[Abstract] Reducers are widely used in daily existence, and are used in various mechanical systems in commercial production, such as: automobiles, boats, some heavy equipment and some factory creation lines. The range of the reducer is usually extremely wide, from the transmission of the bigger power to the transmission of the exact angle, the reducer can work very well. The internal framework of the reducer is definitely a range of equipment of different specs. By interlocking the armor and weapon upgrades, the swiftness input from the input shaft can become decreased, and the quickness can be reduced to the mechanical gadget through the result shaft, and the speed can end up being realized. . This paper generally research 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 primarily depends on the gear conversion rate of different sizes, and finally the electric motor shaft velocity reaches the required range, and a huge torque system is definitely attained. In the current practical application, the reducer can be used to transmit mechanical rate and convert mechanised power, and the software of the reducer is definitely even more and even more wide-spread. In the creation process of general industrial enterprises, the acceleration conversion and deceleration of the reducer are mainly utilized to realize the acceleration conversion of numerous mechanised products. Consequently, once the failure of the reducer will significantly have an effect on the production actions of the enterprise, it is normally extremely important to make accurate judgments for the failing of the reducer and to look for a solution to guarantee the normal procedure of various products.
1 Reducer common failure
1.1 Parts heat leaking
In order to improve the working efficiency of the reducer, most reducer manufacturers choose nonferrous 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 stroke and glide between the parts during the working procedure, which produces a great deal of high temperature, and since the components of the internal parts of the reducer are different, the level of thermal growth of the material is certainly different, to ensure that the original installing difference between the parts It becomes smaller and continually wears out friction. At the same period, the lubricating oil between the parts is definitely also affected by the heat range rise, and the concentration becomes slim, producing in essential oil leakage failure of the reducer.
1.2 Turbine wear failure
The components used to make the worm equipment 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 in regular operation, the worm provides a high hardness, which causes long-term friction with the turbine during operation, resulting in severe use 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 program life of the reducer. In addition to the turbine and worm hardness mismatch, the turbine put on and rip, the reducer application and model, the reducer operating period and the weight during the operation of the reducer will generate different levels of use on the turbine of the reducer.
1.3 Drive small 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 straight reducer, the personnel will add a specific amount of lubricant to the inside. When the reducer is normally controlled for a period of period, due to the intake of lubricating oil or leakage, the lubrication of the parts of the reducer is definitely lacking. When the swiftness reducer stops working, the lubricating essential oil will gradually drop to the bottom of the reducer credited to gravity. When the quickness reducer begins once again, the upper part of the equipment or other parts does not have the protection of lubricating essential oil, which is more serious. Use and rip. In this way, not just will the life of the reducer become decreased, but also additional complications will occur due to friction between the parts.
1.4 Worm bearing damage
In the course of action of failure of the reducer, actually if the covered box is well secured, the gear oil may be emulsified, causing in damage, corrosion and rust of the bearing. This is definitely since the sprockets wetness produced by the sudden cooling of the gear oil during the operation of the reducer is agglomerated.
2 Effective method to solve 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. Dust and fine particles in the working environment of the reducer will enter the inside of the machine through the distance of the reducer housing. Since there are many viscous chemicals such as lubricating oil within the reducer, these small contaminants will adhere to the lubricating oil after entering. When the machine is definitely operating, it will be transmitted to all parts of the reducer as the gear rotates, which will result in an increase in the friction of the reducer parts, and ultimately the equipment unit will failure. Therefore, in purchase to ensure the regular operation of the reducer, the staff should pay interest to the operating environment of the reducer. Specifically in some dusty working conditions, a defensive cover can end up being added to the reducer casing according to actual needs to decrease the particles entering the machine and prevent dust from entering the machine, which impacts the steady operation of the machine. . In addition, if the functioning environment of the reducer is fairly severe, after the daily work can be finished, it can be required to clean and check the reducer in time, mainly to clean the dust attached to the body of the decrease gear to avoid the dust and influence the reducer. Regular 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 definitely primarily triggered by the problem of machining precision in the processing process of the reducer. Consequently, when the reducer neglects, the maintenance personnel can cut the machining accuracy and improve the machining precision of the reducer. First of all, in purchase to prevent oil leakage in the chassis, the joint between the higher and lower casings of the machine should become floor to ensure that the casing of the casing can end up being tightly involved; secondly, in the procedure of installing the higher and lower casings of the reducer, a joint should end up being inserted at the joint of the casing. The sealing remove is after that coated with a coating of sealant on the joint to form a shut continuous apron, which efficiently eliminates the oil leakage on the tank surface and ensures the dependability 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 interest to the set up process of the reducer to guarantee the reliability of the reducer. Initial of all, in the procedure of set up of the reducer, advanced calculating devices should become fully used to reinforce the comprehensive inspection of the parts and the dimensions of the parts of the reducer and the precision of the joint parts. For example, check the joint parts of the upper 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 become elevated, and the performance should become examined 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 period, the vibration level of the reducer is decreased by effective inspection, and the operation impact of the reducer is improved to some extent. These tasks can efficiently promise the quality of the reducer installation and lay a solid foundation for the clean procedure of the reducer.
2.4 Standards 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 additional tools to directly strike, so as not to affect the cooperation between these parts. threshold. When replacing parts, pay interest to the components that match the mechanised model. In the process of putting together the result bearing, it is normally necessary to pay out interest to the mutual complementing of the patience beliefs. When Deb≤50mmeters, H7/e6 is followed; when Deb>50mm, L7/m6 is usually followed. At the same period, it is certainly required to use reddish Dan essential oil and anti-adhesive agent to achieve the purpose of safeguarding the hollow shaft, and to prevent the wear and rust of the parts to a certain level, which is normally advantageous for disassembly and installation during maintenance.
In overview, many companies need to make use of reducers in the creation procedure. However, due to numerous elements, the reducer frequently has several problems during procedure, which seriously affects the basic safety and dependability of the reducer. It also impacts the production efficiency and product quality of the company. At this time, it is required for the management and maintenance employees to perform on-site inspections on a regular basis, and to discover out the cause of the failure of the reducer, and immediately provide related maintenance and maintenance to avoid impacting the normal production process.