gearbox fault diagnosis and solution

[Abstract] Reducers are widely used in daily lifestyle, and are used in various mechanical systems in industrial production, such as: vehicles, boats, some heavy machinery and some factory creation lines. The range of the reducer is extremely wide, from the transmission of the larger power to the transmitting of the specific angle, the reducer can function very well. The internal structure of the reducer is certainly a variety of equipment of different specs. By interlocking the gears, the speed insight from the insight shaft can end up being decreased, and the swiftness can end up being reduced to the mechanical device through the output shaft, and the speed can be noticed. . This paper generally research the common errors 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 works, it mainly depends on the equipment transformation speed of different sizes, and finally the engine shaft acceleration gets to the required range, and a huge torque sprial bevel gear system can be obtained. In the current useful application, the reducer is used to transmit mechanised rate and convert mechanised power, and the software of the reducer can be more and even more prevalent. In the creation procedure of general commercial enterprises, the rate transformation and deceleration of the reducer are mainly used to realize the velocity transformation of several mechanical devices. Therefore, once the failing of the reducer will significantly affect the production actions of the enterprise, it is usually very important to make accurate decision for the failure of the reducer and to find a solution to guarantee the regular procedure of numerous products.

1 Reducer common failure
1.1 Parts temperature leaking
In order to enhance the working efficiency of the reducer, most reducer manufacturers choose nonferrous materials to produce the turbine of the reducer, and the materials for manufacturing the worm is the harder steel. This causes the reducer to continuously scrub and slide between the parts during the functioning procedure, which generates a lot of high temperature, and because the components of the inner parts of the reducer are different, the degree of thermal growth of the materials is different, so that the original fitted difference between the parts It becomes smaller sized and continuously wears out friction. At the same period, the lubricating oil between the parts is normally also affected by the temp rise, and the concentration becomes thin, producing in essential oil leakage failing of the reducer.

1.2 Turbine wear failure
The materials used to make the worm gear are generally nonferrous 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 normally in normal operation, the worm has a high hardness, which causes long-term friction with the turbine during procedure, causing in significant wear of the turbine. Since the turbine and the worm are key components of the reducer, the wear of the turbine can result in a reduced provider life of the reducer. In addition to the turbine and worm hardness mismatch, the turbine put on and rip, the reducer program and model, the reducer working time and the load during the procedure of the reducer will create different levels of put on on the turbine of the reducer.

1.3 Drive little helical gear 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 installing the vertical reducer, the staff will add a certain amount of lubricant to the inside. When the reducer is operated for a period of period, credited to the usage of lubricating essential oil or leakage, the lubrication of the parts of the reducer is certainly lacking. When the swiftness reducer stops functioning, the lubricating oil will gradually drop to the bottom of the reducer due to gravity. When the quickness reducer starts again, the higher part of the equipment or various other parts does not have the security of lubricating oil, which is usually even more significant. Use and tear. In this method, not really just will the existence of the reducer become decreased, but also other complications will happen due to friction between the parts.

1.4 Worm bearing damage
In the course of action of failure of the reducer, actually if the sealed box is well protected, the gear oil may be emulsified, causing in damage, corrosion and rust of the bearing. This is because the dampness generated by the sudden air conditioning of the gear essential oil during the procedure of the reducer can be agglomerated.

2 Effective way to resolve the issue of reducer
2.1 Improve the working environment
The working environment will have a extremely large impact on the operating efficiency of the reducer. Dirt and good particles in the working environment of the reducer will enter the inside of the machine through the difference 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 certainly operating, it will become 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 unit will failure. Therefore, in order to guarantee the regular procedure of the reducer, the staff should pay attention to the working environment of the reducer. Especially in some dusty operating conditions, a protective cover can be added to the reducer casing regarding to real requirements to decrease the particles getting into the machine and prevent dust from entering the machine, which affects the stable operation of the machine. . In addition, if the working environment of the reducer can be fairly severe, after the daily function is completed, it is usually required to clean and check the reducer in period, 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 accuracy of the reducer
The common faults of the reducer also include the oil leakage of the chassis. The fundamental problem is certainly primarily triggered by the problem of engineering accuracy in the making procedure of the reducer. Consequently, when the reducer falters, the maintenance workers can trim the machining precision and improve the machining accuracy of the reducer. First of all, in order to prevent essential oil leakage in the framework, the joint between the upper and lower casings of the machine should be ground to make sure that the casing of the casing can become tightly engaged; secondly, in the procedure of installing the upper and lower casings of the reducer, a joint should become inserted at the joint of the casing. The closing strip is then coated with a coating of sealant on the joint to type a shut continuous apron, which efficiently eliminates the essential oil leakage on the container surface and ensures the dependability of the operation 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. Consequently, the company should pay out interest to the installation procedure of the reducer to make certain the reliability of the reducer. First of all, in the procedure of installation of the reducer, advanced calculating tools should be fully utilized to strengthen the detailed inspection of the parts and the dimensions of the parts of the reducer and the accuracy of the joint parts. For example, check the joint parts of the top and lower cabinets. The verticality and level between the shaft, the shaft and the bearing and the patience between the gears; secondly, the set up and inspection strength of the reducer should end up being improved, and the performance should be checked before starting up. For example, the bolts at the connection component of the reducer show up loose, and should be reinforced in time. At the same period, the vibration level of the reducer is normally reduced by effective inspection, and the operation effect of the reducer is usually improved to some degree. These duties can efficiently guarantee the quality of the reducer installation and lay a solid foundation for the smooth procedure of the reducer.

2.4 Standards of installation and repair practices
In order to guarantee 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 utilizing a hammer and other tools to directly strike, so as not to affect the cooperation between these parts. tolerance. When replacing parts, pay out attention to the components that match the mechanised model. In the procedure of assembling the result bearing, it is definitely necessary to pay attention to the mutual matching of the tolerance beliefs. When Chemical≤50mm, L7/t6 is definitely followed; when M>50mmeters, H7/m6 is adopted. At the same period, it is definitely necessary to make use of reddish Dan essential oil and anti-adhesive agent to attain the purpose of safeguarding the hollow shaft, and also to avoid the wear and corrosion of the parts to a particular level, which is usually beneficial for disassembly and set up during maintenance.

In overview, many companies want to make use of reducers in the production procedure. However, due to numerous factors, the reducer often has various faults during procedure, which seriously affects the security and reliability of the reducer. It also affects the production performance and product quality of the firm. At this period, it can be necessary for the administration and maintenance employees to perform on-site inspections on a regular basis, and to discover out the trigger of the failure of the reducer, and immediately provide matching maintenance and maintenance to avoid impacting the normal production process.


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