gear box fault diagnosis and solution

[Abstract] Reducers are widely used in daily lifestyle, and are used in various mechanical systems in commercial creation, such while: cars, ships, some large machinery and some factory production lines. The range of the screw jacks reducer can be very wide, from the transmitting of the larger power to the transmission of the specific angle, the reducer can function extremely well. The internal framework of the reducer is certainly a variety of things of different specifications. By interlocking the gears, the speed input from the input shaft can end up being reduced, and the speed can be decreased to the mechanical gadget through the output shaft, and the speeding can be recognized. . This paper mainly studies the common errors of the reducer and lists many effective solutions.

Introduction
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 equipment transformation acceleration of different sizes, and finally the motor shaft rate reaches the needed range, and a sizable torque system is certainly obtained. In the current useful software, the reducer is used to transmit mechanised swiftness and convert mechanical power, and the program of the reducer is certainly more and more prevalent. In the creation procedure of general industrial enterprises, the quickness conversion and deceleration of the reducer are primarily utilized to understand the quickness transformation of different mechanical gadgets. As a result, once the failing of the reducer will seriously affect the creation actions of the business, it is usually very important to make accurate decision for the failure of the reducer and to find a answer to make certain the regular operation of numerous gadgets.

1 Reducer common failure
1.1 Parts warmth leaking
In order to improve the operating efficiency of the reducer, most reducer manufacturers choose non-ferrous materials 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 procedure, which creates a lot of heat, and because the materials of the inner parts of the reducer are different, the level of thermal enlargement of the material is different, so that the unique fitting gap between the parts It becomes smaller and consistently wears out friction. At the same time, the lubricating essential oil between the parts is certainly also affected by the heat rise, and the concentration turns into thin, ensuing in oil leakage failing of the reducer.

1.2 Turbine wear failure
The materials used to help to make the worm gear 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 definitely in normal procedure, the worm has a high hardness, which causes long-term friction with the turbine during procedure, ensuing in significant wear of the turbine. Since the turbine and the worm are key parts of the reducer, the put on of the turbine can lead to a shortened service existence of the reducer. In addition to the turbine and worm hardness mismatch, the turbine put on and tear, the reducer software and model, the reducer functioning period and the fill 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 installing 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 essential oil or leakage, the lubrication of the parts of the reducer is certainly lacking. When the speed reducer halts operating, the lubricating oil will gradually drop to the bottom level of the reducer due to gravity. When the velocity reducer starts again, the top component of the equipment or additional parts does not have the safety of lubricating essential oil, which is usually even more severe. Wear and tear. In this method, not just will the existence of the reducer end up being decreased, but also various other problems will happen due 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 protected, the gear oil might be emulsified, ending in damage, corrosion and corrosion of the bearing. This is certainly because the moisture generated by the unexpected chilling of the equipment essential oil during the procedure of the reducer is definitely agglomerated.

2 Effective way to solve the issue of reducer
2.1 Improve the working environment
The working environment will have a very large impact on the operating efficiency of the reducer. Dust and good contaminants in the operating environment of the reducer will enter the inside of the machine through the difference of the reducer housing. Since there are many viscous substances such as lubricating essential oil in the reducer, these small contaminants will adhere to the lubricating essential oil after entering. When the machine is certainly functioning, 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 eventually the gear device will malfunction. Consequently, in order to make sure the regular procedure of the reducer, the personnel should pay interest to the working environment of the reducer. Especially in some dusty operating environments, a protective cover can be added to the reducer casing relating to actual requirements to reduce the debris entering the machine and prevent dirt from entering the machine, which impacts the stable procedure of the machine. . In addition, if the working environment of the reducer is definitely relatively harsh, after the daily function is normally finished, it is normally required to clean and check the reducer in period, primarily to clean the dirt attached to the body of the reduction gear to avoid the dirt and have an effect on 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 generally caused by the issue of engineering accuracy in the developing procedure of the reducer. As a result, when the reducer breaks down, the maintenance staff can cut the machining accuracy and improve the machining precision of the reducer. Initial of all, in purchase to prevent essential oil leakage in the framework, the joint between the upper and lower casings of the machine should end up being surface to make sure that the casing of the casing can be tightly engaged; subsequently, in the procedure of installing the upper and lower casings of the reducer, a joint should be put at the joint of the casing. The closing strip is definitely then coated with a level of sealant on the joint to type a closed continuous apron, which successfully eliminates the oil leakage on the tank surface area and ensures the reliability 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 organization should pay out interest to the set up procedure of the reducer to make certain the dependability of the reducer. First of all, in the process of installation of the reducer, advanced measuring tools should end up being completely used to strengthen the detailed inspection of the parts and the sizes of the parts of the reducer and the accuracy 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 armor and weapon upgrades; secondly, the installation and inspection power of the reducer should end up being increased, and the overall performance should end up being checked before beginning up. For example, the bolts at the connection part of the reducer show up loose, and should be strengthened in time. At the same time, the vibration degree of the reducer is definitely reduced by effective inspection, and the procedure effect of the reducer is definitely improved to some degree. These jobs can successfully guarantee the quality of the reducer installation and lay a solid basis for the simple 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 changing parts, pay attention to the accessories that match the mechanical model. In the process of assembling the output bearing, it is usually required to pay attention to the mutual matching of the tolerance values. When G≤50mm, L7/t6 is definitely adopted; when G>50mm, H7/m6 can be adopted. At the same time, it is necessary to make use of crimson Dan essential oil and anti-adhesive agent to attain the purpose of safeguarding the hollow shaft, and also to prevent the wear and corrosion of the parts to a certain extent, which is beneficial for disassembly and installation during maintenance.

Conclusion
In overview, many businesses want to make use of reducers in the creation process. However, due to several elements, the reducer often offers various errors during procedure, which significantly impacts the safety and reliability of the reducer. It also affects the creation effectiveness and item quality of the business. At this period, it is definitely necessary for the management and maintenance workers to perform on-site inspections on a regular basis, and to find out the cause of the failing of the reducer, and instantly provide matching maintenance and maintenance to avoid affecting the regular creation process.