Split Type Cylindrical Roller Bearing

Split-type cylindrical roller bearings are specialized rolling bearings designed for large-scale heavy-load equipment and hard-to-disassemble shaft components. Their core feature is "radial splitability of inner/outer rings". By dividing the bearing into 2-4 independent segments, they completely solve the pain points of traditional integral bearings-such as "difficult installation, high maintenance costs, and long downtime"-on large main shafts and long shaft systems. In industries like metallurgy, mining, and wind power, they have become key supporting components that "reduce equipment operation and maintenance costs and ensure continuous production". Their radial load-bearing capacity is equivalent to that of integral bearings, while their installation and maintenance efficiency is improved by 3-5 times.​

I. Product Structure: Maintenance-Oriented Gene of Split Design​

The structural design of split-type cylindrical roller bearings focuses on the dual goals of "convenient installation, efficient maintenance" and "heavy-load bearing", with targeted optimization of core components:​

(I) Core Component Design​

Split Inner/Outer Rings: According to the requirements of the shaft system, there are three forms: "inner ring split", "outer ring split", or "double split of inner and outer rings". The split surfaces adopt a "precision docking + positioning pin/bolt locking" structure, with a flatness error of ≤0.005mm and a gap of ≤0.002mm, ensuring that the geometric accuracy after assembly is consistent with that of integral bearings (radial runout ≤0.01mm). The inner/outer rings are made of high-strength bearing steel (GCr15SiMn, SUJ2) or carburized bearing steel (20CrNiMo), undergoing integral forging, segmental processing, and quenching. Their hardness reaches HRC 60-64, ensuring that the structural strength after splitting is not lower than that of integral bearings.​

Rollers and Cages: Cylindrical rollers are used, with a diameter 5%-10% larger than that of integral bearings of the same size. The roller surfaces undergo super-finishing grinding (Ra ≤0.2μm) and crowned modification to reduce contact stress at the raceway edges. The cages are mostly solid brass cages or segmented steel cages; some heavy-load models adopt a "full-complement roller" design (without cages), increasing the number of rollers by 20%-30%. This improves the radial load-bearing capacity by 30%-40% compared with caged models, making them suitable for extreme heavy-load scenarios.​

Sealing and Positioning Structures: In terms of sealing, a "double-lip seal + labyrinth composite seal" is equipped, adapting to dusty and humid working conditions with an IP65 protection rating, which can effectively block dust and cooling fluid. In terms of positioning, the inner ring is fixed to the shaft journal via an adapter sleeve or withdrawal sleeve, and the outer ring is locked via bearing housing steps and bolts. During disassembly, there is no need to remove other components of the shaft system-only the locking parts need to be removed to take down the bearing segments.​

(II) Assembly and Precision Control​

During assembly, positioning pins are used to ensure precise alignment of each split segment, and the bolt preload is strictly controlled (50-200N·m depending on the bearing size) to avoid deformation of the split surfaces due to uneven force. After assembly, radial runout and end runout tests are required to ensure the precision meets equipment requirements (usually Grade P5-P6). The radial clearance can be precisely controlled via adjusting shims or adapter sleeves (clearance range: 0.02-0.08mm).​

II. Product Performance: Dual Advantages of Heavy-Load Bearing and Convenience​

Heavy-Load Bearing Capacity: The basic dynamic load rating is equivalent to that of integral cylindrical roller bearings of the same size; some full-complement roller models even show an improvement of 30%-40%. Taking a split-type bearing with an inner diameter of 300mm (e.g., 23160CAK/W33) as an example, its basic dynamic load rating can reach 1800-2000kN, stably bearing radial loads of 1000-1500kN. It is suitable for heavy-load equipment such as large rolling mill backup rolls and wind turbine main shafts.​

Installation and Maintenance Efficiency: During installation, there is no need to pull the shaft out of the equipment-only the split segments need to be spliced and fixed on the shaft journal. The installation time is reduced by 70%-80% compared with integral bearings (e.g., for a bearing with a diameter of 1m, integral installation takes 8-12 hours, while split-type installation only takes 2-3 hours). During maintenance, segmented disassembly is possible without shutting down and disassembling the entire equipment; maintenance downtime is shortened from the traditional 3-5 days to 12-24 hours, significantly reducing the enterprise's production loss due to shutdown.​

Operational Stability: The radial rigidity is equivalent to that of integral bearings, with radial deformation ≤0.015mm and shaft radial runout controlled within 0.008mm. It is suitable for low-speed heavy-load equipment (rotational speed ≤1500r/min), with an operating noise of ≤75dB and vibration velocity of ≤2.8mm/s. The performance difference from integral bearings is less than 5%, ensuring equipment operational precision.​

III. Product Model Classification: Adapting to Scenarios by Split Form​

Based on split positions and application requirements, split-type cylindrical roller bearings are mainly classified into the following mainstream models, each with clear functions and applicable scenarios:

IV. Application Fields: Maintenance Innovation for Large Heavy-Load Equipment​

Metallurgical Industry: Used as backup roll bearings for large hot strip mills and cold strip mills, with an inner diameter of up to 1-2m. Traditional integral bearings require disassembly of the rolling mill stand for installation, taking 3-5 days; split-type bearings can be replaced in only 12-24 hours. They can also bear radial rolling forces of 2000-3000kN, ensuring continuous production of the rolling mill.​

Wind Power Industry: Adapted as main shaft bearings for wind turbines above 1.5MW. The main shaft of a wind turbine is installed in the tower; replacing integral bearings requires hoisting the main shaft, which is costly and time-consuming. Split-type bearings can be installed and maintained in segments inside the tower, reducing maintenance costs by 50%-60%. They can also bear radial loads (800-1200kN) generated by the main shaft's self-weight and wind loads.​

Mining Machinery Industry: Applied as main shaft bearings for large jaw crushers and cone crushers. The crusher main shaft is fixed in the frame; replacing integral bearings requires disassembling the entire machine. Split-type bearings can be disassembled in segments, shortening maintenance time from 3 days to 1 day. Meanwhile, they can bear impact loads (single impact ≤500kN) generated by ore crushing.​

Energy Equipment Industry: Used as rotor bearings for large hydro generators and thermal power units, with a diameter of up to 2-3m. Traditional maintenance requires shutting down and disassembling the stator and rotor, taking 1-2 weeks; split-type bearings can be maintained in segments, shortening downtime to 2-3 days and ensuring stable power generation of energy equipment.

V. Core Advantages of the Product​

Significantly Reduce Operation and Maintenance Costs: Installation and maintenance time is reduced by 70%-80%, minimizing equipment downtime losses (e.g., for metallurgical enterprises, hourly downtime losses can reach tens of thousands of yuan). There is no need to remove other components of the shaft system, avoiding damage to associated components caused by disassembly and reducing maintenance costs by 30%-50%.​

Adapt to Large Hard-to-Disassemble Shaft Systems: For large equipment main shafts and long shaft systems (shaft length >5m, diameter >1m), it solves the problems of integral bearings-such as "inability to pass through the shaft end" and "requiring equipment disassembly"-expanding the application range of cylindrical roller bearings in ultra-large equipment.​

Uncompromised Heavy-Load Performance: The split structure design does not affect load-bearing capacity; the basic dynamic load rating and radial rigidity are equivalent to those of integral bearings, and some full-complement roller models even perform better. It meets the load-bearing requirements of large heavy-load equipment, with no significant differences in operational precision and stability.​

Strong Adaptability to Working Conditions: Diverse sealing solutions adapt to harsh working conditions such as dust, humidity, and high temperatures (≤200℃). The split structure facilitates regular inspection of internal wear, enabling early fault warning, avoiding sudden shutdowns, and extending the equipment's mean time between failures (MTBF) by 30%-40%.​

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