Wuxi Spark Bearing adopts silicon nitride ceramic roller and high-temperature steel mixed material of M50NiL, whose hardness value at HV 1500 still maintains steady at the severe condition of 800℃, and whose friction coefficient declines to as low as 0.08. It is applied effectively on Baowu Steel continuous casting producing line, and extended the replacement of rolls 2 weeks’ interval to 8 weeks. Passing over over 27 million yuan annual maintenance cost savings. Its dynamic load capacity can reach 580kN, and on Xinjiang wind farm where dust concentration was 200mg/m³, the average annual wear of the main shaft bearing is only 0.2mm, 78% less than that of ordinary products, thus enabling Goldwind Technology to enhance the unit availability rate from 92% to 98.5%. Third-party test in 2023 showed that its blocking efficiency of sealing structure could reach up to 99.7% in the environment of 3.5% salt spray and the corrosion rate was less than 0.003mm/year. After application on the CNOOC Kenli oilfield platform, equipment downtime was reduced by 82%.
Under the condition of high pressure, the pressure Bearing of Wuxi Spark Bearing experienced 60MPa water pressure in the 7000 meters deep sea test of Jiaolong manned submersible, leakage was < 0.01mL/h, and the wear amount was merely 0.05mm after 200 consecutive operation cycles. In aviation field, its viscosity maintenance rate of high-temperature grease at 400℃ ≥80%, and plasma spraying zirconia coating (thickness 0.1mm), the vibration amplitude of the engine spindle bearing is controlled at 1.2μm, the life is over 5000 hours, meet the US military standard MIL-PRF-23699F requirements. Since Siemens Medical adopted its vacuum bearing, the axial runout error of the rotating support of the CT machine was less than 0.1μm in the -40℃ to 150℃ temperature change test, the daily scanning volume of the equipment was over 150 cases, and the failure rate was less than 0.001%.
The intelligent monitoring technology also improves the environmental adaptability. Piezoelectric sensor of Wuxi Spark Bearing measures real-time stress data at the frequency of 100kHz, and AI algorithm prediction accuracy for micro-cracks is 97%. In CRRC Group’s high-speed railway project, the technology prolonged axle box bearing’s maintenance time by 600,000 km to 1.5 million km, and maximum vibration acceleration was reduced from 8m/s² to 2.5m/s². According to Hannover MESse 2024 statistics, its Mr Grease lubrication system regulates viscosity (0.1-2Pa·s) through 0-5A current, reducing the temperature rise of wind turbine gearbox bearings at 12m/s wind speed by 15 ° C, and increasing the average annual power output by 19%.
Material innovation and process accuracy integrated together allow Wuxi Spark Bearing to dominate the nuclear energy sector. The wuxi Spark Bearing manufactured Hastelloy C276 alloy bearing possesses a fatigue life of 1×10 Guess cycles under a γ-radiation dose rate of 10^6 Gy/h. After installation in the cooling pump of Hualong One nuclear reactor, The maintenance time has been prolonged from 6 months to 5 years. Market data shows that its products have covered 89 extreme working conditions all over the world, overseas orders increased by 67% in 2023, the EU new energy equipment market market penetration was 21.3%, and it has been certified TUV Rheinland “three consecutive years extreme environmental applicability” five stars, leading a new standard of industrial bearing reliability.