Bearing: Long-Term Consequences of Neglecting Replacement

Have you neglected the necessary replacement time for bearings?

Bearings are ubiquitous in the machinery industry, though they often go unnoticed. While some may jokingly refer to them as "Bread and Butter," I believe they are just as crucial as the machinery itself.

Many people neglect bearing replacement for long periods, assuming that once they handle the initial installation, adjustment, and lubrication, they don’t need to think about it again.

What I want to stress is that neglecting bearing replacement can lead to serious and unpredictable issues. To clarify this point, this article will use “Ball Bearings” as a case study to illustrate the importance of regular bearing replacement and provide relevant operational insights.

1. Effects of Neglecting Bearing Replacement

If ball bearings are not replaced as needed, the lubricating oil will deplete over time, resulting in metal-on-metal friction and excessive wear. This wear can increase noise, cause vibrations, and compromise the equipment’s stability and accuracy. Eventually, the ball bearings may seize or collapse, leading to equipment failure and reduced production efficiency and safety.

2. How to identify whether the bearing is faulty

Abnormal noise is often a key indicator of faulty ball bearings. When a ball bearings is misaligned with its seat or its lubricant is exhausted, it usually produces noticeable grinding or squealing sounds, indicating potential damage to the ball bearings' internal structure. Excessive vibration or rough movement can also signal problems within the ball bearings.

Regularly checking for these symptoms is crucial for mechanical safety and efficiency. If you're unsure, use vibration analysis tools such as vibration analyzers or accelerometers, or consult professional maintenance personnel regarding the ball bearings.

3. How to determine when a bearing needs to be replaced

When obvious signs of wear, such as noise, vibration, or performance degradation, appear, consult the manufacturer's ball bearings instruction guide for details on ball bearings lifespan and abnormal status indicators. Evaluate the condition of the ball bearings based on this information. If the ball bearings fail the assessment or show significant performance degradation, they should be replaced promptly.

4. Bearing Replacement Cost

The cost of bearing replacement is estimated as follows, taking ball bearings used in large, medium, and small machines as examples:

Large machines:

Example: Large industrial motors, heavy machinery and equipment

Cost estimate: The price of each ball bearings ranges from $200 to $2,000, depending on its size and specifications. Large machines typically require larger ball bearings, and replacing multiple ball bearings at once can raise the total cost. Considering installation and other maintenance, the overall expense for ball bearings may range from $2,000 to $10,000 or more.

Medium machines:

Example: Medium-sized industrial equipment, lathes, pumps

Cost estimate: The price of each ball bearings typically ranges from $50 to $500. Medium-sized machines generally use medium-sized ball bearings, and if several ball bearings need replacement, the total cost—including installation—may range from $500 to $2,000.

Small machinery:

Example: Small motors, household appliances

Cost estimate: Each ball bearing costs from $10 to $100. Small machinery usually requires smaller ball bearings and fewer replacements, and the total cost may be between $100 and $500.

Notes:

• The above costs are estimated prices, please take the actual price as the main factor.
• The brand and quality of the ball bearings will also affect the final cost price.
• The installation fee is added to take into account that large machinery may require professional operation.
• If the machinery has been damaged, the estimated cost should be higher. If necessary, Contact JLCMC for a quote.

5. Time required to replace the bearing

It usually takes several hours or a whole day to replace a ball bearings, mainly depending on the complexity of the machinery and the experience of the operator. Screening and purchasing the ball bearings that need to be replaced in advance, and disassembling the machinery during procurement can help speed up the process and minimize downtime.

6. What if the new bearing fails?

If the new ball bearings fail to meet expectations, check for installation errors or compatibility issues. Reassess its load capacity, verify the specifications, and ensure all details are accurate. Confirm that the replacement process follows the manufacturer's instructions. If problems persist, consult professionals or the manufacturer.

Given the critical role and widespread use of ball bearings, regular attention and maintenance are essential. Bearing issues can affect the entire machine, making ongoing maintenance a valuable investment compared to the cost of major repairs.

JLCMC understands the high cost of factory mechanical parts and offers cost-effective ball-bearing replacement solutions. Click the image link below to become our member and enjoy more affordable and better quality mechanical parts procurement. Welcome to JLCMC’s Online Wholesale Store.