gear box fault diagnosis and solution

[Abstract] Reducers are widely used in daily life, and are used in various mechanical systems in industrial production, such as: autos, boats, some heavy machinery and some factory creation lines. The range of the reducer can be very wide, from the transmitting of the bigger power to the transmission of the precise angle, the reducer can work very well. The inner structure of the reducer is a variety of equipment of different specifications. By interlocking the armor and weapon upgrades, the velocity insight from the insight shaft can be reduced, and the quickness can become decreased to the mechanised gadget through the result shaft, and the speeding can become noticed. . This paper mainly studies the common problems of the reducer and lists many 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 generally depends on the gear conversion velocity of different sizes, and finally the electric motor shaft acceleration gets to the required range, and a huge torque system is normally obtained. In the current useful program, the reducer is utilized to transmit mechanical quickness and convert mechanical power, and the application of the reducer is certainly more and even more wide-spread. In the creation process of general commercial enterprises, the swiftness transformation and deceleration of the reducer are mainly utilized to understand the quickness conversion of various mechanical devices. Consequently, once the failing of the reducer will seriously affect the production actions of the business, it is usually very essential to make accurate judgments for the failure of the reducer and also to find a alternative to ensure the normal operation of various products.

1 Reducer common failure
1.1 Parts temperature leaking
In order to enhance the operating efficiency of the reducer, most reducer producers choose nonferrous materials to manufacture the turbine of the reducer, and the material for production the worm is the harder steel. This causes the reducer to constantly scrub and slip between the parts during the working procedure, which creates a lot of high temperature, and because the materials of the internal parts of the reducer are different, the level of thermal expansion of the materials can be different, so that the initial installing gap between the parts It becomes smaller and continually wears out friction. At the same period, the lubricating oil between the parts is normally also affected by the temperature rise, and the focus becomes thin, ensuing in 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 definitely in normal procedure, the worm has a high hardness, which causes long lasting friction with the turbine during procedure, ensuing in serious wear of the turbine. Since the turbine and the worm are essential elements of the reducer, the put on of the turbine can result in a shortened service life of the reducer. In addition to the turbine and worm hardness mismatch, the turbine wear and rip, the reducer application and model, the reducer working period and the load during the operation of the reducer will produce different degrees of wear on the turbine of the reducer.

1.3 Drive small 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 up and down reducer, the staff will add a certain amount of lubricant to the inside. When the reducer is usually operated for a period of time, credited to the consumption of lubricating oil or leakage, the lubrication of the parts of the reducer is normally missing. When the rate reducer halts functioning, the lubricating oil will steadily drop to the bottom of the reducer credited to gravity. When the velocity reducer starts again, the upper part of the gear or additional parts does not have the safety of lubricating essential oil, which is certainly even more critical. Wear and tear. In this method, not really just will the existence of the reducer end up being decreased, but also various other problems will happen credited to friction between the parts.

1.4 Worm bearing damage
In the process of failure of the reducer, also if the covered box is well safeguarded, the gear oil may be emulsified, ensuing in damage, corrosion and rust of the bearing. This is because the wetness generated by the sudden chilling of the gear oil during the operation of the reducer is certainly agglomerated.

2 Effective way to resolve the issue of reducer
2.1 Improve the functioning environment
The working environment will have a very large impact on the operating efficiency of the reducer. Dirt and good particles in the operating environment of the reducer will enter the inside of the machine through the difference of the reducer casing. Since there are many viscous chemicals such as lubricating oil inside the reducer, these little contaminants will adhere to the lubricating oil after entering. When the machine is operating, it will be transmitted to all parts of the reducer as the equipment rotates, which will result in an increase in the friction of the reducer parts, and eventually the equipment device will malfunction. Consequently, in purchase to ensure the normal operation of the reducer, the staff should pay out attention to the operating environment of the reducer. Especially in some dusty operating environments, a defensive cover can be added to the reducer casing relating to real needs to reduce the particles getting into the machine and prevent dirt from getting into the machine, which impacts the steady procedure of the machine. . In addition, if the operating environment of the reducer can be screw jacks relatively harsh, after the daily work is certainly finished, it is certainly required to clean and check the reducer in time, primarily to clean the dust attached to the body of the decrease equipment to prevent the dust and influence the reducer. Regular procedure ensures stable procedure 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 issue is usually generally caused by the problem of engineering accuracy in the processing process of the reducer. Consequently, when the reducer fails, the maintenance employees can cut the machining precision and improve the machining precision of the reducer. First of all, in purchase to prevent oil leakage in the chassis, the joint between the upper and lower casings of the machine should be floor to make sure that the casing of the casing can be tightly engaged; second of all, in the procedure of setting up the upper and lower casings of the reducer, a joint should be placed at the joint of the casing. The sealing strip can be then covered with a layer of sealant on the joint to form a closed continuous apron, which efficiently eliminates the essential oil leakage on the container surface and guarantees the dependability of the operation of the reducer.

2.3 Improve the installation quality of the reducer
The unreasonable installation phase of the reducer is one of the biggest causes of the current failure of the reducer. Therefore, the firm should pay interest to the set up process of the reducer to make certain the dependability of the reducer. First of all, in the procedure of installation of the reducer, advanced measuring devices should end up being fully utilized to improve the detailed 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 things; secondly, the set up and inspection strength of the reducer should end up being increased, and the functionality should become checked before starting up. For example, the bolts at the connection part of the reducer appear loose, and should become reinforced in period. At the same period, the vibration degree of the reducer is definitely reduced by effective inspection, and the procedure effect of the reducer is normally improved to some degree. These jobs can effectively assurance the quality of the reducer set up and place a solid basis for the easy operation of the reducer.

2.4 Specification of installation and repair practices
In order to make sure the installation or repair quality of the reducer, the company needs to buy 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 other tools to directly strike, so as not to affect the cooperation between these parts. threshold. When replacing parts, pay attention to the accessories that match the mechanical model. In the process of assembling the output bearing, it can be required to pay attention to the mutual matching of the tolerance ideals. When G≤50mm, H7/t6 is normally used; when G>50mmeters, H7/meters6 is definitely followed. At the same time, it is definitely necessary to use red Dan oil and anti-adhesive agent to accomplish the purpose of safeguarding the hollow shaft, and to prevent the use and corrosion of the parts to a specific extent, which is usually beneficial for disassembly and set up during maintenance.

In overview, many companies want to make use of reducers in the creation process. Nevertheless, credited to various elements, the reducer frequently offers numerous problems during procedure, which seriously affects the safety and dependability of the reducer. It also affects the production effectiveness and product quality of the organization. At this time, it is certainly necessary for the administration and maintenance employees to perform on-site inspections on a regular basis, and also to find out the trigger of the failing of the reducer, and immediately offer matching maintenance and maintenance to prevent influencing the normal production procedure.

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