軸承清潔度檢測規(guī)程

1、.Document edit information文件修訂信息Version No.版本號Modification reason & content修改原因/內(nèi)容Edit Date修訂日期Edit Person修訂人Remark備注B27-WI-103-F03 表格換版2013-01-18張儀君C增加各尺寸的清潔度檢測方法及判定標準等2014/11/05張儀君Review 審核Correlative department相關部門Review opinion評審意見Review person / Date評審人/日期Approval 批準Department 部門Opinion 評審意見App

2、roval person / Date批準人/日期MR（limit to procedure only）管理者代表（僅限于程序文件）Department Manager 部門經(jīng)理OK汪洋1 Purpose 目的為規(guī)范成品軸承裝配后的清潔度檢測操作程序。To regulate the assembly of finished bearing after the dirt count test procedures.2 Scope 使用范圍本規(guī)程適用于成品軸承涂油包裝后的清潔度檢測。 The procedure applied to bearings dirt count testing afte

3、r packaging.3 Responsibility 職責工流體實驗室負責各單元的清潔度檢測工作。 Fluids lab is responsible for dirt count test.4 Definition 術語（無）5 Procedures 過程及要求5.1 (浸沒法)方法適用于外徑0 到12英寸的軸承和零部件，檢測頻次及數(shù)量參照附錄1。 (Dip Method)Test for contaminant content of 0 to 12 inch OD bearing components，test frequency and quantity per addendum 1

4、.5.1.1 儀器設備 Apparatus5.1.1.1 微孔耐熱玻璃支架（xx10 047 20 ）Millipore pyrex filter holder xx10 047 205.1.1.2 標準微孔濾膜-0.45微米孔隙HAWP 04700 20Standard Millipore filters-0.45 micrometer pore size HAWP 047005.1.1.3 微孔玻璃密封裝置，顯示屏和制動器xx10 0470 32Millipore glass seal base, screen, and stopper xx10 0470 321-2L規(guī)格的彎臂抽氣瓶（1

5、公升微孔xx10 047 05）One or two liter side arm filter flasks（Millipore one liter xx10 047 05）5.1.1.4 塑料管 Plastic tubing5.1.1.5 防爆炸真空泵（適當?shù)姆乐狗鬯榫涂梢裕acuum pump Fisher Scientific5.1.1.6 塑料洗瓶 Plastic Wash bottle5.1.1.7不銹鋼容器或玻璃燒杯（必須足夠大，可讓部件平放到容器底部，并與容器有一定間隙）。Stainless container or glass beaker(must be large e

6、nough to allow components to lay flat on bottom with room to spare)5.1.1.8 不銹鋼鑷子 Stainless steel forceps5.1.1.9 干燥箱 Drying oven5.1.1.10分析天平（0.0001 g靈敏度0.1mg。） Analytical balance capable of weighing to 0.0001 g5.1.1.11通風柜 Ventilation hood5.1.2 清洗溶劑 Washing Solvent閃點大于60度的石蠟基溶劑，如 Shell sol D60；LPA142；

7、Ashland sol 142等注意：危險物極其易燃，水蒸氣也可能引起火花。遠離熱源，火花，和明火。在足夠的通風和有通風櫥的情況下使用。NOTE: Extremely flammable, Vapor cause flash fire, Keep away from heat sparks and open flame. Use with adequate ventilation and in hood.5.1.3 操作程序 Procedure5.1.3.1測量殘磁2高斯，預稱重濾膜，并用圓珠筆或鉛筆在每個濾膜上標出識別編號。Measure residual magnetism 2gauss,

8、 pre-weighing filter, mark an identification number on each filter with a pencil or ball point pen.5.1.3.2對試驗濾膜進行稱重并記錄重量，精確到0.1mg。Weigh filters to the nearest 0.1mg and record weigh.5.1.3.3為每個試驗濾膜配置一個額外的濾膜，并稱重每個控制濾膜。（在進行過濾前，這個控制濾膜將直接插入到試驗濾膜下。上膜為試驗濾膜，下膜為控制濾膜）Weigh an extra filter for each test filter

9、.(This control filter is inserted directly beneath the test filter prior to the filtration procedure)注意：在操作整個過程中，用鑷子操縱過濾器。NOTE: Handle filters with forceps at all times.5.1.4 清洗軸承部件 Cleaning of bearing components5.1.4.1 在清洗容器中倒入足夠的溶劑，使一個軸承部件完全浸入溶劑中。清洗容器首選玻璃燒杯，但對大尺寸軸承，需要用不銹鋼杯或盤。Pure into the washing

10、container enough solvent , completely cover one bearing component. Glass beakers are preferred but stainless beakers or trays are needed for larger size bearing.5.3.2 在充分攪動中清洗軸承部件15秒，以便有效去除微粒和防腐劑。對裝配后的內(nèi)圈，為充分去除所有微粒和防腐劑，必須轉(zhuǎn)動部件或溶液至少15秒。Wash bearing components for 15 seconds to remove particles and pres

11、ervative. For assembled cones, rotating the components in the solvent to remove particles and preservative.5.1.4.2 從溶劑中取出軸承，然后用溶劑噴霧劑徹底噴灑至少10秒鐘。在此期間，應邊清洗邊讓沖洗物流入容器。對組裝后的軸承應邊轉(zhuǎn)動邊清洗。分開清洗每一個部件，然后立即干燥。最后用防銹材料如Quaker FERROCOTE 5856BF T1將軸承重新防護。Remove the bearing from the solvent and wash thoroughly with a f

12、ine spray of hexane from the wash bottle for at least 10 seconds. During this step, all washing should drain into the container. Cone assemblies should be rotated. Wash each component and then immediately dry. preserve the bearing with Quaker FERROCOTE 5856BF T1注意：軸承部件用一個過濾盤。由于溶劑煙霧是危險的，所以整個清洗過程必須在實驗

13、室環(huán)境下進行。不可接觸皮膚。在整個操作過程中，可使用鉗子或塑料手套處理軸承部件。但只有（經(jīng)過含污量）證實的防塵手套可使用（聚乙烯手套）。避免使用已破損，有斑點的手套。NOTE: Use one filter disk for five bearings. The cleaning procedure must be in the lab hood since the solvent fumes is hazardous. Use tongs or plastic gloves to clean the bearing component. Only gloves proven to be fr

14、ee of dirt (such as PE gloves) can be used5.1.5過濾清洗后溶液 Filtering washing solvent5.1.5.1 將事先已稱重的0.45微米孔隙的濾膜，安放于微孔過濾器上。（上膜）Assemble Millipore filter with a pre-weighed 0.45um filter. （top filter）5.1.5.2在實驗濾膜下放置一張事先已稱重的控制濾膜。(下膜)Insert a pre-weighed control filter beneath the test filter.(bottom filter)

15、5.1.5.3小心的將清洗后溶液倒入過濾漏斗，并用裝有真空抽氣裝置的抽氣瓶將溶液通過濾膜真空過濾。Pour the solvent into the filter funnel carefully and apply vacuum to draw the solvent through the filter.5.1.5.4所有的溶劑過濾后，用裝有溶劑的洗瓶噴洗容器四次，以便將容器殘留的微粒洗掉。然后噴洗過濾漏斗壁，確保濾液的所有的微粒已收集，所有的防腐劑或殘油已完全收集。再移開固定裝置，噴洗漏斗和裝置結(jié)合處，清洗出任何遺留在那里的殘油。重新清洗漏斗后再卸下。After filtered all

16、 solvent, wash the container four times with a wash bottle to remove particles. Then wash the walls of filter funnel. Remove clamp and spray outside of the funnel-base junction to draw in any oil collected there. Rewash funnel and disassemble.5.1.5.5 釋放真空后，用鑷子移動濾膜盤，放置到干凈平整的紙上晾干。After releasing vacuu

17、m, use forceps to remove the filter disks. Place them on a sheet of flat paper for drying.5.1.6 重新稱重 Reweighing5.1.6.1將濾膜放置在干燥箱中干燥15分鐘，干燥溫度為80-100（175-212）。Place the filters in a oven at 80-100（175-212）and dry for 15 minutes.5.1.6.2 從干燥箱中取出濾膜并冷卻15分鐘。Remove from the oven and let the filter cool 15 mi

18、nutes。5.1.6.3 重新稱重濾膜，精確到0.1mg。Reweigh the filters to the nearest 0.1mg.5.1.7 計算 Calculation5.1.7.1用最終的測試濾膜重量，減去初始濾膜的重量。可減去控制濾膜增加重量或加上控制濾膜失去的重量，以修正每次的測試結(jié)果。用合成的總含污量除以參與試驗的總部件數(shù)，就可得到每個部件的平均含污量。（如果用足夠的洗液去除殘油的話，控制濾膜增加的重量不應該超過0.5mg）Subtract the initial weigh of the test filter from the final test filter we

19、ight. Then subtract weight gain or add weigh loss of control filter as a correction factor for each test result. Divide the resultant total dirt count by the number of components used in the test to obtain the average dirt content of each component.(The weight increase of the control filter should n

20、ot exceed 0.5mg if adequate washing is used to remove oil residue)5.1.7.2 表面積的數(shù)據(jù)可從27-WI-103-F02“成品軸承表面積一覽表”查得。5.1.7.3 評判標準（參見附錄1）Limits(Refer to addendum 1)5.1.7.3.1 總重量Total Weight 5.1.7.3.2 顆粒物尺寸/類別 Particle size/type5.1.8 相關措施 Corrective Action5.1.8.1 若測試軸承的含污量超過允許值，工藝流體及防銹實驗室應立即通知車間對相關產(chǎn)品進行處置，并分析

21、原因，針對原因制定并實施糾正措施，工藝流體及防銹實驗室對實施效果進行驗證。糾正措施還可包括：過程流程調(diào)查，對濾膜，油槽含污量，與過程流程和濾膜相關的維護準則、操作程序回顧。車間應將更換、及相應的一些措施記錄于27-WI-103-F03 “清洗液/防銹油/過濾系統(tǒng)更換記錄”。When bearings tested contain more contaminant or particles than the maximum allowable, appropriate corrective actions must be initiated. These include but are not

22、limited to: a physical investigation of process fluids, filters, contaminant content in reservoirs, a review of the maintenance practices related to process fluids and filters, a review of handling procedures, and any other appropriate problem solving activities aimed at producing bearings free from

23、 contaminants. Workshop should be replaced, and the corresponding measures recorded in the 27-WI-103-F03 cleaning fluid / RP oil / filter system replacement record.注意：用塑料桶收集廢液。在桶上貼上危險物和易燃標簽。將所有的桶送到EHS指定的地點。Note: Drum up waste solvent in plastic drums. Hazardous waste and flammable labels must be on

24、drums. Send full drums to the appropriate off-site disposal facility.5.2 （吊索壓力噴淋法）方法適用于外徑12到18英寸的軸承和零部件，檢測頻次及數(shù)量參照附錄1。(Sling/Pressure Spray Method) Test for contaminant level of 12 to 18 inch bearing components. Test frequency and quantity per addendum 1.5.2.1 儀器設備Apparatus 5.2.1.1參照5.1.1(注意：濾膜是5.0um

25、帶網(wǎng)格的標準微孔濾膜，型號：SVWG 047 00)See section 5.1.1.1 (Note exception: 5.0um gridded filter SVWG 047 00)5.2.1.2 噴射容器罐型號：XX67 00P 05 Millipore Pressure Vessel model # XX67 00P 055.2.1.3 溶劑噴霧槍型號：XX67 025 00 Millipore Filter jet Solvent Dispenser with fan spray nozzle model # XX67 025 00.5.2.2 清洗溶劑 Washing Sol

26、vent閃點大于60度的石蠟基溶劑，如 Shell sol D60；LPA142；Ashland sol 142等注意：危險物極其易燃，水蒸氣也可能引起火花。遠離熱源，火花，和明火。在足夠的通風和有通風櫥的情況下使用。NOTE: Extremely flammable, Vapor cause flash fire, Keep away from heat sparks and open flame. Use with adequate ventilation and in hood.5.2.3 操作程序 Procedure5.2.3.1 測量殘磁，將零部件放在合適的容器內(nèi)以便收集清洗后的溶劑

27、，對于重量或是尺寸過大的零件必須要使用行車。Measure residual magnetism; place the parts in/over an appropriately sized collection vessel such that all the solvent will be collected. It may be necessary to hang the part from a crane due to its weight and size. 5.2.3.2 調(diào)節(jié)容器噴淋口的壓力在15 psig 5 psig。Pressurize the spray vessel

28、to a pressure. A recommended value is 15 psig 5 psig.5.2.3.3 將零部件放在收集容器內(nèi)開始噴淋清洗，每個零部件噴淋清洗510秒，之后重復3次。注意噴淋清洗過程中的壓力要保持在15 psig 5 psig。Place the part into/over the collection vessel， A good rule of thumb is to give the area of the part 5 to 10 seconds of spray. Repeat each spray 3 times. Be aware of the

29、 sprayer pressure. The pressure of the vessel should be maintained at the recommended value of 15 psig 5 psig.5.2.3.4 將零部件移出，讓溶劑殘留回到收集容器內(nèi)，再翻個身以收集盡量多的溶劑。如果有必要，將零部件懸空以收集所有的溶劑Remove the part and let the residual fluid drain back into the collection vessel. Turn the part to make sure as much of the flui

30、d as possible is collected. If necessary, suspend the part over the collection vessel by some method until all of the solvent is collected.5.2.3.5 按照5.1.5的步驟，用5.0m濾紙過濾收集的溶劑，用干凈的溶劑漂洗收集容器、微孔過濾玻璃支架。所有用來漂洗清潔度設備的溶劑必須經(jīng)過5.0m的濾紙過濾。Filter the collected solvent through a gridded 5.0m filter prepared as per pa

31、ragraph 5.1.5. Rinse out the collection vessel with clean solvent. Rinse down the filter holder. All solvent used for rinsing the equipment must be filtered through a 5.0um filter. 5.2.3.6用鑷子移動濾膜盤，放置到干凈平整的紙上晾干。Use forceps to remove the filter disks. Place them on a sheet of flat paper for drying.5.2

32、.4 重新稱重 Reweighing5.2.4.1將濾膜放置在干燥箱中干燥15分鐘，干燥溫度為80-100（175-212）。Place the filters in a oven at 80-100（175-212）and dry for 15 minutes.5.2.4.2 從干燥箱中取出濾膜并冷卻15分鐘。Remove from the oven and let the filter cool 15 minutes。5.2.4.3 重新稱重濾膜，精確到0.1mg。Reweigh the filters to the nearest 0.1mg.5.2.5 計算 Calculation5.

33、2.5.1用最終的測試濾膜重量，減去初始濾膜的重量?？蓽p去控制濾膜增加重量或加上控制濾膜失去的重量，以修正每次的測試結(jié)果。用合成的總含污量除以參與試驗的總部件數(shù)，就可得到每個部件的平均含污量。（如果用足夠的洗液去除殘油的話，控制濾膜增加的重量不應該超過0.5mg）Subtract the initial weigh of the test filter from the final test filter weight. Then subtract weight gain or add weigh loss of control filter as a correction factor fo

34、r each test result. Divide the resultant total dirt count by the number of components used in the test to obtain the average dirt content of each component.(The weight increase of the control filter should not exceed 0.5mg if adequate washing is used to remove oil residue)5.2.5.2 表面積的數(shù)據(jù)可從27-WI-103-F

35、02“成品軸承表面積一覽表”查得。5.2.5.3 評判標準（參見附錄1）Limits(Refer to addendum 1)5.2.5.3.1 總重量Total Weight 5.2.5.3.2 顆粒物尺寸/類別 Particle size/type5.2.6 相關措施 Corrective Action5.1.8.1 若測試軸承的含污量超過允許值，工藝流體及防銹實驗室應立即通知車間對相關產(chǎn)品進行處置，并分析原因，針對原因制定并實施糾正措施，工藝流體及防銹實驗室對實施效果進行驗證。糾正措施還可包括：過程流程調(diào)查，對濾膜，油槽含污量，與過程流程和濾膜相關的維護準則、操作程序回顧。車間應將更換、

36、及相應的一些措施記錄于27-WI-103-F03 “清洗液/防銹油/過濾系統(tǒng)更換記錄”。When bearings tested contain more contaminant or particles than the maximum allowable, appropriate corrective actions must be initiated. These include but are not limited to: a physical investigation of process fluids, filters, contaminant content in reser

37、voirs, a review of the maintenance practices related to process fluids and filters, a review of handling procedures, and any other appropriate problem solving activities aimed at producing bearings free from contaminants. Workshop should be replaced, and the corresponding measures recorded in the 27

38、-WI-103-F03 cleaning fluid / RP oil / filter system replacement record.注意：用塑料桶收集廢液。在桶上貼上危險物和易燃標簽。將所有的桶送到EHS指定的地點。Note: Drum up waste solvent in plastic drums. Hazardous waste and flammable labels must be on drums. Send full drums to the appropriate off-site disposal facility.5.3 （標記壓力噴淋法）方法適用于外徑大于18

39、英寸的軸承和零部件，檢測頻次及數(shù)量參照附錄1。 (Masking/Pressure Spray Technique) Test for contamination level of bearing components greater than 18 in OD. Test frequency and quantity per addendum 1.5.3.1 儀器設備Apparatus 5.3.1.1參照5.1.1(注意：濾膜是5.0um帶網(wǎng)格的標準微孔濾膜，型號：SVWG 047 00)See section 5.1.1.1 (Note exception: 5.0um gridded f

40、ilter SVWG 047 00)5.3.1.2 壓力容器罐型號：XX67 00P 05 Millipore Pressure Vessel model # XX67 00P 055.2.1.3 溶劑噴霧槍型號：XX67 025 00 Millipore Filter jet Solvent Dispenser with fan spray nozzle model # XX67 025 00.5.3.2 清洗溶劑 Washing Solvent閃點大于60度的石蠟基溶劑，如 Shell sol D60；LPA142；Ashland sol 142等注意：危險物極其易燃，水蒸氣也可能引起火花

41、。遠離熱源，火花，和明火。在足夠的通風和有通風櫥的情況下使用。NOTE: Extremely flammable, Vapor cause flash fire, Keep away from heat sparks and open flame. Use with adequate ventilation and in hood.5.3.3操作程序 Procedure5.3.3.1測量殘磁，用記號筆劃分出一個需要清洗的區(qū)域,記錄下標記的長度以便計算出軸承被清洗區(qū)域的表面積。Measure residual magnetism; measure off an area to be cleane

42、d and record. Mark off area with magic marker. Record bearing number and length of section marked off. This information will be necessary to determine the surface area of the cleaned section. 5.3.3.2將被清洗區(qū)域的周邊清洗干凈，用膠帶將此區(qū)域粘上Clean off the area adjacent to the area to be cleaned with solvent，apply tape

43、over area just cleaned5.2.3.3 設定噴淋壓力15psi，用壓力噴槍噴淋被清洗區(qū)域30秒，收集清洗溶劑，確保收集的容器能收集到所有的溶劑。Using the Filterjet spray gun set at 15 psi, spray off area to be cleaned for 30 seconds and collect the solvent and particulate in a drip pan. Make sure that the collection vessel is positioned properly in order to co

44、llect all of the wash solvent. 5.2.3.4按照5.1.5的步驟 用5.0um的濾紙過濾收集的溶劑和濾膜支架。Filter the collected solvent through a gridded 5.0um filter as prepared in paragraph 5.1.5 . Rinse down the sides of the filter holder using 5.0um filter solvent. 5.2.3.6用鑷子移動濾膜盤，放置到干凈平整的紙上晾干。Use forceps to remove the filter disk

45、s. Place them on a sheet of flat paper for drying.5.3.4 重新稱重 Reweighing5.3.4.1將濾膜放置在干燥箱中干燥15分鐘，干燥溫度為80-100（175-212）。Place the filters in a oven at 80-100（175-212）and dry for 15 minutes.5.3.4.2從干燥箱中取出濾膜并冷卻15分鐘。Remove from the oven and let the filter cool 15 minutes。5.3.4.3重新稱重濾膜，精確到0.1mg。Reweigh the

46、filters to the nearest 0.1mg.5.3.5 計算 Calculation5.3.5.1用最終的測試濾膜重量，減去初始濾膜的重量?？蓽p去控制濾膜增加重量或加上控制濾膜失去的重量，以修正每次的測試結(jié)果。用合成的總含污量除以參與試驗的總部件數(shù)，就可得到每個部件的平均含污量。（如果用足夠的洗液去除殘油的話，控制濾膜增加的重量不應該超過0.5mg）Subtract the initial weigh of the test filter from the final test filter weight. Then subtract weight gain or add wei

47、gh loss of control filter as a correction factor for each test result. Divide the resultant total dirt count by the number of components used in the test to obtain the average dirt content of each component.(The weight increase of the control filter should not exceed 0.5mg if adequate washing is use

48、d to remove oil residue)5.3.5.2表面積的數(shù)據(jù)可從27-WI-103-F02“成品軸承表面積一覽表”查得。5.3.5.3評判標準（參見附錄1）Limits(Refer to addendum 1)5.3.5.3.1 總重量Total Weight 5.3.5.3.2 顆粒物尺寸/類別 Particle size/type5.3.5.4相關措施 Corrective Action5.3.5.4.1 若測試軸承的含污量超過允許值，工藝流體及防銹實驗室應立即通知車間對相關產(chǎn)品進行處置，并分析原因，針對原因制定并實施糾正措施，工藝流體及防銹實驗室對實施效果進行驗證。糾正措施

49、還可包括：過程流程調(diào)查，對濾膜，油槽含污量，與過程流程和濾膜相關的維護準則、操作程序回顧。車間應將更換、及相應的一些措施記錄于27-WI-103-F03 “清洗液/防銹油/過濾系統(tǒng)更換記錄”。When bearings tested contain more contaminant or particles than the maximum allowable, appropriate corrective actions must be initiated. These include but are not limited to: a physical investigation of p

50、rocess fluids, filters, contaminant content in reservoirs, a review of the maintenance practices related to process fluids and filters, a review of handling procedures, and any other appropriate problem solving activities aimed at producing bearings free from contaminants. Workshop should be replace

51、d, and the corresponding measures recorded in the 27-WI-103-F03 cleaning fluid / RP oil / filter system replacement record.注意：用塑料桶收集廢液。在桶上貼上危險物和易燃標簽。將所有的桶送到EHS指定的地點。Note: Drum up waste solvent in plastic drums. Hazardous waste and flammable labels must be on drums. Send full drums to the appropriate off-site disposal facility.6 Records 相關記錄表格代號Index NO.記錄名稱Record Title版本Edition收集時間Collection Date 收集崗位Collection Post保存期限Retention Periods保存地點Storage Locations27-WI-103-F01軸承清潔度檢測報告Bearing di