What Solutions Are There When the Load-Carrying Capacity of a Bearing Is Insufficient?

When the load-carrying capacity of a bearing is insufficient, it can lead to premature wear, increased friction, and even bearing failure, which may cause significant operational issues and downtime in various machinery and mechanical systems. Fortunately, there are several methods and solutions available to increase the load-carrying capacity of bearings, ensuring better performance, longevity, and reliability. Below are some common and effective strategies:

1. Increase the Size of the Bearing

One of the most direct and simple approaches to increasing the load-carrying capacity of a bearing is to enlarge its size. By increasing the bearing's diameter, the surface area available for load distribution is expanded, which helps to share the load more effectively. A larger bearing can handle greater forces without experiencing undue stress on its components.

Additionally, adjusting the ratio of the bearing's width to its diameter can also improve its load capacity. Increasing the bearing width can allow for a thicker film of lubricating oil, which reduces the chances of metal-to-metal contact, leading to lower friction and wear. This approach can be particularly useful in applications where space allows for larger bearings without compromising the overall design.

Turbine Bearings

2. Increase the Viscosity of the Lubricating Oil

Lubrication plays a critical role in reducing friction and wear in bearings. One way to enhance the load-carrying capacity is by increasing the viscosity of the lubricating oil. Higher-viscosity oils form thicker lubrication films between the bearing's moving parts, which can help to prevent metal-to-metal contact under heavy loads. This thicker oil film ensures that the load is distributed more evenly and reduces the chances of surface degradation or damage.

However, it is essential to balance the viscosity of the oil with the operating conditions, as overly viscous oils can increase friction at low speeds and impair the bearing’s efficiency. Therefore, selecting the appropriate viscosity for specific conditions, such as load, speed, and temperature, is crucial.

3. Use Bearings with Higher Load-Carrying Capacity

In some cases, the solution may lie in upgrading to a bearing that is specifically designed to handle higher loads. Bearings such as circular bearing bushes and tilting pad thrust bearings are excellent choices for heavy-duty applications. Circular bearing bushes are typically used in cases where the bearing needs to accommodate large radial loads, while tilting pad thrust bearings are ideal for applications that require the handling of axial loads.

Tilting pad thrust bearings, for example, consist of multiple pads that can tilt in response to the load, which allows for an even distribution of pressure across the bearing's surface. This design helps to significantly increase the load-carrying capacity, especially in high-speed and high-load applications such as turbines and large motors.

 tilting pad journal bearing

4. Adopt Hydrostatic and Hydrodynamic Composite Bearings

Hydrostatic and hydrodynamic composite bearings are advanced bearing solutions that use high-pressure oil to create a stable and reliable lubrication film between the bearing surfaces. In hydrostatic bearings, oil is supplied at a high pressure through an external source, which helps to separate the bearing surfaces completely, preventing direct contact and reducing wear and friction. This solution is particularly effective for applications requiring heavy loads and low speeds.

Hydrodynamic composite bearings combine the benefits of both hydrodynamic and hydrostatic principles. These bearings use the motion of the shaft to generate the necessary oil film for lubrication, while also incorporating high-pressure oil at certain points to maintain a stable lubrication layer. This combination can significantly improve the bearing's load-carrying capacity, especially in applications where the load varies or is extremely high.

5. Use Bearing Bushes Made of PTFE Composite Materials

Bearings made from PTFE (polytetrafluoroethylene) composite materials offer excellent performance in terms of load capacity and wear resistance. PTFE is a high-performance plastic known for its low friction, high wear resistance, and ability to withstand harsh operating conditions. Bearings made from PTFE composites can carry heavier loads without experiencing excessive wear, making them an ideal choice for applications that require long-lasting, high-performance bearings.

PTFE composite materials are often used in self-lubricating bearings, as they reduce the need for external lubrication. This makes them ideal for environments where maintaining lubrication is challenging, such as in high-temperature or underwater applications.

Conclusion

To address insufficient load-carrying capacity in bearings, there are various methods available, each tailored to different operational needs and environments. Whether by increasing the bearing size, enhancing lubrication, upgrading to higher-capacity bearings, or adopting advanced bearing technologies such as hydrostatic or hydrodynamic composite bearings, each solution plays a vital role in ensuring that the bearing can withstand heavy loads without compromising performance or durability. Choosing the right solution depends on the specific requirements of the application, including load, speed, temperature, and space constraints, ensuring optimal performance and longevity of the bearing system.