固体润滑剂嵌入式轴承：免维护运行的优选解决方案
Solid Lubricants Embedded Bearing: The Ultimate Solution for Maintenance-Free Operation
1. What Are Solid Lubricants Embedded Bearings?
1. 什么是固体润滑剂嵌入式轴承？
Solid Lubricants Embedded Bearings (also known as Self-Lubricating Bearings, Oilless Bearings, or JDB Bearings) are advanced sliding bearings that integrate solid lubricants directly into a metallic or non-metallic matrix. Unlike traditional bearings requiring continuous external lubrication, these bearings release lubricant during operation to form a durable tribofilm, enabling maintenance-free performance even under extreme conditions.
固体润滑剂嵌入式轴承（又称自润滑轴承、无油轴承或JDB轴承）是一种将固体润滑剂直接集成到金属或非金属基体中的先进滑动轴承。与传统轴承需要持续外部润滑不同，这类轴承在运行过程中会释放润滑剂形成持久的摩擦膜，即使在极端条件下也能实现免维护性能。
These bearings break through the limitations of conventional oil-film-dependent bearings, making them ideal for high-temperature, heavy-load, anti-corrosion, or hard-to-lubricate applications. They combine the high load-bearing capacity of metals with the low friction properties of solid lubricants like graphite, PTFE, or molybdenum disulfide (MoS₂).
这类轴承突破了传统油膜润滑轴承的局限，非常适合高温、重载、防腐或难以润滑的应用场景。它们将金属的高承载能力与石墨、PTFE或二硫化钼（MoS₂）等固体润滑剂的低摩擦特性相结合。
2. How Do They Work? Self-Lubricating Mechanism
2. 工作原理：自润滑机制
The self-lubricating system operates through a continuous cycle of lubricant release, transfer, and regeneration:
自润滑系统通过 润滑剂释放、转移和再生 的连续循环运作：
Embedded Lubricant Release: During friction, solid lubricant plugs (graphite or MoS₂) are gradually discharged from machined cavities onto the sliding surface.
嵌入式润滑剂释放：在摩擦过程中，固体润滑剂塞（石墨或MoS₂）从加工孔穴中逐渐释放到滑动表面。
Tribofilm Formation: The lubricant transfers to the counterpart shaft, creating a low-shear-strength solid lubrication film that separates friction pairs.
摩擦膜形成：润滑剂转移到对偶轴上，形成低剪切强度的固体润滑膜，将摩擦副分离。
Self-Regeneration: As the bearing wears minimally, fresh lubricant continuously replenishes the film, ensuring lifelong lubrication without external intervention.
自再生：随着轴承轻微磨损，新鲜润滑剂持续补充润滑膜，确保终身润滑而无需外部干预。
This mechanism allows the bearing to perform reliably in dry, dusty, underwater, or chemically aggressive environments where oil or grease would fail.
该机制使轴承能在干燥、粉尘、水下或化学腐蚀环境中可靠运行，这些环境下油脂润滑会失效。
3. Material Composition & Structural Design
3. 材料构成与结构设计
3.1 Matrix Materials (Base Alloys)
3.1 基体材料（合金类型）
3.2 Solid Lubricant Types
3.2 固体润滑剂类型
4. Core Performance Advantages
4. 核心性能优势
✔ Maintenance-Free Operation
✔ 免维护运行
Eliminates the need for regular greasing, reducing downtime and labor costs by up to 90%.
无需定期加脂，减少停机时间和人工成本高达90%。
✔ Superior Load Capacity
✔ 优异承载能力
High-strength brass matrix supports static loads up to 300 N/mm² and dynamic loads up to 130 N/mm², outperforming most polymer bearings.
高力黄铜基体可承受静载荷达300 N/mm²，动载荷达130 N/mm²，性能优于大多数聚合物轴承。
✔ Wide Temperature Range
✔ 宽温域适应
Operates reliably from -80°C to +400°C, surpassing conventional lubricants that degrade at high temperatures.
可在-80°C至+400°C可靠运行，超越传统润滑剂的高温降解极限。
✔ Exceptional Wear Resistance
✔ 卓越耐磨性
Friction coefficient as low as 0.05-0.12, with wear life 3-5 times longer than traditional bronze bushings.
摩擦系数低至0.05-0.12，使用寿命是传统铜套的3-5倍。
✔ Corrosion & Contamination Resistance
✔ 耐腐蚀与抗污染
Performs in seawater, acidic/alkaline solutions, and dusty environments without lubricant contamination.
可在海水、酸碱溶液和粉尘环境中工作，无润滑剂污染风险。
5. Primary Applications by Industry
5. 主要行业应用领域
5.1 Water Conservancy & Hydropower
5.1 水利水电工程
Gate roller bearings (定轮轴承): Work gates, emergency repair gates
Arc gate hinge bearings (弧门支铰): Radial and axial composite loads
Hydraulic hoist bushings (液压启闭机): Piston rod guides
Turbine guide vanes (水轮机导叶): Underwater long-term operation
5.2 Heavy Industry
5.2 重型工业
Mining machinery: Crushers, ball mills, coal mining machines
Metallurgical equipment: Rolling mills, continuous casting machines
Petroleum machinery: Mud pumps, oil extraction machines
Shipbuilding: Rudder systems, anchor winches, propeller shafts
5.3 Infrastructure & Transportation
5.3 基础设施与交通
Bridge bearings: Expansion joints, seismic isolation
Construction machinery: Excavator slewing rings, loader pivot points
Railway systems: Bogie components, braking systems
Aerospace: Landing gear, control linkages (specific grades)
5.4 Special Environments
5.4 特殊环境应用
Nuclear power: Radiation-resistant, lubricant-free
Food & Pharma: Clean operation without oil contamination
Textile machinery: Dust-resistant, fiber-free environment
6. Product Selection Guide
6. 产品选型指南
Step 1: Determine Load & Speed
步骤1：确定载荷与速度
High load (>50 N/mm²) + Low speed (<1 m/s): Choose JDB-1 or JDB-5
Medium load + Corrosive environment: Choose JDB-2 (tin bronze)
Low load + Precision requirement: Choose JDB-4
Step 2: Evaluate Environmental Conditions
步骤2：评估环境条件
Seawater/High humidity: Use tin bronze (JDB-2) with PTFE lubricant
High temperature (>250°C): Use graphite lubricant (SL1)
Dusty/Contaminated: Ensure sealing; FZ-5 structure is recommended
Step 3: Check Dimensional Requirements
步骤3：确认尺寸要求
Standard sizes: Available per DIN 1494 / ISO 3547
Custom designs: Non-standard geometries, flanges, spherical surfaces available
Tolerance: H7 for inner diameter, r7 for outer diameter
7. Technical Standards & Quality Control
7. 技术标准与质量控制
Material Standards: GB/T 1176 (China), ASTM B505 (USA), DIN 1705 (Germany)
Hardness Testing: Brinell (HB) method, multi-point measurement on base alloy
Friction Testing: Thrust-washer method per ASTM D3702, coefficient ≤0.16
Dimensional Inspection: CMM (Coordinate Measuring Machine) for precision verification
8. Economic & Environmental Benefits
8. 经济与环境效益
Cost Savings
成本节约
Reduced equipment size: Lower friction allows smaller actuators, saving 15-30% in system cost
Zero lubricant expense: Eliminates grease/oil purchases and disposal costs
Extended maintenance intervals: Maintenance-free operation for 5-10 years in many applications
Environmental Impact
环境影响
No lubricant leakage: Prevents soil and water contamination
Energy efficiency: Lower friction reduces power consumption by 5-15%
Resource conservation: Bi-metal designs (JDB-5) reduce copper usage by 30-50%
9. Global Suppliers & Market Trends
9. 全球供应商与市场趋势
Leading Manufacturers
主要制造商
China: www.BUSHING.cn
Europe: SANKYO OILLESS (Germany), GGB Bearing Technology
USA: Oilite (founder of sintered bearings), Bronzelube
Market Growth
市场增长
Driven by Industry 4.0, automation, and sustainability mandates, the self-lubricating bearing market is projected to grow at 6.8% CAGR through 2030. Key trends include:
受工业4.0、自动化和可持续发展要求的推动，自润滑轴承市场预计到2030年将以6.8%的年复合增长率增长。主要趋势包括：
Nano-enhanced lubricants: Improved wear life and load capacity
Smart bearings: Embedded sensors for condition monitoring
Green manufacturing: Recyclable alloys and reduced carbon footprint
10. Conclusion
10. 结论
Solid Lubricants Embedded Bearings represent a paradigm shift from lubrication management to material engineering . By integrating graphite, PTFE, or MoS₂ into high-strength bronze matrices, these bearings deliver unparalleled reliability in the harshest operating conditions while reducing total cost of ownership by 40-60% over their lifecycle.
固体润滑剂嵌入式轴承代表了从润滑管理 向 材料工程的范式转变。通过将石墨、PTFE或MoS₂集成到高强度青铜基体中，这些轴承在最恶劣的运行条件下提供无与伦比的可靠性，同时在其生命周期内将总拥有成本降低40-60%。
Whether in water gates, mining equipment, or aerospace systems, choosing the right matrix alloy and solid lubricant combination is critical for optimal performance. Consult with bearing specialists to customize solutions for your specific PV values, temperature range, and environmental challenges.
无论是在水闸、矿山设备还是航空航天系统中，选择合适的基体合金和固体润滑剂组合对最佳性能至关重要。建议咨询轴承专家，根据具体的PV值、温度范围和环境挑战定制解决方案。