What other methods besides preventive maintenance can improve the reliability of ZJY180-12.5 gearbox

In addition to preventive maintenance, the reliability of the gearbox can also be improved through correct selection and installation, optimization of operating conditions, improvement of design and manufacturing processes, condition monitoring and fault diagnosis. The following is a specific introduction:

Correct selection and installation

Reasonable selection: Based on actual working conditions such as load size, speed, working environment, etc., accurately calculate the required gearbox transmission ratio, torque, power and other parameters, select the appropriate model and specification of gearbox, and avoid overloading or long-term inefficient operation of the gearbox due to improper selection, which affects its reliability and service life.

Correct installation: Strictly follow the installation instructions to install the gearbox and ensure installation accuracy. For example, during installation, it is necessary to ensure the coaxiality between the reducer, drive motor, and working machine, and the deviation should be controlled within the allowable range. Otherwise, the gears, bearings, and other components inside the reducer will bear additional loads, accelerate wear, and reduce reliability.

Optimize operating conditions

Control load: Avoid excessive impact load and frequent start stop on the gearbox. During the operation of the equipment, try to maintain the stability of the load as much as possible to prevent damage to the gearbox caused by sudden load changes. For possible overload situations, overload protection devices such as safety clutches, overload relays, etc. should be installed. When the load exceeds the set value, the power should be cut off in a timely manner to protect the gearbox.

Improve working environment: Keep the working environment of the gearbox clean, avoid dust, debris, etc. from entering the interior of the gearbox, and accelerate the wear of gears and bearings. At the same time, it is necessary to control the temperature and humidity of the working environment to avoid the gearbox operating in high temperature, humid or corrosive environments. In high-temperature environments, measures such as forced air cooling or water cooling can be taken to reduce the temperature of the gearbox; In humid or corrosive environments, the gearbox can be treated with anti-corrosion measures such as spraying anti-corrosion paint or using stainless steel components.

Improve design and manufacturing processes

Optimization design: In the design phase of the gearbox, advanced design methods and techniques such as finite element analysis and modal analysis are used to analyze the strength, stiffness, and fatigue of key components of the gearbox, optimize structural design, and improve component reliability. For example, designing parameters such as module, number of teeth, and tooth profile of gears in a reasonable manner can improve their load-bearing capacity and transmission efficiency; Optimize the structure of the box, improve its rigidity and stability, and reduce vibration and noise.

Improve manufacturing technology level: Adopt high-precision processing equipment and advanced manufacturing processes to ensure the machining accuracy and quality of gearbox components. For example, the machining of gears requires precision grinding technology to improve the tooth profile accuracy and surface quality of gears, reduce transmission errors, and minimize vibration and noise; The installation and coordination of bearings must meet the specified precision requirements to ensure the normal operation of the bearings. At the same time, it is necessary to strengthen the quality control of raw materials, select high-quality materials such as steel and cast iron, and ensure the strength and wear resistance of components.