[Abstract] Reducers are widely used in daily life, and are used in various mechanical systems in commercial creation, such as: autos, ships, some large equipment and some factory production lines. The range of the reducer is usually very wide, from the transmission of the larger power to the transmission of the specific angle, the reducer can work extremely well. The inner framework of the reducer is normally a range of equipment of different specs. By interlocking the things, the quickness input from the insight shaft can become decreased, and the velocity can become decreased to the mechanised gadget through the output shaft, and the speed can become recognized. . This paper primarily studies the common faults 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 mainly relies on the gear conversion rate of different sizes, and finally the motor shaft swiftness reaches the needed range, and a huge torque mechanism is definitely attained. In the current practical software, the reducer is utilized to transmit mechanised velocity and convert mechanised power, and the application of the reducer is even more and even more extensive. In the production process of general industrial enterprises, the velocity conversion and deceleration of the reducer are generally used to understand the rate transformation of different mechanical products. As a result, once the failing of the reducer will significantly have an effect on the production actions of the enterprise, it is certainly extremely important to make accurate judgments for the failing of the reducer and also to look for a alternative to ensure the normal procedure of different 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 manufacture the turbine of the reducer, and the material for manufacturing the worm is the harder steel. This causes the reducer to continuously scrub and glide between the parts during the operating process, which produces a lot of high temperature, and since the components of the internal parts of the reducer are different, the level of thermal enlargement of the materials is normally different, to ensure that the primary fitted space between the parts It turns into smaller and continuously wears out friction. At the same period, the lubricating oil between the parts is certainly also affected by the heat rise, and the focus becomes slim, causing 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 steel, and in order to ensure the hardness, it will be quenched and its hardness can reach HRC45-55. When the reducer is in normal procedure, the worm provides a high hardness, which causes long-term friction with the turbine during operation, producing in significant put on of the turbine. Since the turbine and the worm are key components of the reducer, the use of the turbine can lead to a shortened assistance life of the reducer. In addition to the turbine and worm hardness mismatch, the turbine use and rip, the reducer program and model, the reducer functioning period and the fill during the procedure of the reducer will generate different degrees 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 staff will add a specific amount of lubricant to the inside. When the reducer is usually controlled for a period of period, due to the intake of lubricating essential oil or leakage, the lubrication of the parts of the reducer is lacking. When the quickness reducer halts operating, the lubricating essential oil will gradually drop to the bottom of the reducer credited to gravity. When the speed reducer starts again, the top component of the gear or various other parts does not have the security of lubricating oil, which is more serious. Put on and tear. In this way, not really just will the lifestyle of the reducer become reduced, but also additional problems will take place due to friction between the parts.
1.4 Worm bearing damage
In the approach of failure of the reducer, even if the sealed package is well secured, the gear oil might be emulsified, producing in damage, corrosion and rust of the bearing. This is because the moisture produced by the unexpected air conditioning of the equipment oil during the procedure of the reducer is agglomerated.
2 Effective way to solve the problem of reducer
2.1 Improve the working environment
The working environment will have a very 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 space of the reducer housing. Since there are many viscous substances such as lubricating oil within the reducer, these small particles will adhere to the lubricating essential oil after getting into. When the machine is usually operating, it will end up being transmitted to all parts of the reducer as the equipment rotates, which will lead to an boost in the friction of the reducer parts, and ultimately the gear unit will malfunction. Therefore, in order to make sure the regular operation of the reducer, the personnel should pay out interest to the working environment of the reducer. Specifically in some dusty working conditions, a defensive cover can end up being added to the reducer casing according to real requirements to decrease the debris getting into the machine and prevent dirt from getting into the machine, which impacts the stable operation of the machine. . In addition, if the operating environment of the reducer is definitely fairly harsh, after the daily work is usually finished, it is necessary to clean and check the reducer in time, primarily to clean the dust attached to the body of the reduction equipment to avoid the dirt and influence the reducer. Normal operation ensures steady operation 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 issue is normally mainly triggered by the problem of machining precision in the processing procedure of the reducer. Consequently, when the reducer fails, the maintenance staff can trim the machining accuracy and enhance 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 become surface to make sure that the casing of the casing can end up being tightly involved; second of all, in the procedure of installing the higher and lower casings of the reducer, a joint should end up being put at the joint of the casing. The sealing remove is normally after that covered with a layer of sealant on the joint to form a shut constant 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 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. Consequently, the organization should pay out interest to the set up procedure of the reducer to ensure the reliability of the reducer. First of all, in the procedure of set up of the reducer, advanced calculating instruments should become completely utilized to reinforce the comprehensive inspection of the parts and the proportions of the parts of the reducer and the accuracy of the joint parts. For example, check the joints of the higher and lower cabinets. The verticality and level between the shaft, the shaft and the bearing and the tolerance between the gears; secondly, the set up and inspection strength of the reducer should end up being increased, and the efficiency should be examined before beginning 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 degree of the reducer is reduced by effective inspection, and the procedure impact of the reducer is improved to some extent. These tasks can successfully promise the quality of the reducer installation and lay a solid base for the even operation of the reducer.
2.4 Standards of installation and repair practices
In order to make certain 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 various other tools to directly strike, so as not to affect the cooperation between these parts. patience. When changing parts, pay out interest to the variators accessories that match the mechanised model. In the procedure of putting together the result bearing, it is normally required to pay interest to the mutual matching of the patience beliefs. When D≤50mmeters, L7/k6 is usually followed; when Chemical>50mmeters, L7/m6 is usually used. At the same time, it is definitely necessary to make use of crimson Dan oil and anti-adhesive agent to obtain the purpose of safeguarding the hollow shaft, and also to avoid the wear and rust of the parts to a certain degree, which is definitely advantageous for disassembly and set up during maintenance.
In overview, many businesses need to use reducers in the creation process. Nevertheless, due to different factors, the reducer often offers several errors during operation, which seriously affects the safety and reliability of the reducer. It also impacts the creation performance and item quality of the company. At this period, it is necessary for the management and maintenance personnel to perform on-site inspections on a regular basis, and to find out the trigger of the failure of the reducer, and immediately provide related maintenance and maintenance to avoid affecting the normal creation process.