Fault Analysis and Solution Methods for WPEEDO135-200,WPEEDO155-250,WPWEK40-70,WPWEK50-80,WPWEK60-100 Gear Reducers
Due to the harsh operating environment of the gearbox, faults such as wear and leakage often occur, mainly including:
1. The bearing chamber of the gearbox is worn, including the wear of the housing bearing box, the bearing chamber of the inner hole of the housing, and the bearing chamber of the gearbox;
2. The gear shaft diameter of the reducer is worn, mainly at the shaft head, keyway, etc;
3. The bearing position of the gearbox transmission shaft is worn;
4. Leakage at the joint surface of the gearbox.
The traditional solution to the problem of wear and tear is repair welding or machining after brush plating, but both have certain drawbacks: the thermal stress generated by high temperature repair welding cannot be completely eliminated, which can easily cause material damage, leading to bending or fracture of the components; However, brush plating is limited by the thickness of the coating and is prone to peeling, and both methods use metal to repair the metal, which cannot change the "hard to hard" relationship. Under the combined action of various forces, it will still cause re wear. For some large bearing enterprises, on-site solutions are even more difficult, and they often rely on external repair. Contemporary Western countries often use polymer composite materials as repair methods to address these issues, which have comprehensive properties such as strong adhesion and excellent compressive strength. The application of polymer materials for repair can avoid disassembly and machining, without the influence of welding thermal stress, and the repair thickness is not limited. At the same time, the metal materials in the product do not have the flexibility to absorb the impact and vibration of the equipment, avoid the possibility of re wear, and greatly extend the service life of equipment components, saving a lot of downtime for enterprises and creating huge economic value.
In response to the problem of leakage, traditional methods require disassembling and opening the gearbox, replacing the sealing gasket or applying sealant, which is not only time-consuming and labor-intensive, but also difficult to ensure the sealing effect, and leakage may occur again during operation. Polymer materials can be used for on-site leakage control. The superior adhesion, oil resistance, and 350% elongation of the materials overcome the impact of gearbox vibration and effectively solve the problem of gearbox leakage for enterprises.
Analysis of the causes of oil leakage in the gearbox
1. Pressure difference between the inside and outside of the reducer: During the operation of the reducer, the friction and heating of the moving pair, as well as the influence of environmental temperature, cause the temperature of the reducer to increase. If there are no ventilation holes or the ventilation holes are blocked, the internal pressure gradually increases. The higher the internal temperature, the greater the pressure difference with the outside world. Under the pressure difference, lubricating oil leaks out from the gap.
2. Unreasonable structural design of the gearbox
1) The inspection hole cover plate is too thin, and it is easy to deform after tightening the bolts, causing uneven joint surfaces and oil leakage from the contact gap;
2) During the manufacturing process of the gearbox, if the casting is not annealed or aged, and internal stress is not eliminated, deformation will inevitably occur, resulting in gaps and leakage;
3) There is no oil return groove on the box, and lubricating oil accumulates in the shaft seal, end cover, joint surface, etc. Under the pressure difference, it leaks out from the gap;
4) The design of the shaft seal structure is unreasonable. Early reducers mostly used oil groove and felt ring type shaft seal structures, which caused deformation of the felt during assembly and sealed the gaps on the joint surface. If the contact between the journal and the seal is not very ideal, due to the poor compensation performance of the felt, the seal will fail in a short period of time. Although there are oil return holes on the oil ditch, they are easily blocked and the oil return effect is difficult to exert.
3. Excessive refueling: During the operation of the gearbox, the oil pool is stirred violently, and the lubricating oil splashes everywhere inside the machine. If the refueling amount is too much, a large amount of lubricating oil accumulates in the shaft seal, joint surface, and other areas, leading to leakage.
4. Improper maintenance process: During equipment maintenance, oil leakage can also occur due to incomplete removal of dirt on the joint surface, improper selection of sealant, reverse installation of sealing components, and untimely replacement of sealing components.
