擺線針輪減速機維護檢修規(guī)程(Specification-for-maintenance-and-overhaul-of-cycloidal-pin-gear-reducer)

擺線針輪減速機維護檢修規(guī)程（Specificationformaintenanceandoverhaulofcycloidalpingearreducer）Specificationformaintenanceandoverhaulofcycloidalpingearreducer1GeneralProvisionsThisregulationappliestothemaintenanceandoverhaulofcycloidalpinwheelreducer(hereinafterreferredtoasreducer),andthemaintenanceandoverhaulofcycloidalgearreducercanalsobereferredtoexecution.2inspectioninterval2.1overhaulcategoryRepairandoverhaulincludesminorrepairs,three.2.2inspectionintervalTheperiodofinspectionandmaintenanceisshowninTable1Table1hOverhaulcategoryMinorrepairsRepairOverhaulMaintenanceintervalFourthousandandthreehundredThirteenthousandTwenty-sixthousand3overhaulcontent3.1minorrepairs3.1.1cleaningbodyoildirtanddebris,replacementoflubricatingoilorgrease.3.1.2checkandfastenboltsoneachpart.3.1.3checkandeliminatetheoilleakageinthejointsurfaceandtheseal.3.2mediummaintenance3.2.1includesminorcontent3.2.2inspection,cleaningallpartsofthebody,washoildirtanddebris.3.2.3removelubricatingoilanddredgeoilcircuit.3.2.4check,replaceeachdepartmentbearing(especiallythearmbearing)andtheskeletonrubberoilseal.3.2.5check,replacethedippad,paperpad,oilresistantrubberpadandOtypesealingring.3.2.6checkthepinsleeve,pinpin,pinpinandpinsleeveoftheoutputshaft.3.2.7lookforthepositivecouplingtoensurethecoaxialityofthereductionshaftandthedrivenshaft.3.3overhaul3.3.1includesmediummaintenance3.3.2inspection,repairorreplacementofcycloidgear,needletoothshell,outputshaftandrotatingarm(eccentricsleeve)andotherkeyparts.3.3.3inspect,repairorchangethebase,fasteningring,isolatingring,camandsoon.4preparationbeforeoverhaul4.1technicalpreparation4.1.1manuals,drawingsandrelatedstandardsandothertechnicaldata.4.1.2recordsofoperation,repair,defect,hiddentrouble,malfunction,malfunction,etc..4.1.3reducertemperaturerise,noise,vibration,power(asmeasuredbytheworkingvoltageandcurrentcalculation)andleakageofthetechnicalperformanceofpreflightingandrecord.4.1.4formulatetheplanofmediumrepairandoverhaul.4.2materialreadiness4.2.1sparepartsrequiredtobereplaced:turnarmbearings,cycloidgears,needlesleeves,pinpins,pinpinsleeves,dipgaskets,paperpads,frames,rubberseals,Otypeseals,andotherrequiredreplacements.4.2.2cleaningoil,oilandlubricatingoil(grease).4.2.3inspectiontools,measuringtoolsanddismountingtools.4.3securitytechnologyreadiness4.3.1cutoffthepowerandsignthe"noopen"warningsign.4.3.2flammableandexplosivepositionsrelatedmeasures.5overhaulmethod5.1disassembly5.1.1program5.1.1.1removethelubricatingoilpump(verticalreduceronly).5.1.1.2unscrewtheoilplugatthebottomoftheseatandcleartheoil.5.1.1.3loosenthefasteningbolts,separatetheframepartfromthegearpart.5.1.1.4takeouttheaxlepinsleeve.5.1.1.5removethecushionatthefrontofthearmandtakeoutthecycloidalgearii.5.1.1.6takeouttheswivelarmanditsbearingassembly.5.1.1.7removetheisolationringandcycloidgeari..Whenremovingthecycloidgear,5.1.2mustrememberthelocationofitscrosssectionmarkprefix.5.2pingearhousingandpinThepinholeoftheneedletoothshellmatcheswiththepinoftheneedletooth,ifthelooseortheproductionprocesscrack,needstochangetheneedletoothshell.5.3isolationringTheisolationringsuchaswear(surfaceabrasion),bygrindingorgrindingmethodtorepairseriouswear,needtobereplaced.5.4armbearingIfthearmbearingisfounddamagedorthebearingsupportframeisdamaged,itshallbereplacedandreplaced.Thearmbearingmustberemovedbyspecialdisassemblingtool.5.5pinsleeveForindividualwearpins,themethodofgrindingoutercircle(grindingsizeandremovingtheoriginalwearmark)shallbeadopted.5.6oilspillsTheoilleakrequiresreplacingthesealtorepairit.5.7assemblyBeforethe5.7.1assembly,cleantheinnercavityandpartsoftheboxandgreasetherollingbearings.The5.7.2assemblyiscarriedoutinreversedisassembly.5.7.3whenassembling,rememberthemarkheadsofthetwocycloidalgears(180degreesintoeachotheroroverlapupanddown).6qualitystandardsforinspectionandrepair6.1cycloidgear6.1.1replacementofgearmaterialshallcomplywiththefollowingrequirements:A.needletoothcirclediameterDe=270mmGCr15De>330mmbearingsteel,bearingsteelGCr15SiMn,arenotallowedtousethanothermaterialssubstitutionofGCr15bearingsteel;ThehardnessofB.isHRC58~62C.microstructureofmartensite+Crystalmartensiteandfineuniformcementite(martensite=3).ThetoleranceT2oftheadjacentholedistanceofthepinholeofthe6.1.2cycloidalgearcolumnshallbeinaccordancewiththeprovisionsoftable2.Table2mmD2OnehundredandfiftyOnehundredandeightyTwohundredandtwentyTwohundredandseventyThreehundredandthirtyThreehundredandninetyDeltaT2ZeropointzerofourtwoZeropointzerofivezeroZeropointzerosixzeroThesizeaccuracyandsurfaceroughnessof6.1.3cycloidgearsandbearingsshallcomplywithtable3.Table3PositiondimensionalaccuracyRavalue,mumFittingholeH6Lessthanorequalto0.86.1.4toothsurfaceshallnothaveburrs,cracks,scuffingmarksandpittingcorrosionmarks.6.1.5,suchasrotatingarmbearingsrollingbearings,withtype2000(GB288)rollingbearingsreplacement,wemustensurethatthecycloidgearbearings,matingholeswiththerotationarmbearingclearancegap:ThediameterofA.D0islessthanorequalto60mm,thegapislessthanorequalto0.05mm,thegapwiththelimitof0.10mm.WhenB.D0>60mm,theclearanceis0.05~0.08mm,andtheclearancelimitis0.13mm.6.2pingearhousing6.2.1replacementoftheneedleshellmaterialisnotlessthanHT200grayiron,andartificialagingtreatment.ThetoleranceT1oftheadjacentholedistanceofthe6.2.2pinholeshallbeinaccordancewithtable4.Table4D2OnehundredandfiftyOnehundredandeightyTwohundredandtwentyTwohundredandseventyThreehundredandthirtyThreehundredandninetyDeltaT2ZeropointzerofourZeroPointZeroFiveZeropointzerosixZeropointzerosevenThemainsizeaccuracyandsurfaceroughnessof6.2.3shallcomplywithtable5.Table5PositiondimensionalaccuracyRavalue,mumPinholeH7Lessthanorequalto1.6HolefittedwithendcapLessthanorequalto3.2AnoutercircularringthatfitswiththebaseH6Theallowabledeviationoftheholesinthe6.2.4pinholesisshownintable6.Table6PinholediameterAllowableupperdeviationLessthanorequalto10Zeropointzerothreezero>10Zeropointzerothreeseven6.3outputshaft6.3.1replacementoftheoutputshaftof45#steelmaterial,andquenchedandtemperedtreatment,hardnessofHB187~229.6.3.2shaftandshaftneckshallnothavecracks,burrs,scratchesandotherdefects.6.3.3dimensionalaccuracyandsurfaceroughnessshallcomplywithtable7.Table7PositiondimensionalaccuracyRavalue,mumShaftjournalmatchedwithbearingK6(D2=450mm)Js6(D2=550mm)Lessthanorequalto1.60BearingholeG7Lessthanorequalto3.2PinholeR76.4turnarm(eccentricsleeve)Thematerialoftheeccentricsleevereplacedby6.4.1is45#steel,whichistreatedbyquenchingandtemperingornormalizing,andthehardnessisHB170~217.Thelimitdeviationof6.4.2eccentricityshallbenomorethan+0.02mm.6.4.3formtolerancesshallbeinaccordancewithtable8.Table8NameoflocationandshapetoleranceAccuracylevelisnotlessthanRoundnessoftwooutercircleLevel6(GB1184-80)RoundnessofinnerholeLevel7(GB1184-80)6.5stand6.5.1replacementofthebaseofthematerialisHT200grayiron,artificialagingtreatmentshouldbecarriedout.6.5.2baseshallnothavecracks,blisters,withthepingearhousingsurfaceshouldbesmooth,ensurestrictassembly.6.6pingearsleeveandpin6.6.1replacementofthepingearandpinmaterialforGCr15bearingsteelafterquenchandtemperinghardnessisHRc58~62.6.6.2surfaceroughness:outercircle,Ravalueisnotgreaterthan0.80mum;innercircle,Ravalueisnotgreaterthan1.6mum.6.6.3surfacesshallnotbesubjecttoburrs,cracks,scratches,orscuffingdefects.Thefitgapbetweenthe6.6.4pingearsleeveandthepingearshallbespecifiedintable9.Table9mmOuterdiameterofpinsleeveNeedlepindiameterClearancestandardUselimitLessthanorequalto14Lessthanorequalto10ZeropointzeroeightthreeZeropointonethree14~3510~24ZeropointonezerozeroZeropointonefive>35>35ZeropointoneonenineZeropointonesevenSix7pinpinsleeve(outputshaftpinsleeve)andpin(outputshaftpin).The6.7.1replacementpinandstudpinaremadeofGCr15bearingsteel.Afterquenchingandtempering,thehardnessisHRC58~62.6.7.2surfaceroughness:outercircle,Ravalueisnotgreaterthan0.80mum;innercircle,Ravalueisnotgreaterthan1.6mum.6.7.3surfacesshallnotbesubjecttoburrs,cracks,scratches,orscuffingdefects.6.8skeletonrubberoilseal6.8.1inputshaftselectsPGorSGhighspeedskeletonrubberoilseal;theoutputshaftselectsPDorSDlowspeedskeletonrubberoilseal.6.8.2replacementoftheoilsealmaterialshouldhavegoodoilresistance,oilseallipsandedgesshouldbesharpandsmooth,openenoughaftertheradialforce,thewaistshouldbesoftandelastic,springtensionshouldmoderate.6.8.3oilsealdoesnotallowaging,wrinkles,cracksandotherdefects.6.9beforeassembly,shouldchecktheOsealingringsurfacesmoothanddiameter,sizeuniformityqualified,surfacewithoutscratches,cracks.6.10gasket6.10.1sealinggasket,impregnatedgasketpaperoroilresistantrubberpadusedineachjointsurfacerequiregoodoilresistanceandsmoothsurface.6.10.2impregnatedpaperboard,freeform,thicknessis0.8mm,compressedthicknessshouldbe0.5mm,andsmoothsurface,noburrandburr.6.11coordinationofmainpartsThemainpartsofthematch,meettherequirementsoftable10Table10MatingpartsnameFitlevelPinhousingandpinH7/h6PinrackandpinD8/h6PinhousingandendcapandframeH7/h6ColumnpinandpinsleeveR7/h6OutputshaftandfasteningringH7/r67commissioningandacceptance7.1preparationbeforetestrun7.1.1dothelubricationaccordingtothefollowingrequirements:A.lubricatingoil(grease),oilcontentmeetthespecificationsrequirements;ThekeypartoftheB.lubricationisthearmbearing.7.1.2checkzero,partintegrity,fasteningoftheconnectingbolts.7.1.3manualturningwithoutexception.7.2trialrun7.2.1no-loadtest7.2.1.1no-loadtestruntimeisnotlessthan4hours.7.2.1.2testrunshallmeetthefollowingrequirements:A.connectionsandfastenersshallnotbeloose;B.eachsealingplace,theunionmaynothavetheseepageoilandtheoilleakagephenomenon;C.reducerrunningsmoothly,normal,noshock,vibrationandabnormalsound,thebodyamplitudeislessthan0.03mm.TheD.oilpumpisworkingproperly.Theoilindicatorshowsclearoilflowandtheoilcircuitisclear.7.2.2loadtestrun7.2.2.1shallbeloadedgraduallyat50%,75%and100%stagesoftheratedload,andthethreeloadingstagesshallbenolessthan2hours,andthetemperatureriseofeachstageshallbestableinthreestages.7.2.2.2loadcommissioningtimeshallbenolessthan24hours.7.2.2.3loadcommissioningshallmeetthefollowingrequirementsA.attopspeedandconstantload,themaximumoiltemperatureshallnotexceed80degreescentigrade,andthecurrentshallnotexceedthetopandtopcurrentspecifiedbythemotor;B.speedreducershouldberunningsmoothly,normal,noshock,vibrationandabnormalsound,thebodyshouldbelessthan0.08mm.7.3acceptance7.3.1recordsofmaintenanceandtrialrunarecompleteandcorrect.7.3.2machineappearanceandrepairqualityisqualified.7.3.3testrunsinaccordancewith7.2.1and7.2.2throughacceptance.8maintenanceandtroubleshooting8.1maintenancepoints8.1.1thismachineshouldworkattheenvironmenttemperatureof-25degreesto40degreescentigrade.Iftheenvironmenttemperatureishigher,ventilationmeasuresshouldbeadoptedorinsulatedwithasbestosboard.8.1.2lubricationA.focusonthehighspeedandheavydutyworkofthearmbearinglubrication,shouldberegularlyrefueling,checktheoillevel,strictlyprohibittheoperationofoilfree.B.recommends50oilorotherlubricantsimilartoitsperformance.Forover18.5KWspeedreductiongear,extremepressureindustrialgearoilcanbeused;C.avoidcorrosiveanddirtysubstancesmixedintotheoil;D.:afirstrunoilcycleoilby200hours,24hoursofworkeverydayfrom10toMarchthefirstoilchange,workinglessthan10hoursadayinJunethefirstoilchange,usingthegrease,onceevery6monthsforoil;Whentheworkingenvironmentisover35degreescentigradeorhighhumidityorhasactivegasaround,theoilchangecycleisshortenedbyhalf.8.1.3checkthetemperature,vibrationandsealofeachpart.Ifabnormal,itshouldbestopped.8.1.4checktheoilflowoftheoildetectorandjudgetheworkingstateoftheoilpump.8.1.5oftenlistentothesoundofthemachine,ifabnormal,shouldbedealtwithintime.8.1.6operatingcurrentshallnotexceedthefullloadcurrentspecifiedbythemotor.8.1.7checkandfastenboltsoneachpart.8.1.8keeptheequipmentneatandhygienic.8.2commontroubleshootingCommonfaultsareshowninTable11FaultphenomenonCausesprocessingmethodSeepageoilWhenthe1reducershaftisinstalledwiththedriveshaft,thecenteringaccuracyislow,thewearoftheoilsealandbearingisquickened,andtheleakageoilisformed2sealingpad(impregnatedgasketoroilresistantrubberpad)orOtypesealingringisdamaged3,theoutputshaftsealdamageorfasteningringoutercirclesurfacewear4jointfaceboltsloose5,dirtyoilandimpuritiesaretoomuch,sothatoilsealswearfaster6excessiveoil,theformationoforexcessiveheatintheoperation,resultinginoilleakagefromtheoilseal.1realigningandadjustingcouplingstoensurealignmentaccuracy;replacementofnewskeletonrubberseals(PDorDS)2replaceasrequi