speed reducer fault diagnosis and solution

[Abstract] Reducers are widely used in daily life, and are used in various mechanical systems in industrial production, such as: autos, boats, some heavy equipment and some factory creation lines. The range of the reducer is extremely wide, from the transmission of the bigger power to the transmitting of the exact angle, the reducer can work very well. The inner structure of the reducer is usually a range of gears of different specs. By interlocking the things, the acceleration insight from the insight shaft can be decreased, and the acceleration can end up being reduced to the mechanised device through the result shaft, and the acceleration can become understood. . This paper generally research the common faults of the reducer and lists several 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 works, it primarily relies on the gear conversion speed of different sizes, and finally the electric motor shaft quickness gets to the required range, and a big torque mechanism is usually attained. In the current practical program, the reducer is utilized to transmit mechanical velocity and convert mechanised power, and the application of the reducer is usually even more and even more widespread. In the production process of general commercial enterprises, the rate transformation and deceleration of the reducer are generally used to realize the rate conversion of various mechanised devices. Consequently, once the failure of the reducer will significantly influence the production activities of the organization, it is certainly extremely essential to make accurate judgments for the failing of the reducer and also to look for a alternative to make sure the normal procedure of several products.

1 Reducer common failure
1.1 Parts high temperature leaking
In order to enhance the working efficiency of the reducer, most reducer producers 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 constantly rub and slip between the parts during the working process, which generates a great deal of temperature, and since the components of the internal parts of the reducer are different, the degree of thermal expansion of the materials can be different, to ensure that the primary installing distance between the parts It turns into smaller sized and constantly wears out friction. At the same period, the lubricating oil between the parts is usually also affected by the temperatures rise, and the focus becomes slim, resulting in essential oil leakage failure of the reducer.

1.2 Turbine wear failure
The materials used to produce 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 regular operation, the worm provides a high hardness, which causes long lasting friction with the turbine during operation, ending in serious put on of the turbine. Since the turbine and the worm are essential elements of the reducer, the use of the turbine can result in a reduced assistance life of the reducer. In addition to the turbine and worm hardness mismatch, the turbine wear and rip, the reducer program and model, the reducer working time and the load during the procedure of the reducer will generate different levels of use on the turbine of the reducer.

1.3 Drive little helical equipment wear
This type of failure primarily occurs in vertical reducer equipment, which is due to certain problems in the type and amount of lubricant. When setting up the vertical reducer, the personnel will add a particular quantity of lubricant to the inside. When the reducer is certainly controlled for a period of period, due to the usage of lubricating oil or leakage, the lubrication of the parts of the reducer is usually missing. When the acceleration reducer stops functioning, the lubricating essential oil will steadily drop to the bottom of the reducer credited to gravity. When the swiftness reducer begins once again, the upper part of the gear or other parts lacks the security of lubricating oil, which is certainly more critical. Use and rip. In this method, not really only will the life of the reducer be reduced, but also other complications will take place credited to friction between the parts.

1.4 Worm bearing damage
In the course of action of failure of the reducer, even if the sealed package is well shielded, the gear oil may be emulsified, ensuing in damage, corrosion and rust of the bearing. This is usually since the wetness produced by the sudden cooling of the gear oil during the operation of the reducer is certainly agglomerated.

2 Effective method to resolve the problem of reducer
2.1 Improve the functioning environment
The working environment will have a extremely large impact on the operating efficiency of the reducer. Dirt and fine particles in the functioning environment of the reducer will enter the inside of the machine through the space of the reducer casing. Since there are many viscous chemicals such as lubricating oil inside the reducer, these little particles will adhere to the lubricating oil after getting into. When the machine is usually operating, it will be 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 ultimately the equipment unit will failure. Therefore, in purchase to make certain the normal operation of the reducer, the staff should pay out attention to the operating environment of the reducer. Specifically in some dusty working conditions, a defensive cover can become added to the reducer casing regarding to real needs to decrease the particles getting into the machine and prevent dust from getting into the machine, which affects the steady operation of the machine. . In addition, if the operating environment of the reducer is normally fairly severe, after the daily work is definitely completed, it is definitely necessary to clean and check the reducer in time, mainly to clean the dust attached to the body of the decrease equipment to prevent the dust and impact the reducer. Normal operation ensures steady 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 issue is usually mainly triggered by the problem of machining precision in the processing process of the reducer. Consequently, when the reducer does not work out, the maintenance workers can trim the machining precision and enhance the machining accuracy of the reducer. First of all, in order to prevent oil leakage in the chassis, the joint between the top and lower casings of the machine should be floor to ensure that the casing of the casing can become tightly involved; secondly, in the process of setting up the higher and lower casings of the reducer, a joint should end up being placed 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 efficiently eliminates the essential oil leakage on the container surface and guarantees 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. Consequently, the business should pay attention to the installation process of the reducer to make sure the reliability of the reducer. Initial of all, in the procedure of set up of the reducer, advanced calculating instruments should be fully utilized to improve the comprehensive inspection of the parts and the proportions of the parts of the reducer and the precision of the joint parts. For example, check the bones of the higher and lower cabinets. The verticality and level between the shaft, the shaft and the bearing and the patience between the equipment; secondly, the set up and inspection strength of the reducer should be elevated, and the functionality should be examined before starting up. For example, the bolts at the connection component of the reducer appear loose, and should become strengthened in time. At the same period, the vibration level of the reducer is normally decreased by effective inspection, and the operation impact of the reducer is normally improved to some extent. These duties can effectively promise the quality of the reducer set up and place a solid base for the easy procedure of the reducer.

2.4 Standards of installation and repair practices
In order to ensure 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. threshold. When replacing parts, pay out interest to the components that match the mechanised model. In the procedure of putting together the result bearing, it is certainly necessary to pay out interest to the shared complementing of the patience ideals. When D≤50mmeters, H7/k6 is normally used; when D>50mmeters, L7/meters6 is followed. At the same period, it can be required to use red Dan oil and anti-adhesive agent to achieve the purpose of protecting the hollow shaft, and also to avoid the use and rust of the parts to a specific level, which can be beneficial for disassembly and set up during maintenance.

Conclusion
In summary, many companies need to use reducers in the production procedure. Nevertheless, credited to numerous factors, the reducer often provides different faults during operation, which seriously affects the protection and dependability of the reducer. It also impacts the production efficiency and product quality of the company. At this time, it is certainly required for the administration and maintenance staff to perform on-site inspections on a regular basis, and also to discover out the trigger of the failure of the reducer, and immediately offer related maintenance and maintenance to prevent influencing the normal production procedure.