括以下步骤中的一个或多个:
在1000℃至1150℃下奥氏体化;
气体淬火(quench);
在-40℃至-150℃下深冷处理(/零下处理/冷处理)(subzero treatment);
针对不同的尺寸稳定性性质,回火至一定温度。
表1示出了与基准钢AISI 440C相比的被覆盖的钢(covered steel)的一个示例:DIN X30CrMoN15-1(AMS 5898)。它还示出了:对于相同的耐腐蚀钢,不同的回火温度会取得不同的尺寸稳定性性质。
表1耐腐蚀钢参数的示例
优选地,滚动轴承10、20是混合滚动轴承,其中,滚动元件(即,滚子16和球26)是氮化硅(Si3N4)球/滚子:滚动元件16、26通过最严格的陶瓷质量控制和等级制成,并且必须通过ASTM F 2094或ISO 26602I级和II级且滚动元件等级等于或优于G10。
除了如上面提到的粗糙度差之外,本发明人还发现了,优选将用于在UTFT状况下操作(/运行)的应用的混合滚动轴承10、20的滚道和滚动元件的组合粗糙度调节到预定范围。已经证明,具有如下列出的粗糙度值的混合滚动轴承10、20即使在UTFT状况下也特别耐腐蚀引起的磨损:
对于混合球轴承20,适用以下值:
滚道和其余球的组合表面RMS粗糙度Rq为Rq≤4×10-9(1000dm)0.55[米],并且具有增大的粗糙度的至少一个球和滚道的组合表面RMS粗糙度Rq为Rq≤f*4×10-9(1000dm)0.55[米],其中,2≤f≤12,其中Rq被定义为
滚道和其余球的组合粗糙度斜率(roughness slope)参数RΔqx为RΔqx≤8[mrad],并且具有增大的粗糙度的至少一个球和滚道的组合粗糙度斜率参数RΔqx为RΔqx≤f*8[mrad],其中,2≤f≤12,其中RΔqx被定义为
对于混合滚子轴承10,适用以下值:
滚道和其余滚子的组合表面RMS粗糙度Rq为Rq≤5×10-8(1000dm)0.2[米],并且具有增大的粗糙度的至少一个滚子和滚道的组合表面RMS粗糙度Rq为Rq≤f*5×10-8(1000dm)0.2[米],其中,1.2≤f≤18,其中Rq被定义为
滚道和其余滚子的组合粗糙度斜率参数RΔqx为RΔqx≤50[mrad],并且具有增大的粗糙度的至少一个滚子和滚道的组合粗糙度斜率参数RΔqx为RΔqx≤f*50[mrad],其中,1.2≤f≤18,其中RΔqx被定义为
通过为滚动轴承提供附加保护流体涂层,可以实现滚动轴承在由介质润滑的应用中的稳健(/鲁棒)操作(/运行)。由介质(制冷剂)润滑的轴承经常遭受直接暴露于工艺介质,在许多情况下,工艺介质作为润滑剂具有不良的性质,并且不能防止腐蚀或者甚至促进腐蚀。在介质润滑的应用中使用的流体本身可能是腐蚀性的,或者与水分/湿气、其他物质结合或通过老化而产生腐蚀性元素。保护流体(例如,包括防锈添加剂的防腐剂)覆盖功能轴承表面,保护它们,并且防止轴承表面受到化学侵蚀(/化学攻击)。为了保护轴承表面,防腐剂可能包含的添加剂为高碱性磺酸盐(overbased sulfonate)、酰胺和酰亚胺以及环烷酸锌(Zinc naphthenates)。这些添加剂具有结合到极性轴承表面的极性头部和防止其他极性元素与轴承表面接触的非极性尾部。
在将轴承安装到应用中之前,不应去除覆盖轴承表面的保护流体。特殊的轴承处理使得滚动元件轴承能够针对这种苛刻的应用(刚性、简单性、鲁棒性、紧密间隙……)而可靠地操作。
Claims (11)
1.一种滚动轴承,特别是混合滚动轴承,包括:
内滚道,
外滚道,以及
多个滚动元件,配置在所述内滚道与所述外滚道之间,其中,所述滚动轴承是介质润滑的或无油润滑的,其中,
润滑剂在所述滚动元件与滚道之间形成弹性流体动力润滑剂膜,并且其中,
在首次使用所述滚动轴承时,利用保护流体涂覆所述滚动轴承的至少一个表面,优选地,所述保护流体是油基防腐流体。
2.根据权利要求1所述的特别是混合滚动轴承的滚动轴承,其特征在于,所述保护流体是防水/防湿的和/或是疏水性的。
3.根据权利要求1所述的特别是混合滚动轴承的滚动轴承,其特征在于,所述滚动轴承利用形成弹性流体动力润滑剂膜的纯制冷剂或制冷剂混合物来介质润滑。
4.根据权利要求1所述的特别是混合滚动轴承的滚动轴承,其特征在于,特别是所述混合滚动轴承的所述滚动轴承借助于配置在所述滚动元件与所述滚道之间的超薄润滑膜来润滑,并且,所述润滑膜的厚度小于300nm,优选地,所述润滑膜的厚度小于100nm,最优选地,所述润滑膜的厚度小于30nm。
5.根据权利要求1所述的特别是混合滚动轴承的滚动轴承,其特征在于,所述保护流体是具有防腐蚀添加剂的防腐流体。
6.根据权利要求1所述的特别是混合滚动轴承的滚动轴承,其特征在于,所述保护流体或添加剂是具有极性头部和非极性尾部的极性物质,并且,所述极性头部适于结合到轴承表面,所述非极性尾部防止元素与所述轴承表面接触。
7.根据权利要求6所述的特别是混合滚动轴承的滚动轴承,其特征在于,所述极性物质是清净剂、分散剂或抑制剂,并且,优选地,所述防腐流体包括高碱性磺酸盐、酰胺、酰亚胺和/或环烷酸锌。
8.根据权利要求1所述的特别是混合滚动轴承的滚动轴承,其特征在于,至少一个滚道由硬化的耐腐蚀钢制成,所述硬化的耐腐蚀钢的耐腐蚀性的点蚀电位比根据ASTM G61-86的不锈钢基准(AISI 440C)高至少25mV。
9.根据权利要求1所述的特别是混合滚动轴承的滚动轴承,其特征在于,至少一个滚动元件由氮化硅(Si3N4)制成。
10.根据权利要求1所述的特别是混合滚动轴承的滚动轴承,其特征在于,所述滚动元件借助于保持架引导,所述保持架优选由纤维增强材料制成,优选地,所述保持架由玻璃纤维或碳纤维增强的PEEK或者碳纤维材料制成。
11.一种介质润滑的和/或无油的机器,特别是制冷剂压缩机,包括至少一个滚动轴承,特别是混合滚动轴承,所述混合滚动轴承具有:
内滚道;
外滚道;以及
多个滚动元件,配置在所述内滚道与所述外滚道之间,其中,所述滚动轴承是介质润滑的或无油润滑的,其中,
润滑剂在所述滚动元件与滚道之间形成弹性流体动力润滑剂膜,并且其中,
在首次使用所述滚动轴承时,利用保护流体涂覆所述滚动轴承的至少一个表面,优选地,所述保护流体是油基防腐流体。
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