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Cement, sputum bath, Ding 800 type reducer transmission parts damage emergency repair Fang Guangliang China Great Wall Aluminum Company Cement Plant, Henan Zhengzhou 450041 speed device, due to lack of oil, resulting in three sets of bearings on the reducer gear shaft, The tooth ends are all broken, the length accounts for 10 of the total length, but the shaft is not worn; the gear shaft has partial broken teeth, and the bearing blocks at both ends wear unevenly about 6,250, 25,1 grooves, and the shaft is not worn.
Due to the sudden occurrence of the accident, there is no spare parts, and the new parts are processed, and the cycle is long. Therefore, our factory resumed the production as soon as possible by using the emergency repair method of the polished broken-tooth repaired bearing housing.
1Repair process 1800 reducer adopts upper and lower opening cover structure, the upper cover is welded structure, the body is made of 1300 material as a whole, the whole machine is grade drive, and the gears and bearings are sprayed with oil.
The 1.1-stage gear repairing gear shaft material is 400-touch 1 and is a positive-displacement gear. We used a 3, 35-person 25-person angle grinder to polish and grind the broken wear of the gears. Thus, the total length of the gears of the gear shaft was reduced by 10; the new gear shaft bearings were replaced with new ones.
The teeth of the repair grade gear of the 1.2-stage bearing housing have not been damaged due to less damage, and only the damaged bearing housing has been repaired.
The groove of the bearing seat wear is repaired by field arc welding on the site, and finally the grinding by hand grinding and the grinding of semi-circular oilstone. To ensure technical requirements, special grinding and clamping mechanisms are produced. Since the casing material is 1300, white joints and cracks are easily generated during welding. We have developed the following maintenance schemes and process measures. The main reason for the white mouth is that the post-weld cooling is too fast and the graphitization elements are insufficient. Therefore, ¢3.2mm cast 508 electrode is selected, which is graphite type, nickel-copper alloy nickel 70 copper 30, and is slowly cooled after welding.
Soldering using a cold welding process. In order to prevent the crack of the casing, the welding current of 120 people and the faster welding speed are adopted. The welding method of short-distribution and intermittent multi-layer is adopted. When welding, the welding rod can not be oscillated laterally, and after each layer is cooled to about 5060. Then continue welding, after each weld is welded, the hammer metal layer should be struck from the crater in time to avoid cracks and remove the welding slag. The welding layer is 34 higher than the inner hole surface of the original bearing housing as a grinding allowance.
3 After the welding is completed, fully cool. Check to make sure there is no crack before proceeding to the next step. The grinding frame is fixed at both ends of the bearing housing for grinding, and the outer surface of the selected hand grinding wheel should be tangent to the inner surface of the bearing housing. When fixing the hand grinding wheel, it is necessary to confirm that there is no radial displacement. The grinding amount is tested by bearing outer ring assembly and finally polished with oil stone. The original hole size of the housing housing is 2307, which is reduced after the actual machining and the original requirements. The gear unit can be assembled after grinding.
2Adjustment of various technical parameters 2.1 Adjustment of axial clearance The single-row tapered roller bearing is installed at both ends of the reducer and the step shaft. The axial clearance is adjusted by adjusting the spacer ring between the bearing end cover and the bearing. achieve. According to the situation of the reducer and the wear amount of the gear, adjust the axial clearance to the grade shaft 0.100.15, the adjustment of the tooth side clearance and contact position of the gear pair 2.2. In the actual assembly, we adjust the side clearance of the gear pair to 0.32, the contact area of ​​the tooth, the contact with the tooth length 70 in the length direction, the contact in the tooth height direction is 48.
After the assembly was completed, after the test run, the temperature riser of the oil pool was replaced by the gears at the end of 2003, which was in good condition.
Editor Wang Yanli> The quality of the heavy box. In addition, as the belt runs for a long time, the tension of the belt is in the winter or summer, it is necessary to pay attention to the regular observation of the entire belt tube, the force will also be reduced, and the quality of the weight box should be adjusted regularly. Whether it is full, whether it is sufficient contact with each roller, and then increase or decrease the matching editor Wang Yanli