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Analyze the common faults and solutions of SEW reducers: What are the common faults and solutions for SEW reducers?
SEW reducer is a transmission machine with compact structure, large transmission ratio and self-locking function under certain conditions. Among them, the hollow shaft type worm gear reducer not only has the above characteristics, but also has convenient installation and reasonable structure, and is more and more widely used. It is equipped with a helical gear reducer at the input end of the worm gear reducer. The multi-stage reducer can achieve very low output speed, higher efficiency than single-stage worm gear reducer, and low vibration, noise and energy. Low consumption.
First, SEW reducer common problems and their causes
1. SEW reducer heat and oil leakage. In order to increase the rate, the worm gear reducer generally uses a non-ferrous metal as a worm wheel, and the worm uses a 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.
2. Worm gear wear. The worm gear is generally made of tin bronze, and the paired worm material is hardened with 45 steel to hrc4555, or 40cr hardened hrc5055 and then ground by a worm grinder to a roughness of 0.8 μm. 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.
3. Drive small helical 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.
4. The worm bearing is damaged. 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.
Second, SEW reducer solution
1. Guarantee the quality of assembly. 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.
2. Selection of SEW reducer. The worm gear reducer generally uses 220# gear oil. For heavy-duty trucks with heavy load, frequent start and poor use environment, some lubricating oil additives can be used to make the gear oil still adhere to the gear surface when the reducer stops running, forming protection. Membrane to prevent heavy load, low speed, high torque and direct contact between metals at start-up. The additive contains a seal regulator and a leak preventer to keep the seal soft and elastic, effectively reducing lubricant leakage.
3. Selection of SEW reducer installation position. 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.
Reduction ratio: The ratio of input speed to output speed. Series: Number of sets of planetary gears. Generally, Zui can reach Level 3, and the efficiency will be reduced. Full load efficiency: In the case of large load of zui (fault stop output torque), the transmission efficiency of the reducer. Working life: The cumulative working time of the reducer under rated load and rated input speed. Rated torque: It is the long-running torque allowed for the rated life. When the output speed is 100 rpm, the life of the reducer is the average life. When this value is exceeded, the average life of the reducer will decrease.
The gear unit fails when the output torque exceeds twice. Noise: dB (A) in decibels. This value is the input speed of 3000 rpm, without load, measured at a distance of 1 m from the reducer. Hysteresis: The input end is fixed, the output end rotates clockwise and counterclockwise. When the output end is subjected to positive and negative 2% rated torque, the output end of the reducer is displaced by a slight angular displacement, which is the return gap. The unit is "minute", which is 1/60 of the first degree.

Interpretation of common problems of B35 motor

There are many ways to install the motor. The most common ones are horizontal B3, B5 and B35, vertical V1, V3 and V5. What effect does the different installation methods have on the motor itself? What should be focused on in the design, production and quality process control? Today, Ms. participated in the actual case to talk to everyone about the problems that motor people have to face in minutes.

See the installation method

B3, B5 and B35 are horizontal installations. The main difference is that B3 is mounted on the base of the base, B5 is mounted on the flange end cover, and the B35 is mounted on both the foot and the flange end.

V 1 , V3 and V5 are both vertical installations. V1 uses a flanged end cap to mount the shaft to extend downwards, V3 uses a flanged end cap to mount the shaft to extend upwards, and V5 uses a foot mounting shaft to extend downward.

B35 motor common problems

Relatively speaking, motors that are only mounted on the ground or only with flanges are relatively simple, while B35 motors and vertical mounted motors with foot and flange mounting are more problematic.

Seven major problems in high speed motor design?: Seven major problems in high speed motor design? Whether it is domestic or foreign, high-speed motors still have problems that need to be solved in design and analysis. Specifically, high-speed motors have the following problems in design and analysis.

Due to the weak research foundation, China's high-speed motor industrialization level is relatively low, compared with foreign countries, there is still a big gap, especially for high-power high-speed motors and ultra-high-speed high-speed motors above MW level. There are few applications in design and analysis. many problems.

High-speed motors generally refer to motors with a speed exceeding 10,000 r/min or a difficulty value exceeding 100,000. At present, there are mainly induction motors, inner rotor permanent magnet motors, switched reluctance motors and a few outer rotor permanent magnet motors. Claw pole motor, etc.

The high-speed motor is characterized by small size, high power density, and can be directly connected to high-speed loads, eliminating the need for traditional mechanical speed-increasing devices, reducing system noise and improving system transmission efficiency. High-speed motors can be used in a wide range of applications, including high-speed grinding machines, fuel cells, energy storage flywheels, international electricians, etc., with good market prospects.

Foreign research on high-speed motors has a considerable foundation and a high level of industrialization. Due to the late start of China, the development is mostly concentrated in the small and medium power and low speed range. The industrialization level of high speed motor is low, and there is a certain gap compared with foreign countries.

However, whether it is domestic or foreign, high-speed motors still have problems that need to be solved in design and analysis. Specifically, high-speed motors have the following problems in design and analysis.

First, the technology of analyzing high-speed motors based on electromagnetic field, stress field, rotor dynamics, fluid field and temperature field and other multi-physics coupling methods is still not mature;

Second, high-speed bearings face large problems. For example, ball bearings cannot withstand excessively high rotational speeds, air bearings have limited load carrying capacity, and magnetic suspension bearings are complicated to control and expensive.

Third, the rotor dynamics design technology of high-power high-speed motors has not been perfected, and the development of transformation systems, control systems, and real-time monitoring systems is relatively weak;

Fourth, the high-power rate high-speed permanent magnet motor has a complicated cooling structure, and the combination of air cooling and water cooling is adopted, and the cooling effect is limited;

Fifth, the development of high-speed permanent magnet motors in the direction of ultra-high speed and high power is restricted by the low tensile strength and poor temperature resistance of permanent magnets;

Sixth, the alloy protective sleeve of the surface-mounted permanent magnet motor has large eddy current loss, and the thermal conductivity of the carbon fiber protective sleeve is poor, which is not conducive to the heat dissipation of the rotor;

Seventh, conventional laminated rotors cannot withstand large centrifugal forces, and solid rotors have large eddy current losses.

Therefore, the development and research of high-speed motors in the future will be based on the above key issues, such as multi-physics and multi-disciplinary coupling design, the development of high-strength and high-temperature-resistant permanent magnet materials, research on high-strength rotor lamination materials and structures, Develop high-speed motor control systems, etc.

Motor EMC problem, you want to know are here: Electromagnetic interference (EMI) is the radiation or induction of electromagnetic noise on a system. Like most electromagnetic circuit components, DC motors are a common source of EMI. They are potential sources of noise that can generate common mode currents. EMI can cause performance degradation, data corruption, or strong enough to cause the system to fail completely. EMI radiation or conduction comes from the magnetic source and the power source, respectively, and in the case of a direct current motor, there are radiated and conducted emissions.

Electromagnetic compatibility (EMC) is the practice of monitoring and reducing unwanted EMI. Depending on the purpose of the system and the country in which it is used or sold, there are usually different EMC regulations. EMC performance involves the entire system or the final product, so it is usually the responsibility of the OEM (original equipment manufacturer) rather than the person providing the component. The following are ways to reduce motor EMI to improve the EMC performance of the system.

EMI generation

Arc discharge (sometimes referred to as arcing or arcing) is a current characteristic in which current can flow through air or other materials that are generally not electrically conductive. You may have seen an arcing between the two wires or on the power rail of a train or tram. This is not the same as sparks because the arcs are continuous, although they look really similar.

Although arcs can be used for welding and lighting, in some cases it may be a source of EMI. In DC motors, arcing may be common due to periodic interruptions in current in the rotor windings. This very high frequency spectral content can be represented as broadband noise superimposed on other signals, while the structure of the DC motor provides a path for common mode current.

Another source of radiated and conducted emissions may come from the drive circuit. Ideally, a typical H-bridge circuit should provide a constant current to the motor, but this current has a fast rise time spike due to the fast and frequent switching of the current in the drive circuit. Another important issue is that the motor is usually far away from the drive, which creates a considerable loop area between the motor leads and the equipment frame. The radiation potential is a direct function of the loop area; the larger the loop, the greater the EMI noise.

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