Delivery of ground gear ring and gear shaft of wind turbine

/in /by

Recently, Luoyang Hengchang Heavy Machinery Co.,Ltd. cooperated with a company in the wind turbine industry to develop and manufacture a full set of main gear shaft and gear ring.

The R&D personnel adopted advanced design concepts to integrate the gearbox main shaft and main shaft bearing into the interior. Under the premise of ensuring the operating life of the equipment, the technical personnel repeatedly simulated and optimized the selection design, which greatly reduced the bearing supply cycle and purchase price.

From receiving the task to the drawing storage, from the designer’s 24-hour service production to the prototype, all data fully meet the user’s requirements and pass the whole process once. In order to shorten the manufacturing cycle, the company’s R&D, design, and assembly personnel work together, constantly explore, and overcome various processing and assembly difficulties one by one, shortening the original 5-6 months of manufacturing cycle to 3 months, and delivering high quality, high speed, and high standards to users.

If you are interested in our products, please contact us.

Causes and solutions for broken teeth of ball mill pinion

/in /by

1. Causes of fatigue fracture of ball mill pinion
（1）The main reasons for fatigue fracture of ball mill pinion are:
（2）The dynamic load of the transmission system is too large;
（3）The radius of the tooth root fillet is too small;
（4）The surface roughness value of the tooth root is too large;
（5）The tooth root is pulled during rolling;
（6）The material is defective, and heat treatment produces tiny cracks and other harmful residual stresses.
When the alternating stress at the root of the pinion of the ball mill exceeds the fatigue upper limit of the material, fatigue cracks will occur at the root fillet. The cracks will continue to expand after long-term operation, and eventually, the gear will bend and fatigue and break.


2. Overload fracture of ball mill pinion
The fracture of ball mill pinion due to overload is mainly due to the impact load of the ball mill being severely overloaded in a short period of time, which causes the gear to bear stress exceeding the upper limit stress.
When the load of the ball mill is severely concentrated, the dynamic load is too large, or a larger and harder foreign body enters the gear meshing, it will cause overload phenomenon and cause the pinion to break.
The fatigue fracture of the pinion of the ball mill is gradually caused by the long-term action of alternating stress. Since the pinion has a small number of teeth and a relatively large number of stress cycles, fatigue fracture is also possible.

However, the dynamic load of the ball mill transmission system is generally not very large. Moreover, before each replacement, the involute parameters, gear accuracy, and surface quality of the new gear are measured and inspected. The test results are in line with the technical requirements of the drawings. Judging from the time it took for the pinion of the modified wet ball mill to break after several replacements, it should be the combined effect of fatigue and overload.

 

3. Troubleshooting of broken pinion gears of ball mills

For the above-mentioned pinion gears of ball mills, corresponding adjustments can be made according to the technical requirements for the assembly of the main transmission gears of MQG wet ball mills:

1. Adjust the axial distance of the two gears according to the deviation range of the center distance of the gear pair to ensure the tooth top clearance and tooth side clearance between the two wheels. The tooth side clearance is measured by the lead pressing method;

2. Adjust the parallelism of the axes of the two gears so that the contact spot mark after the color inspection in the tooth width direction is centered;

3. Grind the tooth surface of the large gear damaged by broken teeth;

4. Change the splash lubrication of the tooth part to spray lubrication.

Why should large gear processing be finely produced?

/in /by

The production of large gears requires special processes to produce products. Are you curious about the specific processes? Here, the gear manufacturer editor will briefly popularize it for everyone:
The large gears of the dryer adopt a unique heat treatment technology in casting to improve the hardness of the gear ring, improve the wear resistance and impact resistance of the product; secondly, the use of high-strength steel casting and the optimization of the rotary kiln ensure the stability of the components under long-term operation and extend the service life of the product during application. Finally, the scale of large gear processing is increased, the technical content is invested, and the mass production of products is carried out with short construction period and excellent quality.

As a member of the transmission system, the large gear is naturally the source of noise, and it transmits noise with the natural frequency and meshing frequency. If we want to reduce the noise as much as possible, then we need to buy large gears.
The processing accuracy of gears will naturally be higher than that of general large gears. The higher the processing accuracy, the lower the noise will be. Although we cannot completely remove the noise, it is an important means of noise reduction.

How to choose cast or forged gears?

/in /by

People in the foundry industry know that large gears are transmission parts of mechanical equipment and play a key role in the operation of the entire machine. If the large gear (also called the large gear ring) is worn, it needs to be replaced to delay production. In addition, the large gear is a consumable part. From the user’s point of view, the longer the service life, the better. Therefore, when users choose large gears, they require long life, impact resistance, wear resistance, etc., so the specific selection should be based on the actual situation.


Casting steel manufacturers believe that it is better to use forging technology under normal circumstances if there are high speed requirements and low life requirements for gears, because forged gears have dense texture, hardness and wear resistance than cast steel parts. The large gear with the right performance has a large diameter and low speed, so it is more suitable to cast steel castings, which can meet the needs of long-term rotation of mechanical equipment and save production and maintenance costs.
From the above, I believe that users have a general understanding of this. For gears with small diameters and high speeds, forging production can be selected, and forging production can also be mass-produced. If the diameter is relatively large, you can choose to cast a large gear. If the diameter is too large, you can produce it in two halves and then install the large gear together as required.

Gear shaft processing technology analysis – arrangement of heat treatment process

/in /by

In the entire process of shaft processing, sufficient heat treatment processes should be arranged to ensure the mechanical properties and processing accuracy requirements of the gear shaft and improve the processing performance of the workpiece.
Generally, normalizing treatment is arranged first after the shaft blank is forged to eliminate forging internal stress, refine the grains, and improve the cutting performance during machining.
Tempering and tempering treatment is arranged after rough machining. In the rough machining stage, most of the machining allowance of the gear shaft is removed after rough turning, drilling and other processes. The cutting force and heat generation during rough machining are very large. Under the action of force and heat, the shaft produces a lot of internal stress. The internal stress can be eliminated through tempering treatment, replacing aging treatment, and the required toughness can be obtained at the same time.


After semi-machining, except for important surfaces, other surfaces have reached the design size. Only finishing allowance is left for important surfaces. At this time, local quenching treatment is arranged on the teeth to meet the designed hardness requirements and ensure the wear resistance of these surfaces. The subsequent finishing process can eliminate quenching deformation.

Thickness determines the size of the gear

/in /by

The main function of the gear is transmission. Why are some gears large and some gears small? Some people may say it is because of the size of the mold, but not all gear moduli are the ratio of pitch to circumference. The larger the modulus, the stronger and thicker the teeth, and the larger the size of the gear. The tooth height of a standard gear is equal to 2.25 times the modulus, and the tooth thickness is equal to 0.5*3.14*modulus, that is, the larger the modulus, the larger the teeth. The modulus is also large, the higher the number of teeth, the thicker the gear teeth, and if the number of teeth is determined, the larger the radial size of the wheel. Gears with larger moduli also have larger numbers of teeth. The modulus determines the size of a single tooth profile, not the size of the gear, and has nothing to do with the pressure angle. The modulus is the largest parameter that affects the gear. This does not mean that the gear is large. This should also be determined according to the use environment. If a small gear should be used in a place, it is definitely not suitable for a large gear. So it is not the bigger the better, the right one is the best.
The diameter of the involute gear is d=zm, which is the modulus multiplied by the number of teeth. The modulus is related to the load-bearing capacity of the gear. When the gear is made of the same material and heat treated, the larger the modulus, the stronger the load-bearing capacity; the number of teeth is related to the transmission ratio. The speed of the gear is related to this number as n1*z1=n2*z2.


Therefore, there are two factors that determine the size of the gear, the load-bearing capacity and the transmission speed ratio.
Module m
(1) This module is equivalent to the model of the gear, which can determine the size of the gear. Other parameters are the same. The larger the module, the larger the size of the gear.
Number of teeth z
(2) Needless to say, the number of teeth is the number of teeth in the gear. This is related to the gear ratio. The two meshing gears are in the best possible state.
Pressure angle α
(3) The pressure angle usually refers to the pressure angle on the pitch circle. There are other pressure angles: the pressure angle on the base circle, etc. It is generally believed that the pressure angle is on the pitch circle, and the standard gear is 20 degrees.
Helix angle β
For cylindrical spur gears, there is no helix angle, or the helix angle is 0, but cylindrical helical gears have a helix angle. This helix angle also has a certain range of values. See the Mechanical Design Manual for details. Here it is mentioned that if it is a bevel gear, then the pressure angle we refer to is the positive pressure angle on the bevel gear partition ring.

Casting of ring gears and gears and how to repair damaged ring gears?

/in /by

Casting of ring gears and gears and how to repair damaged ring gears?
Large ring gears are important and indispensable parts of equipment, just like gears. Although the two are similar, their main function is to transmit and change the direction of force. However, in addition to this, the protection of the main body of the machine system by the driving of the ring gear cannot be ignored.
The outer teeth of the large ring gear are divided into two types of tooth shapes: drum teeth and straight teeth. It can change the contact conditions of the teeth and improve the ability to transmit torque, thereby meeting the requirements of cost protection and extending the service life. The large ring gear is a thin-walled ring forging. It is easy to have problems such as uneven wall thickness, folding, and ellipse during the forging process. Therefore, the quality of the casting can be improved by controlling the details of the casting process.
Therefore, it can be said that the large gear ring is a very important component for protecting the service life of the machine. So when the large gear is damaged, how should we repair it?


1. To treat the steel castings, different treatment methods should be used for large gears with different degrees of damage, and the damaged parts of the large gear ring should be treated;
2. Before welding, it should be noted that there should be no impurities such as dirty oil, rust, slag, etc. near the welding part, otherwise it will affect the welding effect;
3. After the welding treatment, there may still be relatively small pores or sand holes on the surface of the steel casting. After removing these defects, the area should be repaired.
4. After the welding treatment, the damaged large gear ring can be used normally again, which not only saves the production cost of the enterprise, but also helps to reduce the loss of resources, which can be said to kill two birds with one stone.

What are the effects of slewing bearing?

/in /by

Slewing bearing , also known as a rotary bearing or rotating support, is a mechanical element specifically designed to support and allow rotating motion. It is usually composed of the internal and external ring, roller, roller or roller, and sealing. It can be used for various industrial applications. From small machinery to large engineering equipment, it is an important mechanical element in various fields. It is rotating equipment and The mechanical system plays a key role. This article explains some explanations for the role of re -supporting support.

The role of the slewing bearing

1. Support rotation exercise

The main role of rotating support is to support rotation movements. It allows equipment or mechanical parts to rotate around the axis in a smooth way to achieve the operation of the equipment. This is very critical for applications that require continuous rotation or periodic rotation, such as various types of rotating platforms, robotic arms, wind turbines, etc.

2. Undertaking pile

The slewing bearing can withstand various loads from the rotation device, including radial load, axial load and torque. Through the appropriate design and material selection, the rotation support can withstand highly complex mechanical requirements and maintain the stability of the system.

3. Implement accurate positioning

In some applications that need to be accurately positioned and directed, rotation support is very important. It can ensure that the device can accurately stop at the required position when rotating, thereby meeting the accuracy requirements of production or operation. This is particularly important in the fields of machine tools, automation devices and observation equipment.
Rotate support 4. Reduce friction and energy loss

Slewing bearing  is usually very precise. Rolling elements such as rolling or rolling are used, which helps reduce friction and energy loss. This makes the rotation movement more efficient, reduces energy consumption, and extend the service life of the equipment.

5. Reduce maintenance cost

Good design and high -quality rotation branches usually require less maintenance work. This reduces the stop time and maintenance cost of the device and helps improve production efficiency.

As a mechanical element, the rotary support has many effects of rotation support. They support rotation movement, tolerance, accurate positioning, reducing friction and energy loss, and also help to reduce maintenance costs. The design and application of rotating support has become an indispensable part of the modern engineering field, and promotes the development of various industrial and technological applications. Whether in the fields of construction, energy, manufacturing, and medical fields, the re -supporting support plays a key role in improving equipment performance, improving production efficiency, and ensuring safety.

Factors Affecting Bearing Capacity of Slewing Bearings and Methods of Improving Bearing Capacity

/in /by

Rotary support is a key component for rotating mechanical devices. It can support and rotate weight, so that the device can rotate smoothly. The loading capacity of the rotation support refers to the larger load or weight it can withstand. The loading capacity of the rotary support depends on multiple factors. For specific factors, please affect the factors of the carrier support capacity and the method of increasing the carrying capacity.

1. Factors affecting the loading capacity of the rotary branch

1. Structure design

The structural design of the rotary support directly affects its carrying capacity. Designers need to consider factors such as the materials, size, shape, and bearings of the support to ensure that they can withstand the required load.

2. Material strength

The rotary support is usually made of high -strength metal materials, such as steel. The strength of the material determines the resistance and bending ability of the rotation support, which affects its carrying capacity.

3. Bearing type

The internal internal internal of the rotation supports is usually included in the bearing system to reduce friction and support rotation. The type and quality of the bearings directly affect the carrying capacity of the rotation support. Common bearing types include rolling bearings and sliding bearings.

4. Working environment

The loading capacity of the rotation support will also be affected by the working environment. For example, if the rotary support is working in a high temperature or harsh chemical environment, the corrosion resistance and thermal resistance of the material will become a key factor.

Slewing ring
2. Methods to improve the loading capacity of the rotary branch

1. Optimize the design of support structure

In order to improve the loading capacity of the rotary support, you need to choose good quality support. The second is to optimize the structure design to improve its carrying capacity. For example, strengthening the contact between the steel ball and the arc running in the contact area of the supporting area, increasing the bearing area of the supporting support can effectively improve the support capacity of the support.

2. Use and maintain correctly

In addition, correct use and maintenance support is also the key to improving its carrying capacity. Regular inspections and maintenance can ensure the normal operation of the support, which can effectively use the life.

Factors affecting the loading capacity of the rotary branch are usually tested and evaluated during the manufacturer’s design and manufacturing process. When using the re -supporting support, it is necessary to ensure that the load applied should not exceed its bearing capacity to avoid damage or accidents. Specific carrying capacity parameters can usually be found in the technical specifications of the rotating support products or the technical materials of the manufacturer.