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 while: automobiles, ships, some large equipment and some factory production lines. The range of the air compressor china reducer can be extremely wide, from the transmission of the bigger power to the transmission of the specific angle, the reducer can function very well. The internal structure of the reducer is a variety of equipment of different specs. By interlocking the gears, the swiftness insight from the insight shaft can end up being reduced, and the velocity can end up being decreased to the mechanised device through the output shaft, and the speeding can end up being realized. . This paper primarily research the common flaws 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 works, it primarily relies on the gear transformation velocity of different sizes, and finally the motor shaft velocity gets to the required range, and a large torque mechanism is definitely acquired. In the current practical program, the reducer is used to transmit mechanised acceleration and convert mechanical power, and the software of the reducer is certainly more and more popular. In the creation process of general commercial enterprises, the velocity conversion and deceleration of the reducer are primarily utilized to recognize the rate conversion of numerous mechanical devices. As a result, once the failure of the reducer will seriously impact the creation actions of the enterprise, it can be extremely essential to make accurate decision for the failing of the reducer and to look for a solution to assure the regular operation of numerous gadgets.

1 Reducer common failure
1.1 Parts high temperature leaking
In order to enhance the functioning 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 continuously scrub and slide between the parts during the operating procedure, which generates a lot of warmth, and since the components of the inner parts of the reducer are different, the level of thermal expansion of the material is usually different, to ensure that the first installing gap between the parts It turns into smaller sized and consistently wears out friction. At the same period, the lubricating essential oil between the parts is normally also affected by the heat rise, and the concentration turns into thin, producing in essential oil leakage failure of the reducer.

1.2 Turbine wear failure
The components used to make the worm equipment are generally non-ferrous metals, such as tin bronze alloy, and the worm is made of 45 metal, and in order to ensure the hardness, it will be quenched and its hardness can reach HRC45-55. When the reducer is certainly in regular operation, the worm provides a high hardness, which causes long-term friction with the turbine during procedure, resulting in serious wear of the turbine. Since the turbine and the worm are key parts of the reducer, the use of the turbine can result in a shortened support lifestyle of the reducer. In addition to the turbine and worm hardness mismatch, the turbine put on and tear, the reducer application and model, the reducer functioning period and the weight during the procedure of the reducer will produce different levels of use on the turbine of the reducer.

1.3 Drive little helical equipment wear
This type of failure generally 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 personnel will add a certain quantity of lubricant to the inside. When the reducer is certainly operated for a period of period, credited to the intake of lubricating oil or leakage, the lubrication of the parts of the reducer is certainly lacking. When the velocity reducer halts functioning, the lubricating oil will steadily drop to the bottom level of the reducer due to gravity. When the velocity reducer begins once again, the top component of the gear or other parts does not have the protection of lubricating oil, which is even more critical. Wear and rip. In this method, not really only will the life of the reducer become reduced, but also additional problems will happen credited to friction between the parts.

1.4 Worm bearing damage
In the practice of failure of the reducer, also if the sealed box is well shielded, the gear oil may be emulsified, causing in damage, corrosion and rust of the bearing. This can be because the moisture produced by the unexpected chilling of the gear oil during the operation of the reducer is agglomerated.

2 Effective way 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 particles in the working environment of the reducer will enter the inside of the machine through the gap of the reducer housing. Since there are many viscous chemicals such as lubricating oil within the reducer, these small particles will adhere to the lubricating oil after entering. When the machine is usually working, it will become sent to all parts of the reducer as the gear rotates, which will lead to an boost in the friction of the reducer parts, and ultimately the gear device will failure. Therefore, in purchase to ensure the regular procedure of the reducer, the staff should pay attention to the operating environment of the reducer. Especially in some dusty operating conditions, a protective cover can end up being added to the reducer casing regarding to real requirements to reduce the debris getting into the machine and prevent dirt from getting into the machine, which affects the stable procedure of the machine. . In addition, if the functioning environment of the reducer is usually fairly severe, after the daily function is certainly completed, it is definitely necessary to clean and check the reducer in time, primarily to clean the dust attached to the body of the reduction gear to prevent the dust and affect the reducer. Normal operation ensures stable 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 normally primarily caused by the problem of engineering accuracy in the developing procedure of the reducer. As a result, when the reducer does not work out, the maintenance employees can trim the machining accuracy and enhance the machining precision of the reducer. Initial of all, in order to prevent oil leakage in the chassis, the joint between the upper and lower casings of the machine should be surface to ensure that the casing of the casing can become tightly engaged; subsequently, in the procedure of installing the top and lower casings of the reducer, a joint should end up being placed at the joint of the casing. The closing remove is usually after that coated with a level of sealant on the joint to type a closed continuous apron, which successfully eliminates the essential oil leakage on the container surface area 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 firm should pay out interest to the installation process of the reducer to guarantee the reliability of the reducer. First of all, in the process of set up of the reducer, advanced calculating equipment should become fully used to strengthen the comprehensive inspection of the parts and the measurements 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 patience between the armor and weapon upgrades; secondly, the set up and inspection power of the reducer should end up being increased, and the overall performance should end up being checked before starting up. For example, the bolts at the connection component of the reducer appear loose, and should end up being reinforced in period. At the same time, the vibration level of the reducer is certainly decreased by effective inspection, and the operation impact of the reducer is improved to some level. These tasks can effectively guarantee the quality of the reducer installation and place a solid base for the smooth operation of the reducer.

2.4 Specification of installation and fix 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 various other tools to directly strike, so as not to affect the cooperation between these parts. patience. When replacing parts, pay out attention to the components that match the mechanised model. In the procedure of putting together the result bearing, it can be required to pay out attention to the shared complementing of the tolerance beliefs. When Chemical≤50mmeters, H7/t6 is definitely adopted; when Chemical>50mmeters, H7/meters6 is certainly adopted. At the same time, it is normally required to make use of reddish colored Dan oil and anti-adhesive agent to accomplish the purpose of safeguarding the hollow shaft, and to avoid the wear and corrosion of the parts to a specific extent, which is normally beneficial for disassembly and set up during maintenance.

In summary, many companies need gear 42578 340to use reducers in the production process. However, credited to several elements, the reducer often offers different faults during procedure, which seriously impacts the safety and reliability of the reducer. It also impacts the creation effectiveness and product quality of the company. At this time, it is necessary 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 immediately provide corresponding maintenance and maintenance to avoid influencing the normal creation process.



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