The gear reducer when an inquest and problems found

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1, check the lubrication system
First of all, the 34 weeks before the reducer tooth check should check the quality of lubricating oil. Can rely on the experience for the summary judgment, check the oil color, with or without moisture and precipitation, any abnormal odor with or without foam. If you want to get a precise indicator of desirable oil sample sent to the lubricant supplier for testing. The type and quantity of information available lubricating oil and impurities, according to test results. The bad situation of the oil may show improper use operation, the lubricant duct obstruction or heat exchanger failure. In good condition and no impurities in the oil, said oil could continue another year, do not have oil, which also confirmed that the reducer tooth check is indeed valuable.
Check gear tooth at the same time should also check the lubrication system. The following are the parts should be checked: (1) Check the fuel tank to ensure sufficient oil, check the seals to prevent leakage; (2) Check the fuel tank at the bottom of whether the pollutants and foreign substances; (3) Check the heat exchanger to prevent leakage or obstruction, and observe the oil t emperature is correct to identify the heat exchanger cooling lubricants. (Oil sample tests are subject to excessive oxidation of the oil is not cooled properly. 4) Check the pressure gauge, fuel pumps, fuel injectors, the injection hole, the oil level indicator and filter other lubricating device to ensure normal work; (5 ) If the observation hole of the the reducer tooth box is large enough to be able to see the bearing and for the tank, then, should check the bearings for the tank to determine that no debris blocking the oil, lubricating oil can smoothly flow into bearing; (6) vent and The filter should be installed correctly to ensure the normal operation; (7) universal joints and base conditions should be included in the inspection items.
2, the record reducer tooth
Reducer tooth check should Reducer tooth box is opened. If the situation does not allow, only to observe the hole to open the can also. U se the solvent reducer tooth surface to wipe clean the records of the surface. But even very detailed records, it is difficult to distinguish the difference between this and the next time reducer tooth surfaces, such as conditions allow, the use of color photographs is the best recording method of the surface changes.
Shooting these photos do not need complicated equipment, just near focus and flash, the camera can.
Another way of record reducer tooth is the first reducer tooth surfaces wipe clean, carbon paper and then rubbed, then use transparent tape attached to the paint reducer on the tooth surface of the tooth surfaces Regular shape will be displayed in the adhesive tape. Tape the number depending on the area of ​​the required inspection, has been printed on the shape of the tooth surfaces of the tape retained on white paper to form a permanent record with the reducer tooth the same width.
3 Fault
The Reducer tooth failure modes are many, the following should be noted that when the check point and its causes:
3.1 surface fatigue
The reducer tooth examination should pay attention to the three different stages of surface fatigue.
The three stages are progressive, in the first stage if no measures are taken will be developed into the second stage, if no measures are taken will be further developed into the third stage.
The first stage is the pitting of the tooth surface pitting occurred in the vicinity of the section line.
The new reducer tooth without running its surface will have a certain roughness. Section near the line, two reducer gear tooth contact between the sliding direction is just a shift in the thinnest film thickness, the contact area is very small, and only rolling friction without sliding friction, contact stress, so that the new gear nodal lines near the surface of tiny raised high compressive deformation or loss, resulting in pitti ng corrosion, pitting usually can heal the reducer tooth after the run-in period.
The second phase of contact stress and the number of cycles exceeds a certain limit, two of the tooth surface will produce a tiny crack, the contact stress is the pulse of cyclic stress change over time, with the increase of the cycle, the crack gradually extended, it will crack. between the metal particles flaking off the formation of the tooth surface fatigue pitting.
The final stage is peeling, the formation of many pitting pits, linked together big hole. In this case, the speed of the monitor reducer gear tooth spalling to arrange for replacement of the new reducer tooth reducer gear teeth so as to avoid damage caused by the downtime.
3.2 tooth surface wear
Reducer gear teeth in the meshing process, in addition to the section line of must have a relative sliding. Two tooth surface must produce wear, reducer of a certain degree of tooth wear is normal, especially the new reducer tooth; excessive wear and tear that poor lubrication or parallel to the axis of degree no calibration. The initial signs of excessive wear and the top of the tooth is slightly scratched, followed by development of a more serious scratches or snap to the formation of wrinkling.
Scratch the case from the addendum, left on the surface traces of the same to the sliding direction, shaped like a drag scratched by hard objects. This situation may be stopped after a run-in period.
Early scratches will develop into a serious scratch or bite then wrinkling throughout the addendum to the formation of numerous grooves or wrinkles like marks, if not handled in a timely manner, these scratches will result in more serious consequences. Because these scratches on the sliding direction will cut through the film resulting in metal contact. The reasons for its formation may be the reducer tooth axis is not parallel, not installed correctly, design errors, the oil viscosity is too low, inadequate flow or temperature is too high. In addition, dust, impurities and other contaminants into the tooth surface will be increased wear. Severe tooth profile is damaged, so that the transmission is not smooth, noise, and even broken tooth.
3.3 Plastic Deformation
Reducer tooth surfaces of metal deformation is mainly because of overloading, especially the impact load, the metal deformation is called plastic deformation.
Softer or toughness higher metal raw materials are more vulnerable to plastic flow, and occasionally also on the reducer surface-hardened tooth. The case of plastic flow occurred some plastic deformation, soft reducer tooth metal is rolled or the introduction of the tooth at the top and at both ends; some will produce the same slide at right angles to the waves ripple, usually low-speed heavy-duty, and more hard reducer tooth by the friction of peristalsis; some form with the slide in the same direction the ridges line, this phe nomenon is mostly generated in the low-speed high-load and hard hypoid reducer tooth.
3.4 Tooth Fracture
This situation is rare, but the most serious, because this makes reducer tooth is completely ineffective and a lot of places found in the tooth root. Tooth fracture is generally caused due to overloading or metal fatigue.
Overloading caused by the fracture surface is rough, granulated.
Resilient metal fibrous fracture. Cause this type of fracture may be due to the overloading of impact axis is not parallel to the bearing is damaged, or metal particles fall into the reducer teeth meshing parts.
Fracture caused by metal fatigue is usually made by small cracks spread after a long period. The fracture is very smooth, and usually can see the starting point of metal fatigue. This type of fracture causes the repeated bending stress exceeds the fatigue limit of metal stress may be due to the reducer gear tooth design is not correct, overloading or axis no t parallel.
3.5 lubricating oil contaminated
Any abrasive impurities can cause premature wear and tear. Small abrasive material will make the reducer tooth looks like a mill, but the contours of the tooth has been changed. The coarser the abrasive material will form the scratches, the more impurities, such as screws, nuts, or the reducer tooth fragments, make the reducer gear tooth surface pitting.
3.6 tooth interference
Axis not parallel to the tooth shape or gap deviation will result in mutual interference between the gear taken the initiative to the top of the tooth reducer into the meshing of the separation point Nie servo reducer tooth.
Important the reducer tooth group in the periodic inspection equipment can bring many benefits, the most obvious thing is to take timely measures to prevent failure occurrence or to reduce the failure to further expand reducer gear teeth on the importance of the production of the higher reducer tooth check the be nefits of the more significant. Maintenance work should be appropriate arrangements for periodic factory overhaul, need to book, or difficult to get the parts can be pre-ordered, so you can reduce the cost of manpower and materials.