gear box fault diagnosis and solution

[Abstract] Reducers are widely used in daily lifestyle, and are used in various mechanical systems in commercial creation, such while: autos, boats, some heavy equipment and some factory production lines. The range of the reducer is definitely very wide, from the transmission of the bigger power to the transmitting of the precise angle, the reducer can work very well. The inner framework of the reducer is a variety of armor and weapon upgrades of different specifications. By interlocking the things, the rate input from the insight shaft can end up being reduced, and the quickness can be decreased to the mechanised gadget through the output shaft, and the speeding can become understood. . This paper generally studies the common flaws of the reducer and lists several effective solutions.

The main function of the reducer is to convert the power and provide the right power for the mechanical operation. When the reducer functions, it primarily relies on the equipment transformation velocity of different sizes, and finally the electric motor shaft quickness reaches the required range, and a sizable torque mechanism is certainly acquired. In the current practical software, the reducer is utilized to transmit mechanical swiftness and convert mechanical power, and the program of the reducer is certainly more and even more widespread. In the creation process of general industrial enterprises, the acceleration conversion and deceleration of the reducer are primarily used to realize the acceleration transformation of various mechanised devices. Consequently, once the failing of the reducer will significantly impact the production activities of the business, it can be extremely essential to make accurate judgments for the failure of the reducer and to find a answer to make certain the regular operation of different gadgets.

1 Reducer common failure
1.1 Parts high temperature leaking
In order to improve the working efficiency of the reducer, most reducer manufacturers choose non-ferrous components to produce the turbine of the reducer, and the materials for production the worm is the harder steel. This causes the reducer to constantly rub and slip between the parts during the working process, which produces a lot of heat, and because the components of the inner parts of the reducer are different, the degree of thermal development of the materials is definitely different, to ensure that the initial appropriate gap between the parts It turns into smaller and constantly wears out friction. At the same time, the lubricating essential oil between the parts is usually also affected by the temperatures rise, and the concentration turns into slim, causing in essential oil leakage failure of the reducer.

1.2 Turbine wear failure
The materials used to help to make the worm equipment are generally nonferrous metals, such as tin bronze alloy, and the worm is made of 45 steel, and in order to ensure the hardness, it will be quenched and its hardness can reach HRC45-55. When the reducer is usually in regular procedure, the worm offers a high hardness, which causes long lasting friction with the turbine during procedure, resulting in critical put on of the turbine. Since the turbine and the worm are key parts of the reducer, the put on of the turbine can result in a shortened support existence of the reducer. In addition to the turbine and worm hardness mismatch, the turbine use and tear, the reducer application and model, the reducer operating time and the weight during the operation of the reducer will generate different degrees of use on the turbine of the reducer.

1.3 Drive little helical gear wear
This type of failure mainly occurs in vertical reducer equipment, which is due to certain problems in the type and amount of lubricant. When setting up the straight reducer, the staff will add a particular quantity of lubricant to the inside. When the reducer is definitely managed for a period of time, due to the intake of lubricating essential oil or leakage, the lubrication of the parts of the reducer is missing. When the speed reducer halts working, the lubricating oil will steadily drop to the bottom of the reducer due to gravity. When the velocity reducer begins once again, the upper component of the equipment or other parts does not have the protection of lubricating oil, which can be even more critical. Wear and rip. In this way, not really only will the lifestyle of the reducer end up being reduced, but also additional problems will take place credited to friction between the parts.

1.4 Worm bearing damage
In the approach of failure of the reducer, actually if the covered box is well safeguarded, the gear oil may be emulsified, resulting in damage, corrosion and corrosion of the bearing. This is usually since the wetness produced by the unexpected cooling of the equipment oil during the procedure of the reducer is certainly agglomerated.

2 Effective method to resolve the issue of reducer
2.1 Improve the functioning environment
The working environment will have a extremely large impact on the operating efficiency of the reducer. Dust and great contaminants in the operating environment of the reducer will enter the inside of the machine through the gap of the reducer casing. Since there are many viscous substances such as lubricating oil in the reducer, these small contaminants will adhere to the lubricating oil after entering. When the machine is normally functioning, it will end up being sent to all parts of the reducer as the equipment rotates, which will result in an increase in the friction of the reducer parts, and ultimately the gear unit will malfunction. Consequently, in purchase to make certain the normal operation of the reducer, the staff should pay out interest to the operating environment of the reducer. Especially in some dusty functioning environments, a protecting cover can become added to the reducer casing according to real requirements to reduce the particles entering the machine and prevent dirt from getting into the machine, which impacts the stable procedure of the machine. . In addition, if the operating environment of the reducer is normally fairly harsh, after the daily function is definitely finished, it can be necessary to clean and check the reducer in period, generally to clean the dust attached to the body of the decrease equipment to avoid the dust and have an effect on the reducer. Normal procedure ensures steady operation of the reducer.

2.2 Improve the machining precision of the reducer
The common faults of the reducer also include the oil leakage of the chassis. The fundamental problem is generally caused by the issue of engineering accuracy in the processing process of the reducer. As a result, when the reducer does not work out, the maintenance personnel can cut the machining accuracy and enhance the machining accuracy of the reducer. First of all, in purchase to prevent essential oil leakage in the chassis, the joint between the top and lower casings of the machine should be floor to make sure that the casing of the casing can end up being tightly engaged; second of all, in the process of installing the top and lower casings of the reducer, a joint should end up being put at the joint of the casing. The sealing strip is usually then coated with a level of sealant on the joint to type a closed constant apron, which successfully eliminates the essential oil leakage on the tank surface and ensures the reliability of the procedure of the reducer.

2.3 Improve the set up quality of the reducer
The unreasonable installation phase of the reducer is one of the biggest causes of the current failure of the reducer. As a result, the business should pay attention to the set up process of the reducer to make sure the dependability of the reducer. First of all, in the process of installation of the reducer, advanced calculating equipment should become completely utilized to improve the comprehensive inspection of the parts and the sizes of the parts of the reducer and the precision of the joint parts. For example, check the joints of the top and lower cabinets. The verticality and level between the shaft, the shaft and the bearing and the tolerance between the equipment; secondly, the installation and inspection power of the reducer should be elevated, and the overall performance should become examined before beginning up. For example, the bolts at the connection component of the reducer appear loose, and should become strengthened in period. At the same period, the vibration degree of the reducer is usually decreased by effective inspection, and the procedure effect of the reducer can be improved to some level. These tasks can successfully assurance the quality of the reducer installation and lay a solid basis for the clean operation of the reducer.

2.4 Specification of installation and repair practices
In order to assure the installation or repair quality of the reducer, the company needs to purchase the parts in person, and in the process of disassembling and installing the worm, the worm wheel and the bearing, try to avoid using a hammer and additional tools to directly strike, so as not to affect the cooperation between these parts. threshold. When replacing parts, pay interest to the accessories that match the mechanised model. In the procedure of assembling the output bearing, it can be necessary to pay interest to the shared coordinating of the threshold values. When Deb≤50mmeters, L7/k6 can be adopted; when G>50mm, H7/meters6 is definitely used. At the same time, it can be required to use reddish colored Dan essential oil and anti-adhesive agent to achieve the purpose of safeguarding the hollow shaft, and to avoid the put on and corrosion of the parts to a specific extent, which can be advantageous for disassembly and set up during maintenance.

In summary, many businesses want to use reducers in the production process. Nevertheless, credited to different elements, the reducer frequently offers numerous problems during operation, which significantly affects the protection and dependability of the reducer. It also impacts the creation efficiency and item quality of the company. At this period, it is certainly required for the administration and maintenance workers to perform on-site inspections on a regular basis, and also to discover out the cause of the failing of the reducer, and instantly offer corresponding maintenance and maintenance to prevent affecting the normal creation process.


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