How to replace double row ball slewing bearing

Replacing a double-row ball slewing bearing is a complex and critical procedure that typically requires specialized knowledge, equipment, and adherence to manufacturer guidelines. It’s not a DIY job for most individuals, especially given the heavy machinery and safety implications involved.

This is a general overview, and you MUST consult the specific manufacturer’s manual for your equipment and bearing model for precise instructions and safety protocols.

Double-row Ball Slewing Bearing Replacement

Double-row Ball Slewing Bearing

I. Pre-Replacement Assessment and Preparation:

Safety First:

Disconnect Power: Ensure the machinery is completely de-energized and all power sources are locked out/tagged out.

Secure the Load: If the bearing supports a structure (e.g., crane boom, excavator arm), secure it properly to prevent accidental movement.

Personal Protective Equipment (PPE): Wear appropriate PPE, including hard hat, safety glasses, gloves, and steel-toed boots.

Stable Position: Ensure the entire machine is in a stable position before starting any work.

Assessment of Existing Bearing:

Thoroughly inspect the old bearing for signs of wear, damage, corrosion, or any other issues that might have led to its failure. This can provide insights into potential root causes.

Check for loose bolts, seal integrity, and any abnormal noises or movements.

Gather Necessary Tools and Equipment:

Heavy-duty lifting equipment (cranes, forklifts, hoists).

Torque wrenches (calibrated for high torque values).

Specialized tools for removing and installing large bolts.

Feeler gauges for checking flatness and gaps.

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For more information on how to replace double row ball slewing bearings, please click here:https://www.mcslewingbearings.com/a/news/double-row-ball-slewing-bearing-replacement.html

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Double row slewing bearing noise fault how to troubleshoot

Double-row slewing bearings are crucial components in many heavy-duty machines, and noise can be a significant indicator of an underlying problem. Troubleshooting the noise involves a systematic approach to identify the cause and implement the correct solution.

Double row slewing bearing noise troubleshooting

Double-row slewing bearings

1. Identify the Type of Noise and When it Occurs:

Normal Sounds: A new slewing bearing might produce a soft, uniform rolling sound of steel balls. This is usually normal and may fade after some rotation.

Abnormal Loud Noise: This indicates a problem and requires attention.

Grinding, Popping, Clicking, or Cracking: These are strong indicators of issues.

When does it occur?

New Bearing (before/after installation): Could be slight deformation from transport or improper installation.

Bearing in Service (after some use): Likely wear, lubrication issues, contamination, or loose components.

Under Load vs. No Load: Helps differentiate between issues related to stress and more general problems.

2. Initial Checks (General Troubleshooting):

Confirm the Source: Is the noise definitely coming from the slewing bearing? Sometimes, noises from other steel structures or components can be mistaken for bearing noise. Try stopping the slewing ring’s rotation while other components continue to work to isolate the sound.

Lubrication: This is often the first and easiest thing to check.

Lack of Grease: Insufficient or aged grease can cause rolling elements and separators to rub, creating noise. Timely greasing (every 100-250 hours of operation, or more frequently in harsh conditions) can often eliminate this.

Inspect Purged Grease: When you pump new grease into the bearing, observe the old grease that is purged out. If you see grit, metal particles, or flakes, it indicates wear or contamination.

Incorrect Lubricant: Using the wrong type of grease or one with unsuitable viscosity can also lead to poor lubrication and noise.

Oil Leakage: Check for signs of oil leakage, which can indicate damage to seals or improper lubrication practices.

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For more detailed information on how to troubleshoot noise problems with double-row slewing bearings, please click here:https://www.mcslewingbearings.com/a/news/double-row-slewing-bearing-noise-troubleshooting.html

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What are the principles of seismic design of steel structures?

Seismic design of steel structures is based on several key principles aimed at ensuring life safety, minimizing damage, and maintaining functionality during and after an earthquake. These principles leverage the inherent properties of steel, such as its strength and ductility.

Seismic Design Principles for Steel Structures

Steel Structures

Ductility and Energy Dissipation (Inelastic Behavior):

It’s generally not economical to design structures to remain purely elastic during a major earthquake. Instead, the design philosophy allows for controlled inelastic deformation (yielding) in specific, pre-determined locations within the structure.

Steel is an excellent material for this due to its high ductility, meaning it can deform significantly beyond its elastic limit without fracturing.

This inelastic deformation dissipates seismic energy, reducing the forces transmitted to the rest of the structure and the building’s contents.

This is often achieved through the formation of “plastic hinges” in beams or other designated “fuse” elements.

Capacity Design:

This is a crucial principle that ensures a hierarchy of strength within the structural system. The idea is to force inelastic action (energy dissipation) to occur in ductile elements (e.g., beams, special connections) while ensuring that brittle elements (e.g., columns, foundations, critical connections) remain elastic and retain their strength.

This prevents a sudden and catastrophic collapse. For instance, in moment-resisting frames, the “strong column-weak beam” concept is applied, where columns are designed to be stronger than the beams framing into them, ensuring that plastic hinges form in the beams rather than the columns.

Steel Structures

Redundancy:

A redundant structural system provides multiple load paths, meaning if one element or path fails, the loads can be redistributed to other elements, preventing progressive collapse. This enhances the overall robustness of the structure under seismic loading.

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For more detailed information on the principles of seismic design for steel structures, please click here:https://www.meichensteel.com/a/news/seismic-design-principles-for-steel-structures.html

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What is the price per ton of prefabricated steel structure?

Prefabricated steel structures have become a popular choice in modern construction due to their strength, durability, and cost-effectiveness. One of the most common questions buyers and contractors have is about the price per ton of prefabricated steel. The price per ton of prefabricated steel structure can vary significantly due to several factors, including the type of steel, complexity of fabrication, project size, supplier, market conditions, and location.

Prefabricated Steel Structure Price Per Ton

Prefabricated steel structures

Based on current information (late 2024 – mid 2025):

Raw Steel Prices: Raw steel prices have fluctuated, with recent figures around $700-$900 per ton. Some sources indicate prices reaching up to $1100 per ton in 2025 due to potential tariffs and market uncertainties.

Fabricated/Structural Steel Prices (including raw material, fabrication, and delivery): You can expect to see prices for structural steel, which includes the raw material, fabrication, and often delivery, ranging from $300 to $750 per ton for certain components or larger projects, though some sources list ranges of $400-$700 per ton for general structural steel. Some suppliers may quote as low as $10-$80 per ton for specific, large-volume components or very basic structures, while others may list a broader range up to $650 per ton.

Installed Prefabricated Steel Structures (including raw material, fabrication, delivery, and installation): When considering the full cost of a prefabricated steel structure, which includes the raw steel, fabrication, delivery, and installation on-site, the price per ton is often incorporated into a per-square-foot cost. However, one source explicitly states that the price per ton of structural steel erected on site (including raw steel, fabrication, delivery, and installation) is around $4,000 per ton.

Important Considerations that influence the price:

Prefabricated steel structures

Project Scope and Complexity: Larger and more complex designs with specialized components will generally have a higher cost per ton.

Steel Grade and Type: Different grades (e.g., Q235, Q345B) and types of steel (e.g., H-beams, I-beams, galvanized) have varying costs.

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For more details about the price per ton of prefabricated steel structures, please click here:https://www.meichensteel.com/a/news/prefabricated-steel-structure-price-per-ton.html

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Comparing Steel Workshop Prices: What Affects the Cost per Square Meter?

The cost per square meter for a steel structure workshop can vary significantly, ranging from as low as $10 to $25 per square foot (approx. $107-$269 per square meter) for basic kits, to $20 to $50 per square foot (approx. $215-$538 per square meter) for fully installed prefab buildings, and even $50 to $200+ per square foot (approx. $538-$2150+ per square meter) for custom-built or industrial-grade structures.

Factors affecting the price of steel structure workshop

steel structure workshop

1. Material Prices:

Steel market fluctuations: Global demand, tariffs, and local availability directly impact the price of steel.

Type and quality of steel: Higher-grade steel offers better durability and strength but comes at a higher cost.

Auxiliary materials: Costs for bolts, welding materials, coatings, insulation, roofing, and foundation materials also add up.

2. Design Complexity and Customization:

Standard vs. custom designs: Simple, standard structures are generally less expensive than custom designs with unique features, layouts, or aesthetics.

Building dimensions: Larger buildings require more materials, but often benefit from economies of scale, leading to a lower cost per square foot for very large structures. However, buildings above a certain width (e.g., 32 feet) may require additional structural support (webbed trussing), increasing costs.

Features and accessories: The number of doors, windows, internal walls, mezzanines, skylights, specialized wall panels, and roof styles (e.g., vertical siding vs. horizontal) all add to the material and labor costs.

Load requirements: Designs that need to withstand specific snow loads, wind loads, or seismic loads will affect the structural design and materials used, increasing costs.

3. Labor Costs:

Regional labor rates: These can vary significantly by location.

Skilled labor availability: Shortages in skilled labor can drive up wages.

Construction difficulty: Complex designs or challenging site conditions can increase labor hours.

Pre-engineered metal buildings (PEMBs): These often speed up assembly and can help lower labor costs compared to traditional construction.

DIY construction: For smaller buildings, this can save on labor but requires expertise.

4. Location and Site Preparation:

Geographical location: Material prices, labor costs, and tax policies differ by region. Remote locations may also incur higher transportation costs.

Site accessibility: Difficult-to-access sites can increase delivery and construction costs.

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More about steel structure factory building price comparisons: What affects the cost per square meter? For detailed information, please click to visit:https://www.meichensteel.com/a/news/factors-affecting-the-price-of-steel-structure-workshop.html

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How about the load capacity of the steel structure workshop?

The load capacity of a steel structure workshop is not a single, fixed number; it’s a complex calculation that depends on many factors and is determined during the engineering design process to ensure safety and functionality.

Steel Structure Workshop Load Capacity

steel structure workshop

1. Types of Loads:

Dead Loads (Permanent Loads): These are constant and include the weight of the structure itself (steel beams, columns, roof, walls), as well as fixed elements like permanent flooring, ceilings, and fixed equipment.

Live Loads (Variable Loads): These loads change over time and are due to the intended use of the workshop. They include:

Occupancy loads: Weight of people.

Equipment loads: Weight of machinery, tools, vehicles.

Storage loads: Weight of materials, inventory.

Crane loads: If the workshop has overhead cranes, these are significant dynamic loads that need careful consideration.

Environmental Loads: These are natural forces that the building must withstand:

Wind Loads: Forces exerted by wind blowing against the building. These vary with location, building height, and shape.

Snow Loads: Weight of snow accumulation on the roof, determined by local climate and roof slope.

Seismic (Earthquake) Loads: Forces generated by earthquakes, especially critical in seismically active regions.

Thermal Loads: Forces generated by temperature changes causing expansion or contraction of materials.

2. Design Standards and Codes:

Building codes (e.g., ASCE 7 in the US, Eurocodes) provide minimum design load requirements for different types of structures and occupancies. Engineers must adhere to these codes to ensure safety.

Load factors are applied to the expected loads to account for uncertainties and potential extreme events, determining the “design loads” used for sizing structural members.

steel structure workshop

3. Structural Design Considerations:

Structural System: The chosen structural system (e.g., portal frame, truss, frame structure) significantly impacts load distribution and capacity. Portal frames are common for industrial workshops with small to medium spans.

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For more detailed information about the load capacity of welding positioners, please click here:https://www.meichensteel.com/a/news/steel-structure-workshop-load-capacity.html

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What is Welding Positioner Load Capacity?

Welding positioners are crucial pieces of equipment in fabrication and welding shops, designed to hold and manipulate workpieces, allowing welders to achieve optimal positions for welding. Understanding their load capacity is essential for safe and efficient operation.

Welding positioners are crucial pieces of equipment in fabrication and welding shops, designed to hold and manipulate workpieces, allowing welders to achieve optimal positions for welding. Understanding their load capacity is essential for safe and efficient operation.

What is Welding Positioner Load Capacity?

Welding Positioner

Welding positioner load capacity refers to the maximum weight and associated forces a positioner can safely handle while rotating and tilting a workpiece. It’s not just about the raw weight; it’s a combination of the workpiece’s weight and its center of gravity (CG).Manufacturers typically specify load capacity on a “capacity plate” or in the equipment’s documentation. This often includes:

Maximum Weight Capacity: The absolute maximum weight the positioner can hold.

Tilt Torque Load: The maximum rotational force the positioner can handle when tilting the workpiece.

Rotation Torque Load: The maximum rotational force the positioner can handle when rotating the workpiece.

Center of Gravity (CG) Distance: This is critical. The further the workpiece’s CG is from the positioner’s table surface (for tilt) or the center of the table (for rotation), the greater the torque applied to the positioner, even with the same weight.

How is Welding Positioner Load Capacity Calculated?

The load capacity is heavily influenced by the torque exerted by the workpiece on the positioner’s mechanisms (motor, gears, bearings). Torque is a twisting force, calculated as:

Torque = Weight × Distance

Here’s how this applies to positioners:

Determine the total weight of the weldment: This includes the workpiece itself, any fixtures, chucks, or tooling attached to it.

Calculate the Center of Gravity (CG) of the work:

Distance from the face of the table (for tilt torque): This is the perpendicular distance from the table surface to the workpiece’s CG.

Distance from the rotational center of the table (for rotation torque, also known as eccentricity): This is the parallel distance from the center of the table to the workpiece’s CG. For asymmetrical workpieces, this is crucial.

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For more detailed information about the load capacity of welding positioners, please click here:https://www.bota-weld.com/en/a/news/welding-positioner-load-capacity.html

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Welding positioner torque requirements explained

Welding positioner torque requirements are crucial for selecting the right equipment to safely and efficiently manipulate a workpiece during welding. Understanding these requirements ensures the positioner can handle the weight and dimensions of your weldment without damage or instability.

Welding Positioner Torque Requirements Explained

What is Torque in this Context?

In the context of welding positioners, torque refers to the rotational or twisting force that the positioner’s motors and gearing must exert to move and hold the workpiece in various orientations. There are typically two main types of torque to consider:

Rotational Torque: The force required to rotate the workpiece around its axis (e.g., spinning a pipe).

Tilting Torque: The force required to tilt the workpiece from horizontal to vertical or any angle in between.

Key Factors Affecting Torque Requirements

The torque requirements for a welding positioner are primarily determined by the characteristics of the workpiece and how it’s mounted. Here are the main factors:

Weight of the Workpiece (and Fixture): This is the most significant factor. The heavier the workpiece, the more force (and thus torque) is needed to move and hold it. Don’t forget to include the weight of any chucks, clamps, or custom fixtures used to hold the workpiece.

Center of Gravity (CG): This is the point where the entire weight of an object appears to act. Its location is critical:

Distance from the table’s rotational center (Eccentricity): For rotational torque, the further the CG is from the center of rotation, the greater the rotational torque required. This is especially important for irregularly shaped parts or those with significant offset loads (like pipe elbows or Tees).

Distance from the table’s tilting pivot point (Gravity Center Distance + Inherent Overhang): For tilting torque, the further the CG is from the tilt axis, the more tilting torque is needed. “Inherent overhang” is the fixed distance from the tilting pivot point of the table to its surface.

Workpiece Shape and Dimensions: Large, unwieldy, or asymmetrical workpieces can create larger moments (force x distance) and thus higher torque demands, even if their absolute weight isn’t extreme.

Desired Positioning Speed: While not directly a torque requirement, faster rotation or tilting speeds generally require more powerful motors, which are often associated with higher torque capabilities.

Welding Process and Material: While less direct, certain welding processes might require very precise and stable positioning, indirectly influencing the need for a robust positioner with sufficient torque to prevent any unwanted movement.

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For more detailed information about torque requirements for welding positioners, please click here:https://www.bota-weld.com/en/a/news/welding-positioner-torque-requirements.html

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How to choose welding column boom size and stroke

Choosing the correct size and stroke for a welding column and boom manipulator is crucial for maximizing efficiency, quality, and safety in your welding operations. It essentially comes down to understanding the dimensions of your workpieces and the required welding processes.

How to choose welding column boom size and stroke

welding column and boom

1. Understand the Terminology:

Column (Vertical Travel/Lift): This refers to the vertical height the boom can extend up and down. It’s often expressed as the “vertical reach” or “column stroke.”

Boom (Horizontal Travel/Reach): This refers to the horizontal distance the welding head can extend outwards from the column. It’s often expressed as the “boom reach” or “horizontal stroke.”

Load Capacity: The maximum weight the end of the boom can safely support, including the welding head, wire feeder, flux recovery unit, camera systems, and any other accessories. This is critical for safety and operational stability.

2. Key Factors to Consider for Sizing and Stroke:

Workpiece Dimensions (Length, Diameter, Height):

Maximum Length of Longitudinal Welds: The boom’s horizontal stroke needs to be at least as long as the longest longitudinal weld you’ll be performing. If you’re welding very long components, you might consider a column and boom mounted on a travel car or even a gantry system for extended reach.

Maximum Diameter/Height of Circumferential Welds: The column’s vertical stroke needs to accommodate the height of your largest workpiece when mounted on a positioner or turning rolls. The boom also needs to be able to reach the top and bottom of the circumference. Consider the “minimum height under boom” and “maximum height under boom” specifications.

Minimum Diameter/Height of Workpieces: Ensure the column and boom can retract sufficiently to work on smaller pieces without interference.

Welding Process and Equipment:

Weight of Welding Head and Accessories: Submerged Arc Welding (SAW) heads with flux hoppers and recovery systems are typically heavier than MIG or TIG setups. Factor in the weight of all attachments when considering the boom’s load capacity.

Additional Equipment: If you’re adding cross-slides, seam trackers, laser pointers, or operator platforms, these will add weight and potentially affect the required reach.

Shop Layout and Space Constraints:

Overhead Clearance: Ensure there’s enough vertical space in your facility for the column to extend to its full height.

Floor Space: Consider the footprint of the column and boom, especially if it’s a movable unit on rails.

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For more detailed information on how to choose the welding column arm size and stroke, please click here: https://www.bota-weld.com/en/a/news/how-to-choose-welding-column-boom-size-and-stroke.html

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What is the difference between a welding column boom and a welding robot?

In modern welding automation, both welding column boom systems and welding robots play critical roles in improving efficiency, precision, and safety. While they may seem similar in purpose, these two systems are designed for different applications and operate using distinct principles. While both a welding column boom and a welding robot are automated tools used to improve welding processes, they differ significantly in their design, flexibility, and applications.

Difference Between A Welding Column Boom and A Welding Robot

Welding Column Boom (Manipulator)

Design: A column boom system typically consists of a vertical column mounted on a stable base and a horizontal boom that extends from the column. The welding head is mounted on the end of the horizontal boom. The column allows for vertical movement, and the boom provides horizontal reach. Many also allow for 360-degree rotation of the column.

Movement & Control: Column booms offer precise linear and rotational movement. They are designed to move the welding torch along a pre-defined path, primarily for long, straight, or circumferential welds on large workpieces. While they can have advanced controls and often integrate with other automated equipment (like welding positioners or turning rolls), their motion is generally less complex and more constrained than a robot. They are manipulators that move the welding material to the workpiece, rather than moving the workpiece itself.

Flexibility: They are highly effective for repetitive, large-scale welding tasks on substantial components. However, they are less adaptable to complex, irregular geometries or tasks requiring multiple axes of motion beyond basic linear and rotational movement.

Applications: Commonly used in heavy equipment manufacturing, shipbuilding, pressure vessel fabrication, tank and pipe welding, and large-scale construction projects where long, consistent welds are required.

Advantages:

Excellent for long, continuous welds.

Can handle heavy welding heads and associated equipment (e.g., flux recovery systems for SAW).

Improves safety by removing welders from hazardous environments.

Enhances weld quality and consistency for their specific applications.

Can reduce welder fatigue.

Welding Robot

Design: A welding robot is typically a multi-axis articulated arm (similar to a human arm) that can move in numerous directions (typically 4, 6, or more axes). The welding torch is attached to the “wrist” of the robot.

Movement & Control: Robots are highly programmable and can perform complex, intricate movements. They use advanced controllers and software to execute precise welding paths, often guided by machine vision or touch sensing for adaptability. They can navigate around obstacles and weld in tight spaces.

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For more detailed information about the difference between welding column boom and welding robot, please click here: https://www.bota-weld.com/en/a/news/difference-between-welding-column-boom-and-welding-robot.html

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