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Helical Gearbox with Motor

Helical gearbox with motor is a novel reduction transmission device. Adopting the optimized and advanced design concept of modular combination system, it has the characteristics of small size, light weight, large transmission torque, stable starting, and fine transmission ratio classification. It can be connected at will and a variety of installation positions can be selected according to user requirements.

1. It is space-saving, reliable and durable, with high overload capacity, and the power can reach 132KW;
2. Low energy consumption, superior performance, reducer efficiency as high as 95% or more;
3. Low vibration, low noise and high energy saving;
4. Use high-quality forged steel material, rigid cast iron box, and the gear surface has undergone high frequency heat treatment;
5. After precision machining to ensure shaft parallelism and positioning bearing requirements, the reducer forming the helical gear transmission assembly is equipped with various types of motors, combined into an electromechanical integration, which fully guarantees the quality characteristics of the product.

helical gearbox with motor

Classification and application:
1. R series helical gear reducer
R series helical gear reducer has the characteristics of small size, light weight, high carrying capacity, high efficiency, long service life, convenient installation, wide range of motor power, and fine transmission ratio classification. It can be widely used in equipment that needs to slow down in various industries.
2. S series helical gear worm gear motor
The helical gear worm gear reducer adopts the direct connection of the motor, and the structure is a first-stage helical gear plus a first-stage worm gear drive. The output is shaft-mounted, with six basic installation forms. It can run forwards and backwards. The helical gear adopts hard tooth surface, stable operation, large carrying capacity, and the working environment temperature is -10℃~40℃. Compared with similar products, this product has the characteristics of large speed range, compact structure and convenient installation. It can be widely used in the deceleration mechanism of various mechanical equipment such as metallurgy, mining, lifting, light industry, chemical industry, transportation, construction and so on.
3. K series bevel gear-helical gear reducer motor
The bevel gear-helical gear reducer motor adopts the direct connection form of the motor, and the structure is a first-stage helical gear plus a first-stage worm gear drive. The output is shaft-mounted, with six basic installation forms. It can run forwards and backwards. The helical gear adopts hard tooth surface, stable operation, large carrying capacity, and the working environment temperature is -10℃~40℃. Compared with similar products, this product has the characteristics of large speed range, compact structure and convenient installation. It can be widely used in the deceleration mechanism of various mechanical equipment such as metallurgy, mining, lifting, light industry, chemical industry, transportation, construction and so on.
Four. F series parallel shaft gear motor
F series parallel shaft geared motors adopt the modular design principle of unit structure, which greatly reduces the types of parts and inventory, and greatly shortens the delivery cycle. Products are widely used in light industry, food, beer and beverage, chemicals, escalators, automated storage equipment, construction, machinery, iron and steel metallurgy, papermaking, wood-based panel machinery, automobile manufacturing, tobacco machinery, water conservancy, printing and packaging, pharmaceuticals, textiles, building materials , Logistics, feed machinery, environmental protection and other fields.

helical gearbox with motor

common problem:
Heat and oil leakage
In order to improve efficiency, worm gear reducers generally use non-ferrous metals as worm wheels, and worms use harder steel. Because it is a sliding friction drive, more heat will be generated during operation, which will cause differences in thermal expansion between the parts and seals of the reducer, thereby forming gaps in each mating surface, and the lubricating oil will become thinner due to the increase in temperature, which is easy to cause leakage . There are four main reasons for this situation. One is the unreasonable combination of materials; the second is the poor quality of the friction surface; the third is the incorrect choice of lubricant; the fourth is the poor assembly quality and use environment.
Worm gear wear
The worm wheel is generally made of tin bronze, and the matched worm material is hardened with 45 steel to HRC4555, or 40Cr hardened 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 rate is fast, 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 the reducer installed vertically, mainly related to the amount of lubricant added and the oil variety. When installed vertically, it is easy to cause insufficient lubricating oil. When the reducer stops running, the transmission gear oil between the motor and the reducer is lost, and the gears cannot get the proper lubrication protection. When the reducer is started, the gears are not effectively lubricated, causing mechanical wear and even damage.

helical gearbox with motor
Worm bearing damage
When a failure occurs, even if the gearbox is well sealed, it is often found that the gear oil in the reducer is emulsified, and the bearings are rusted, corroded, and damaged. This is because the condensed water generated by the gear oil temperature rises and cools down after a period of operation of the reducer is mixed with water. Of course, it is also closely related to bearing quality and assembly process.

Ensure assembly quality
Some special tools can be purchased or made by yourself. When disassembling and installing reducer parts, 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 Tolerance matching; anti-sticking agent or red lead oil should be used to protect the hollow shaft to prevent wear, rust, or dirt on the mating area, which is difficult to disassemble during maintenance.
Lubricant selection
Helical gear-worm gear reducers generally use 220# gear oil. For reducers with heavy loads, frequent starts, and poor use environments, some lubricant additives can be used to make the gear oil still adhere to the gear surface when the reducer stops running , To form a protective film to prevent heavy load, low speed, high torque and direct contact between metals when starting. The additives contain seal ring regulator and anti-leakage agent to keep the seal ring soft and elastic and effectively reduce lubricating oil leakage.

helical gearbox with motor
Installation location selection
Where the location permits, try not to use vertical installation. In vertical installation, the amount of lubricating oil added is much larger than that in horizontal installation, which may cause heat generation and oil leakage of the reducer.
Lubrication maintenance
The reducer can be maintained according to the "five fixed" principle of lubrication work, so that every reducer has the person responsible for regular inspections, and it is found that the temperature rise is obvious, if the temperature exceeds 40 ℃ or the oil temperature exceeds 80 ℃, the quality of the oil is reduced or the oil If more copper powder and abnormal noise are found in the system, stop using it immediately, check and repair in time, troubleshoot, and replace the lubricant. When refueling, pay attention to the amount of oil to ensure that the reducer is properly lubricated.
Repair method
To solve the problem of reducer wear and leakage, the traditional solution is repair welding or machining and repair after brush plating, but both have certain drawbacks: the thermal stress generated by the high temperature of repair welding cannot be completely eliminated, and it is easy to cause material damage and cause parts to bend. However, the electric brush plating is limited by the thickness of the coating, which is easy to peel off. The above two methods use metal to repair the metal, which cannot change the "hard-to-hard" coordination relationship. Under the combined action of various forces, it will still cause another Wear. Contemporary Western countries often use polymer composite repair methods for the above problems, which have super adhesion, excellent compressive strength and other comprehensive properties, and can be repaired on-site without disassembly and machining. Repairing with polymer materials is not affected by the thermal stress of repair welding, and the repair thickness is not limited. At the same time, the product has a retreat that the metal material does not have, which can absorb the shock and vibration of the equipment, avoid the possibility of re-wear, and greatly extend the equipment components The service life of the company saves a lot of downtime for enterprises and creates huge economic value.

helical gearbox with motor

Advantages and disadvantages:
1. Good meshing performance, low vibration, low noise and stable transmission.
2. Large degree of coincidence. Reduce the load of each pair of gear teeth, relatively increase the bearing capacity of the gear, and have a long life;
3. Because of the surface contact, the force-receiving area is large and the transmission torque is large, which is often used in heavy machinery;
4. The minimum allowable number of teeth of helical gears is less than that of spur gears, so helical gears are not prone to undercutting;
5. The helical gear mechanism is more compact than spur gears, with smaller volume, lighter weight and higher transmission accuracy.
1. The price is higher;
2. Herringbone helical gears have high technical content and are troublesome to manufacture.

Oil spill problem:
Cause Analysis
1. The pressure in the fuel tank increases
In a closed reducer, each pair of gears meshing and friction will generate heat. According to Boyle Mario’s Law, as the operating time increases, the temperature in the reducer gradually rises, and the volume inside the reducer No change, so the pressure in the box will increase, and the lubricating oil in the box will be splashed on the inner wall of the reduction box. Due to the relatively strong oil permeability, under the pressure in the tank, where the seal is not tight, the oil will leak out from where.
2. Unreasonable structure design of reducer causes oil leakage
If the designed reducer has no ventilation cover, the reducer cannot achieve pressure equalization, causing the pressure in the box to become higher and higher, and oil leakage occurs.

helical gearbox with motor
3. Too much fuel
During the operation of the reducer, the oil pool is greatly agitated, and the lubricating oil is splashed everywhere in the machine. If the amount of oil is too much, a large amount of lubricating oil will accumulate on the shaft seal, joint surface, etc., causing leakage.
4. Improper maintenance process
During equipment maintenance, due to incomplete removal of dirt on the joint surface, improper selection of sealant, reverse installation of the seal, and failure to replace the seal in time, oil leakage may also occur.
Treatment plan
Use polymer composite materials to repair and control the oil leakage of the reducer. The polymer composite materials are made of polymer, metal or ceramic ultrafine powder, fiber, etc. as the base material, and are compounded under the action of curing agent and curing accelerator s material. Various materials complement each other in performance and produce a synergistic effect, so that the comprehensive performance of the composite material is better than the original composition material. With strong adhesion, mechanical properties, and chemical corrosion resistance, it is widely used in the repair of mechanical wear, scratches, pits, cracks, leakage, casting sand holes, etc. of metal equipment, as well as various chemical storage tanks , Chemical corrosion protection and repair of reaction tanks and pipelines. For the leakage of the static sealing point of the reducer, the macromolecule composite material and technology can be used to treat the leakage on the spot. There is no need to disassemble. The polymer composite material is externally treated for leakage, saving time and effort, and the effect is immediate. The product has superior adhesion. , Oil resistance and 350% stretch, overcoming the influence caused by the vibration of the reducer, and well solving the problems that have not been solved for many years. If the static sealing point of the reducer leaks oil during operation, the oil surface emergency repair agent of surface engineering technology can be used to stick it to eliminate the oil leakage.

 sogears manufacturing

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