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Helical bevel geared motor in cement industry

The helical gear reducer is a novel reduction gear. Adopting the optimization, the advanced design concept of the modular combination system has the characteristics of small size, light weight, large transmission torque, stable starting, fine classification of transmission ratio, etc., and can be connected according to user requirements and a variety of installation positions.

Helical bevel geared motor in cement industry

Features:
1. Space saving, reliable and durable, with high overload capacity, power up to 132KW;
2, low energy consumption, superior performance, the efficiency of the reducer is as high as 95% or more;
3. Low vibration, low noise and high energy saving;
4, the selection of high-quality forged steel materials, steel cast iron box, the surface of the gear after high-frequency heat treatment;
5. After precision machining to ensure the parallelism of the shaft and the requirements of the positioning bearing, the reducer that forms the helical gear transmission assembly is equipped with various types of motors, which are combined into mechatronics, which fully guarantees the quality characteristics of the products.

Classification and application:
First, R series helical gear reducer
R series helical gear reducer has the characteristics of small size, light weight, high bearing capacity, high efficiency, long service life, convenient installation, wide motor power range and fine classification of transmission ratio. Can be widely used in equipment that needs to be decelerated in various industries.
Second, S series helical gear worm gear reducer
The helical gear worm reducer adopts the direct connection mode of the motor, and the structure is a first stage helical gear plus a first stage worm gear transmission. The output is shaft mounted and comes in six basic mounting styles. It can be reversed and reversed. The helical gear adopts hard tooth surface, stable operation, large carrying capacity, working environment temperature -10 °C ~ 40 °C. This product has the characteristics of large speed variation range, compact structure and convenient installation compared with similar products. Can be widely used in metallurgy, mining, lifting, light industry, chemical, transportation, construction and other mechanical equipment speed reduction mechanism.

Third, K series bevel gear - helical gear motor
The bevel gear-helical gear reduction motor adopts the direct connection mode of the motor, and the structure is a first-stage helical gear plus a first-stage worm gear transmission. The output is shaft mounted and comes in six basic mounting styles. It can be reversed and reversed. The helical gear adopts hard tooth surface, stable operation, large carrying capacity, working environment temperature -10 °C ~ 40 °C. This product has the characteristics of large speed variation range, compact structure and convenient installation compared with similar products. Can be widely used in metallurgy, mining, lifting, light industry, chemical, transportation, construction and other mechanical equipment speed reduction mechanism.
Four. F series parallel shaft geared motor
The F series parallel shaft geared motor adopts the unit structure modular design principle, which greatly reduces the types of parts and stocks, and greatly shortens the delivery cycle. Products are widely used in light industry, food, beer and beverage, chemical, escalator, automated storage equipment, construction, machinery, steel metallurgy, paper, wood-based machinery, automobile manufacturing, tobacco machinery, water conservancy, printing and packaging, pharmaceutical, textile, building materials , logistics, feed machinery, environmental protection and other fields.

Helical bevel geared motor in cement industry

common problem:
Fever and oil leakage
In order to improve efficiency, worm gear reducers generally use non-ferrous metals for worm gears, while worms use harder steel. Because it is a sliding friction transmission, more heat is generated during operation, which causes a difference in thermal expansion between the various parts of the reducer and the seal, thereby forming a gap in each mating surface, and the lubricating oil is thinned due to an increase in temperature, which is liable to cause leakage. . There are four main reasons for this situation. One is that the material is not properly matched; the other is the poor quality of the surface of the friction surface; the third is that the amount of lubricant added is not correct; the fourth is the poor quality of assembly and use.

Worm gear wear
The worm gear is generally made of tin bronze, and the paired worm material is hardened to 45°C to HRC4555, or 40Cr hardened to HRC5055 and then ground to a roughness of Ra0.8μm by a worm grinder. The reducer wears very slowly during normal operation, and some reducers can be used for more than 10 years. If the wear speed is faster, it is necessary to consider whether the selection is correct, whether it is overloaded, and the material, assembly quality or use environment of the worm gear.
Gear wear
It usually occurs on a vertical mounted reducer, mainly related to the amount of lubricant added and the type of oil. When the vertical installation is installed, it is easy to cause insufficient lubricant. When the reducer stops running, the transmission gear oil between the motor and the reducer is lost, and the gears are not protected by the lubrication. When the reducer is started, the gears are mechanically worn or even damaged due to the lack of effective lubrication.

Broken worm bearing
In the event of a fault, even if the gearbox is well sealed, it is often found that the gear oil in the reducer is emulsified and the bearing is rusted, corroded and damaged. This is because the condensed water produced by the gear oil temperature rises and cools after mixing for a period of time. Of course, it is also closely related to bearing quality and assembly process.

Advantages and disadvantages:
advantage
1. Good meshing performance, low vibration, low noise and stable transmission.
2. The degree of coincidence is large. The load of each pair of teeth is reduced, the bearing capacity of the gear is relatively increased, and the service life is long;
3, because of the surface contact, the force area is large, the transmission torque is large, and it is often used on heavy machinery;
4. The minimum number of teeth of the helical gear is less than the minimum number of teeth of the spur gear, so the helical gear is not easy to undercut;
5. The helical gear mechanism is compacter than the spur gear, small in size, light in weight and high in transmission precision.
Disadvantages:
1. The price is higher;
2. Herringbone helical gears have high technical content and are more troublesome to manufacture.

In the long-term operation of the reducer, there are often faults such as wear and leakage. The most important ones are:
1. The bearing chamber of the reducer is worn, which in turn includes the wear of the bearing housing of the housing, the bearing chamber of the housing, and the bearing chamber of the transmission.
2. The shaft diameter of the gear shaft of the reducer is worn, and the main wear parts are in the shaft head and keyway.
3. The bearing position of the reducer drive shaft is worn.
4. The reducer joint surface leaks.

For the wear problem, the traditional solution of the enterprise is repairing after repair welding or brush plating, but both have certain drawbacks: the thermal stress generated by the repair welding high temperature cannot be completely eliminated, which may cause damage to the material and cause the parts to bend or break; Brush plating is limited by the thickness of the coating, and it is easy to peel off. The above two methods use metal to repair the metal, which can not change the "hard to hard" coordination relationship. Under the combined action of each force, it will still cause re-wear. For some large bearing enterprises, it is impossible to solve on-site, and it is necessary to rely on external repair. In the contemporary Western countries, the repair method of polymer composite materials is often used for the above problems, and the application has more comprehensive properties such as superior adhesion and excellent compressive strength. The application of polymer material repair can be free of disassembly and machining without the influence of repair welding thermal stress, and the thickness of the repair is not limited. At the same time, the metal material of the product does not have the concession, which can absorb the shock vibration of the equipment and avoid the wear again. It is possible, and greatly extends the service life of equipment components, saving a lot of downtime for the enterprise and creating huge economic value

Helical bevel geared motor in cement industry

Troubleshooting:
Guarantee assembly quality
You can purchase or make some special tools. When disassembling and installing the parts of the reducer, try to avoid hitting with other tools such as hammers. When replacing gears and worm gears, try to use original parts and replace them in pairs. When assembling the output shaft, pay attention to it. Tolerance fit; use a release agent or red dan oil to protect the hollow shaft to prevent wear and rust or to match the area scale, which is difficult to disassemble during maintenance.
Lubricating oil selection
Helical gear-worm gear reducer generally uses 220# gear oil. For heavy-duty, frequent start-up and poor-use reducer, some lubricating oil additives can be used to keep the gear oil attached to the gear surface when the reducer stops running. Form a protective film to prevent direct contact between the metal under heavy load, low speed, high torque and start-up. The additive contains a seal regulator and a leak preventer to keep the seal soft and elastic, effectively reducing oil leakage.

Installation location selection
When possible, do not use a vertical installation. When installing vertically, the amount of lubricating oil added is much more than that of horizontal installation, which may cause heat generation and oil leakage of the reducer.
Lubrication maintenance
The reducer can be maintained according to the “five-set” principle of lubrication work. Every reducer has a responsible person to check regularly and find that the temperature rise is obvious. If the temperature exceeds 40°C or the oil temperature exceeds 80°C, the quality of the oil will drop or oil. When more copper powder is found and abnormal noise is generated, stop using it immediately, repair it in time, troubleshoot it, and replace the oil. When refueling, pay attention to the amount of oil to ensure that the gear unit is properly lubricated.

Treatment plan
The polymer composite material is used to repair and treat the leakage oil of the reducer. The polymer composite material is made of high molecular polymer, metal or ceramic ultrafine powder, fiber and the like, and is compounded by the curing agent and the curing accelerator. s material. Various materials complement each other in performance and produce synergistic effects, so that the overall performance of the composite material is superior to the original constituent materials. With strong adhesion, mechanical properties, and chemical resistance, it is widely used in metal equipment for mechanical wear, scratches, pits, cracks, leaks, repair of sand holes, etc., as well as various chemical storage tanks. Chemical corrosion protection and repair of reaction tanks and pipelines. For the static sealing point leakage of the reducer, the surface of the reducer can be treated with MEGAHUA polymer composite materials and technology without disassembly. The polymer composite material is leaked outside, saving time and effort, and the effect is immediate. The superior adhesion of the product. , oil resistance and 350% stretch, to overcome the impact of the vibration of the reducer, a good solution for the enterprise can not solve the problem for many years. If the static sealing point leaks during the operation of the reducer, it can be blocked by the surface engineering technology oil surface emergency repair agent, so as to eliminate the oil leakage.

The product adopts high axial and radial load, high output torque and high reliability. It can be combined with other series of speed reducers to synthesize high torque and high speed ratio. The combination of smooth, reliable, durable and low noise operation products has many kinds of speed ratios and wide coverage. Maintenance service costs are low. However, on the other hand, the product cost is higher. The volume of the product is relatively large and the type is less than that of the hollow shaft. R series products are widely used in power, coal, cement, metallurgy, port, environmental protection, chemical, logistics, textile, manufacturing, light power, plastics, petroleum, shipbuilding industry equipment products using a series of, modular design ideas, make products With a wide range of adaptability, a single product can be independently implemented to achieve its functions, and can be combined with this series or other models to form a customer to meet different needs.

Machine features:
1. The gear is made of high-strength low-carbon alloy steel by carburizing and quenching. The hardness of the tooth surface is up to HRC58-62. The gears are all CNC grinding technology with high precision and good contact.
2. High transmission rate: single stage is greater than 96.5%, double level is greater than 93%, and third level is greater than 90%.
3. Smooth operation and low noise.
4. Small size, light weight, long service life and high carrying capacity.
5. Easy to disassemble and easy to install

Gear reducer use, maintenance and precautions
1. The reducer adopts 460# medium load industrial gear oil, and the working environment temperature is 0~40°C.
Second, after the first use for 100 hours, the inner cavity should be cleaned and replaced with new gear oil, and the oil should be changed every 2000 hours.
3. When disassembling and installing the reducer, hammering should be avoided as much as possible to avoid damage to normal parts.
4. If it is found that there is oil leakage at the shaft extension or joint during use, the seals such as the skeleton oil seal should be replaced in time.

Helical bevel geared motor in cement industry

Maintenance method:
For the wear and tear of the reducer, the traditional solution is repairing after repair welding or brush plating, but both have certain drawbacks: the thermal stress generated by the repair welding high temperature cannot be completely eliminated, which is easy to cause material damage, resulting in bending of the parts. Or rupture; while brush plating is limited by the thickness of the coating, it is easy to peel off, and the above two methods use metal to repair the metal, and can not change the "hard to hard" coordination relationship. Under the combined action of each force, it will still cause again abrasion. In the contemporary Western countries, the repair method of polymer composite materials is often used for the above problems, and it has super-adhesive strength, excellent compressive strength and other comprehensive properties, and can be repaired on site without disassembly and machining. The maintenance of polymer materials has no influence on the thermal stress of repair welding, and the thickness of repair is not limited. At the same time, the metal material of the product does not have the concession, which can absorb the shock and vibration of the equipment, avoid the possibility of re-wearing, and greatly extend the equipment components. The service life saves a lot of downtime for the company and creates huge economic value.

Oil spill problem:
Cause Analysis

1. The pressure in the fuel tank rises.
In the closed reducer, each pair of gears meshes with each other to generate heat. According to the Boeing's law, as the running time is lengthened, the temperature inside the gearbox is gradually increased, and the volume inside the chassis is reduced. It does not change, so the pressure inside the box increases, and the lubricating oil in the box is splashed and sprinkled on the inner wall of the reduction chassis. Because the oil has a relatively high permeability, under the pressure inside the box, which one is not tightly sealed, the oil will seep out from there.
2. The structural design of the reducer is unreasonable and causes oil leakage.
If the designed reducer does not have a hood, the reducer cannot achieve equalization, resulting in higher and higher pressure inside the tank and oil leakage.
3, too much fuel
During the operation of the reducer, the oil pool is stirred a lot, and the lubricating oil splashes everywhere in the machine. If the amount of oil is too much, a large amount of lubricating oil accumulates in the shaft seal, joint surface, etc., resulting in leakage.
4, improper maintenance process
During equipment maintenance, oil leakage may occur due to incomplete removal of dirt on the bonding surface, improper selection of sealant, reverse orientation of the seal, and failure to replace the seal in time.

Gear reducer is generally used for transmission equipment with low speed and high torque. The ordinary reducer of the motor will also have several pairs of identical gears to achieve the desired deceleration effect. The ratio of the number of teeth of the large and small gears is the transmission ratio. With the continuous development of the reducer industry, more and more enterprises have applied the reducer.
Gear reducer 1, R series coaxial helical gear reducer combined with international technical requirements, with high technology content 2, space saving, reliable and durable, with high overload capacity, power up to 132KW; 3, low energy consumption, Excellent performance, the speed reducer efficiency is up to 95%; 4, low vibration, low noise, high energy saving; 5, high-quality forged steel material, steel cast iron box, gear surface after high-frequency heat treatment; 6, after precision machining, ensure Shaft parallelism and positioning bearing requirements, the reducer that forms the helical gear transmission assembly is equipped with various types of motors, combined into mechatronics, which fully guarantees the quality characteristics of the products.

For the leakage problem, the traditional method needs to disassemble and open the reducer, replace the sealing gasket or apply the sealant, which is not only time-consuming and laborious, but also difficult to ensure the sealing effect, and leakage will occur again during operation. The polymer material can be used to treat leakage on site. The material has excellent adhesion, oil resistance and 350% elongation, which overcomes the impact caused by the vibration of the reducer, and solves the problem of leakage of the reducer for the enterprise.Helical bevel geared motor in cement industry

 

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