5464-836

WOODWARD  5464-836

 

减速机使用过程中可能出现的故障有：漏油、轴承部位过热、噪音大、减速机油池温度过高(高于70度)、减速机异响、主动轴窜轴、轴承碎裂、齿轮损坏等，现分析其产生原因及预防措施。

    简单篇

    减速机是一种动力传递机构，利用齿轮的速度转换器，将马达的回转数减速到所要的回转数，并得到较大转矩的机构。

    减速机的种类很多，按照传动类型可分为齿轮减速机、蜗杆减速机和行星减速机以及它们互相组合起来的减速机；

    按照传动的级数可分为单级和多级减速机；按照齿轮形状可分为圆柱齿轮减速机、圆锥齿轮减速机和圆锥一圆柱齿轮减速机；

    按照传动的布置形式又可分为展开式、分流式和同轴式减速机。

    齿轮采用油池润滑和循环润滑两种形式。

    润滑油应定期检查更换，新安装的减速机第一次使用时，在运转10－15天以后，须更换新油。以后应定期（2-3个月）检查油的质量状况，发现不符合要求时应立即更换，一般至少每半年换油一次。

    分析篇

    1减速机齿轮点蚀与剥落由哪些原因？

    1、材质、硬度和缺陷。

    齿轮的材质不符合要求；影响齿轮接触疲劳强度的主要因素是热处理后的硬度较低，无法保证齿轮应有的接触疲劳强度。此外，齿表面或内部有缺陷，也是接触疲劳强度不够的原因之一。

    2、齿轮精度较差。

    齿轮加工和装配精度不符合要求，如啮合精度、运动精度较差等。还有圆弧齿轮的壳体中心距误差太大。

    3、润滑油不符合要求。

    使用的润滑油的牌号不对，油品的粘度较低，润滑性能较差。

    4、油位过高。

    油位过高，油的温升高，降低了润滑油的粘度，破坏了润滑性能，减少了油膜的工作厚度。

    2请简单分析减速机串轴原因？

    1、是由于断齿使输入轴失去轴向约束而发生串轴。

    2、是中间轴上的从动齿轮与轴紧固不牢所致。在实际传动中，往往由于从动齿轮与中间轴之间的过盈量不够，从动齿轮相对中间轴产生轴向串动，进而使输入轴发生轴向串动。因此，过盈量不够是造成减速机串轴的主要原因。

    3、减速机的转向对串轴也有一定的影响。

    3请简单分析减速机油温过高的原因？

    1、润滑油不合格或使用时间过长。

    2、润滑油过多，不利于齿轮箱内机构散热。

    3、机件损坏。机件损坏包括齿轮点蚀严重，断齿，轴承保持架、内外圈、滚珠损坏以及轴承抱死或轴变形严重；

    4、箱体外部被杂物或灰尘覆盖。当减速机周围堆放东西或机体表面长期没有清理时，有可能因杂物或灰尘的覆盖导致减速机散热不完全以致使油温升高；

    5、冷却装置堵塞或失效。冷却装置同减速机一样置于灰尘较大的厂房中，如果长期工作而未清理内部的管路造成冷却装置堵塞或冷却装置坏掉时，都会引起减速机油温升高；

    4平常的维护保养及故障

    1、平常主要的维护保养包括：

    安装时的调整和试车

    定期检查、高温点检和油质化验

    定期补油和换油

    2、常见的故障主要有：

    减速机振动大

    有杂音

    油温高

    漏油

    齿轮损坏

    串轴

    轴承碎裂

    维修保养篇

    1安装和调整

    1、为保障减速机装配精度，安装时不必开机，不破坏密封填胶，可通过开启视油盖检查或用煤油（柴油）侵洗齿轮表面防锈脂。

    2、减速机和电机或主机等联接件之间采用弹性连轴器也可采用齿轮连轴器或其他非刚性连轴器。

    3、减速机应安装平稳牢固，底座调整垫片必须堑实（选用钢垫）。和联接件的同轴度偏差不得大于所用连轴器的允许值。

    4、检查箱体各密合面螺栓是否松动，如有松动重新紧固。

    2使用和维护

    1、减速机正式使用前必须进行负荷试车。

    2、负荷试车前应该按油标位置添加润滑油，用手转动，使输出轴旋转一周，必须灵活，然后空运转两小时，应无不正常的噪音。

    3、负荷试车时应逐步加载至满负荷（有条件时应按25％、50％、75％、100％分四个阶段加载），每个阶段运转的时间不少于2小时，应平稳无冲击振动和漏油，确信无故障后将机内润滑油放掉或用200目过滤网将油过滤后方可使用。

    4、试车过程中如有异常情况应查明原因，予以排除，并立即通知制造厂。

    5、减速机运行半年应检修一次，以后应定期（每周）检查齿面有无点蚀、擦伤、胶合等缺陷，若缺陷面积沿齿长和齿高方向超过20％，并继续发展应更换齿轮副。

    润滑篇

    1、齿轮采用油池润滑和循环润滑两种形式，按设备说明选用润滑油，软齿面、中硬齿面减速机采用：N100～150，硬齿面及行星减速机采用：N220～320。

    2、润滑油应定期检查更换，新安装的减速机第一次使用时，在运转10－15天以后，须更换新油。以后应定期（2-3个月）检查油的质量状况，发现不符合要求时应立即更换，一般至少每半年换油一次。

    在化验油质量时，若遇到下列情况之一必须及时换润滑油：

    润滑油中异物含量超过2%；

    润滑油中金属磨料超过0.5%；

    润滑油中含水量超过2%；

    3、减速机的日常维护保养主要是巡检有无渗油，及时检查箱内液位，润滑情况是否良好，各处螺丝是否坚固完好，定期检查设备的温度情况，运行一定时间要用铅丝咬入齿轮的啮合位，以测齿磨损情况。

    漏油篇

    1原因分析

    漏油方式有多种，但最常见的是主动、从动轴头的密封处漏油，尤其是主动轴密封圈处漏油最为严重。除上述几种情况外，还有以下3个漏油部位：

    沿减速机合箱面处漏油；

    沿减速机上面的视孔盖处漏油；

    沿减速机底部的放油孔处漏油；

    视孔盖处和放油孔处漏油，主要是固定螺栓没有完全拧紧或没有装密封垫片所致。

    个别减速机在组装合箱时，合箱面上留有铁屑使合箱面不严而发生漏油。合箱面漏油的原因，除上述因素外，更重要的是减速机经过一段时间使用之后，壳体发生变形，造成合箱面不平，贴合不紧而发生漏油。

    2预防及排除方法

    1、密封圈压盖采用易拆卸式结构。

    2、密封圈采用开口结构。

    3、输入轴轴承处回油孔要适当加大。

    4、对减速机壳体进行时效处理，可防止壳体变形，避免沿合箱面处漏油。目前有3种时效方法，一是自然失效；二是人工时效；三是振动时效。可根据实际条件进行选择和处理。

    5、在减速机底座的合箱面上铸造出或加工出一条环形油槽，且有多个回油孔与环形油槽连通。在减速机工作时，一旦有油渗入合箱面，将会进入环形油槽，再经回油孔流入油箱内，润滑油不会沿合箱面漏到减速机壳体外面。

    6、组装减速机时，在合箱面上涂一层密封胶（如D05硅橡胶密封胶），可有效地防止合箱面处漏油。

    7、减速机油位过高，不仅增加齿轮搅动油的功率损失，润滑油飞溅严重增加漏油机会，而且还导致油温不断升高，特别是夏季，环境温度高，会使油温增加，润滑油粘度下降，降低润滑性能，增加油的流动性和漏失量，直接影响齿轮和轴承的润滑，降低使用寿命。为此，在使用时必须保持正常的油位高度。

    8、在视孔盖处和放油孔处加装密封垫，且拧紧螺栓。

    9、加大输出轴的回油孔，可防止输出轴漏油。

    10、改进透气帽和检查孔盖板。减速机内压大于外界大气压是漏油的主要原因之一，如果设法使机内、机外压力均衡，漏油就可以防止。减速机虽都有透气帽，但透气孔太小，容易被灰尘、油污堵塞，而且每次加油都要打开检查孔盖板，打开一次就增加一次漏油的可能性，使原本不漏的地方也发生泄漏。可加大透气孔，使内外均压。

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P0918PZ DCS FBM, WDI07A

P0918QC DCS FBM, WDI07B

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P0918SQ DCS FBM, WLJ04A

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P0918VA 10/20 Gb EIDE Tape Backup Upgrade Kit

P0918VC DCS FCM, WFCM10Ef

P0918VD 10/20 Gb SCSI Tape Backup Upgrade Kit

P0918VJ 21" Monitor, Beige, Northern Hemisphere

P0918VK 21" TS Monitor, Beige, Northern Hemisphere

P0918VL 21" Monitor, Gray, Northern Hemisphere

P0918VM 21" TS Monitor, Gray, Northern Hemisphere

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P0918WA 21" Monitor, Beige, Southern Hemisphere

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P0918WH 21" MIC/MIW TS Monitor, Gray, Southern Hemisphere

P0918WQ Parallel Printer Cable, IEEE 1284, 15 Ft.

P0918XA 21" MIW Embedded Monitor Kit

P0918XB 21" MIW Top Monitor Kit

P0918XC 21" MIW Embedded Monitor Kit w/20" Top

P0918XD 21" MIW Top/Embedded Monitor Kit 

P0918XE CRT Pan. To Sony GDM-5402 MIW Top Mounting Kit

P0918XF CRT Pan.To Sony GDM-5402 MIW Embedded Mounting Kit

P0918XG CRT Pan. To Sony GDM-5402 MIW Top And Embedded Kit

P0918XH CRT MIW Top Mounting Plate, Sony GDM-5402 t

P0918XM Dual Head Video Card Kit (70 Series)

P0918XN Quad Head Video Card Kit (70 Series)

P0918XR DCS (Westinghouse) Migration Kit

P0918XS CRT Sony 5001PT To 5402 MIW Embedded Mounting Kit

P0918XT CRT Sony 5001PT To GDM-5402 MIW Top Mounting Kit

P0918XU CRT Sony 5001PT To 5402 MIW Top And Embedded Kits

P0918XX FBI100/Pwr supply mounting plate

P0918YJ 512 Mb Memory Upgrade Kit For Server 70

P0918YM 256 Mb Memory Upgrade Kit For Server 70

P0918YN 18 Gb SCSI HD Upgrade Kit For Server 70

P0918YP RAID Key Upgrade Kit For Server 70

P0918YR Quad Port Modem Card Upgrade Kit For Server 70

P0918YS Ext SCSI I/F Card Upgrade Kit For Server 70

P0918YZ Quad Serial PCI Card Upgrade Kit For Server 70

P0918ZK BNC(x5) To VGA Video Cable Adapter

P0918ZP Honeywell TDC2000 Proc Interface Power Supply Kit

P0920AA Rittal Metal Enclosure, Sealed

P0920AB Rittal Metal Enclosure, Vented

P0920AC RS-232 Cable, Config PC To Analogic FBM FBP20

P0920AG Analogic FBM Mtg Panel Kit

P0920AH 115 V ac Fan & Fan Bracket Kit

P0920AJ 230 V ac Fan & Fan Bracket Kit

P0920CC Analogic Fieldbus Processor 20 (FBP20)

P0920CD Analogic FBM Fieldbus Interface - Copper (FBI-C)

P0920EA Analogic FBM Industrial Chassis - 10 Slot (ICH10)

P0920EB Analogic FBM NEMA Chassis Expander (NCHEX)

P0920EC Analogic FBM NEMA Chassis - 10 Slot (NCH10)

P0920EF Analogic FBM Ribbon Cable Assembly, 1 M (RC101-1)

P0920EG Analogic FBM Ribbon Cable Assembly, 2 M (RC101-2)

P0920EH Analogic FBM Ribbon Cable Assembly, 3 M (RC101-3)

P0920EJ Analogic Digital I/O Signal Distribution Block (DB16)

P0920EK SCB16 Signal Conditioner Board

P0920FA Analogic Single Ended Analog Input Module (FBM H2)

P0920FB Analogic Differential Analog Input Module (FBM H1)

P0920FD Analogic Single Ended Analog Output Module (FBM H4)

P0920FF Analogic Configurable Digital I/O Module (FBM H8)

P0920FG Analogic 24 Vdc Digital Input Module (FBM H7)

P0920FH Analogic 24 Vdc Digital Output Module (FBM H9)

P0920PC Analogic FBM Pwr Supply, 40 Watt 115 Vac (PS40WA)

P0920PD Analogic FBM Pwr Supply, 40 Watt 230 Vac (PS40WB)

P0920PK Analogic FBM Signal Conditioner Pwr Supply (PS5V-C)

P0920PL Analogic FBM Field Circuit Pwr Supply (PS24V-C)

P0920PV Analogic FBM Signal Conditioner Pwr Supply (PS5V-N)

P0920PW Analogic FBM Field Circuit Pwr Supply (PS24V-N)

P0920SA ISC01 (12-32Vac, 10-32Vdc) Input Signal Cond.

P0920SB ISC02 (35-60 Vac Or Vdc) Input Signal Conditioner

P0920SC ISC03 (90-140 Vac Or Vdc) Input Signal Cond.

P0920SD ISC04 (180-280 Vac Or Vdc) Input Signal Cond.

P0920SE ISC11 (4-16 Vdc) Input Signal Conditioner

P0920SK OSC01 (12-140 Vac) Output Signal Conditioner

P0920SL OSC02 (24-280 Vac) Output Signal Conditioner

P0920SM OSC03 (N.C. 24-280 Vac) Output Signal Conditioner

P0920SN OSC11 (5-60 Vdc) Output Signal Conditioner

P0920SP OSC12 (5-200 Vdc) Output Signal Conditioner

P0920SQ OSC13 (N.O. Dry Relay) Output Signal Conditioner

P0920SR OSC15 Hi Current Dry Output Signal Module, 5 AMP

P0920SS OSC18 Hi Current Dry Output Signal Module, 8 AMP

P0921CE 3 Ft Fieldbus Cable

P0921CF 10 Ft Fieldbus Cable

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P0922AE MIW GCIO w/TS For Sony 5402 (EC96)

P0922AF WP20/30 GCIO w/TS w/Tabletop For Sony 5402 (EC96)

P0922AG 50/70 Series GCIO w/TS For Sony 5402 (EC96)

P0922AS Upgrade Kit, MIC, Embedded 21" CRT

P0922AW GCIO Cable, 2 Ft Serial

P0922AY Upgrade Kit, MIC, Top Mounted 21" CRT

P0922BD 100 Ft Audio Extender Cable, NT

P0922BE 100 Ft Mouse/Keyboard Extender Cable, NT

P0922BF TR5 Tape Drive Upgrade Kit For Server 70

P0922BK CRT MIW Top Mounting Plate, Sony GDM-5402 

P0922BQ DCS FBM, WRO09C

P0922CH Series 70 Memory Upgrade Kit:  128 Mb, ECC RDRAM

P0922CJ Series 70 Memory Upgrade Kit:  256 Mb, ECC RDRAM

P0922CK Kit: 18 Gb Hard Drive For P95*B Terminal Server

P0922CQ Dual-Video IF Card Upgrade Kit For Server 70

P0922CR Quad-Video IF Card Upgrade Kit For Server 70

P0922CU 21" TS Monitor, Beige, Northern Hemisphere

P0922CV 21" TS Monitor, Gray, Northern Hemisphere

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P0922DA 21" MIW TS Monitor, Beige, Southern Hemisphere

P0922DB 21" MIW TS Monitor, Gray, Southern Hemisphere

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P0922DR DCS FBM, WRO09D

P0922ED Keyboard, Video, Trackball 100 Ft PC Cable Kit

P0922ET Series 70 Trackball w/Top Switches w/PS2 Connector

P0922EU Series 51 Trackball w/Top Switches w/DIN Connector

P0922FM PS/2 Keyboard/Mouse Set for P93/P95 Processors

P0922FN Spare Black Mouse For P93 & P95 Processors

P0922JC Kit: TR5 EIDE, Black Face, Backup Tape Drive

P0922JE Kit: Dual Head Video AGP Card For Model 93 Proc.  

P0922JL Kit: 256 Mb, ECC Memory For Model P93 Processors

P0922JN Kit: 512 Mb, ECC Memory For Model P93 Processors

P0922JU Kit: 2 Gb Memory For Model P95*B Terminal Server

P0922JX Kit: TR5 SCSI, Black Face, Backup Tape Drive

P0922JY Kit: Ethernet, Combo PCI Card

P0922KC FoxView/FoxDraw V8.0.2 Solaris Media Kit

P0922KD FoxView/FoxDraw V8.0.2 Windows Media Kit

P0922KE I/A Series FoxDraw V8.0.2 Windows Media Kit 

P0922KF Kit: 512 Mb Memory For Model P95*B Terminal Server

P0922KJ Kit:Spare RAID Key For Model P95*B Terminal Server

P0922KS 6-Port Multi-Mode Fiber Optic Hub w/ST Connectors

P0922KT Embedded Windows NT Operating System

P0922KU Embedded Windows NT Server Operating System

P0922KV Embedded Windows XP Operating System

P0922KW Model P92 Kit: 512 Mb Memory Upgrade

P0922LA 21" Monitor, Gray, Northern Hemisphere

P0922LB 21" TS Monitor, Light Gray, Northern Hemisphere

P0922LC 21" Monitor, Gray, Northern Hemisphere

P0922LD 21" TS Monitor, Gray, Northern Hemisphere

P0922LE 21" Monitor, Beige, Southern Hemisphere

P0922LF 21" TS Monitor, Beige, Southern Hemisphere

P0922LG 21" Monitor, Gray, Southern Hemisphere

P0922LH 21" TS Monitor, Gray, Southern Hemisphere

P0922LL Model P92 Kit: Ethernet Card Upgrade

P0922LM Model P92 Kit: 1 Gb Memory Upgrade

P0922LN Model P92 Kit: 20/40 Gb Tape Upgrade

P0922LP Model P92 Kit: 256 Mb Memory Upgrade

P0922MF MIC Inside-Mount Kit For Sony GDM-5502 Monitor

P0922MG MIC Top-Mount Kit For Sony GDM-5502 Monitor

P0922MP 20/40 Gb Travan40 Tape Cartridge

P0922MZ Breakout Cable For Quad Serial Card P0922RN

P0922NF Power Entry Terminal Block Rails

P0922QA I/A Series V9.x FoxDraw Media Kit

P0922QL FoxView/FoxDraw V9.x Media Kit

P0922QN I/A Series V9.x FoxDraw Media Kit

P0922QS FBM228 4 Port FOUNDATION Fieldbus H1 Module

P0922RK Redundancy Adapter For FBM228 and FBM222

P0922RN Quad Serial Card For P92*C

P0922RV FoxView/FoxDraw V10.x For Windows Media Kit

P0922RW FoxDraw V10.x For Windows Media Kit 

P0922RX Replacement USB Keyboard for P92*D/E/F Processors

P0922RY Replacement USB Mouse for P92*D/E/F Processors

P0922SA DCS FBM, AEAM01

P0922SD DCS FBM, AVI202

P0922SG DCS FBM, ART203

P0922SK DCS FBM, ASA211

P0922SN DCS FBM, AOD115

P0922SR DCS FBM, AHF214

P0922SU DCS FBM, AHF216

P0922SW DCS FBM, ASAM01

P0922SZ DCS FBM, AID115

P0922TC DCS FBM, AID230

P0922TE DCS FBM, ADO125

P0922TH DCS FBM, ASDM24

P0922TL DCS (Moore APACS) Migration Kit

P0922TV DCS FBM, ASDM48

P0922UA FBM203b Chan'l Isolated 8 Input Extended RTD Range

P0922UD FBM203c Chan'l Isolated 8 Input 10 ohm RTD Range  

P0922UJ Power Cable Assemblies, 0.5 m

P0922UK Power Cable Assemblies, 1 m

P0922UL Power Cable Assemblies, 3 m

P0922UM Power Cable Assemblies, 5 m

P0922UN Power Cable Assemblies, 10 m

P0922UP Power Cable Assemblies, 15 m

P0922UQ Power Cable Assemblies, 20 m

P0922UR Power Cable Assemblies, 25 m

P0922US Power Cable Assemblies, 30 m

P0922UU Dual Head Video Card For P92*C, Analog/Digital

P0922UV Memory:  256 Mb For P92*C

P0922UW Memory:  512 Mb For P92*C

P0922UX Memory:  1 Gb For P92*C

P0922VC Compression Term Assy FBM228

P0922VT FBM214, HART Inputs, 8 Channels

P0922VU FBM215, HART Output, 8 Channels

P0922VV FBM216, Redundant Ready HART Inputs, 8 Channels

P0922VW FBM218, Redundant Ready HART Output, 8 Channels

P0922WE CP60 Cable Assembly, Fault Tolerant

P0922WF CP60 Cable Assembly, Simplex

P0922WN Print Head For HP3000 Printer, Black

P0922WP Print Head For HP3000 Printer, Cyan

P0922WQ Print Head For HP3000 Printer, Magenta

P0922WR Print Head For HP3000 Printer, Yellow

P0922WS Print Cartridge For HP3000 Printer, Cyan

P0922WT Print Cartridge For HP3000 Printer, Magenta

P0922WU Print Cartridge For HP3000 Printer, Yellow

P0922WW IEEE 1284, 50 Foot Printer Cable