When using a drive reducer for a belt conveyor, some input shafts of the drive reducer are usually broken, which has a certain impact on the user's production.When the shaft breaks, only the input shaft is usually damaged, and the output shaft is rarely broken.In severe cases, the input shaft will be damaged sequentially on several belt conveyors.This happens when all reducers with broken shafts are from the same belt conveyor supplier.When an axle breaks, the stubble at the break of the rear axle is usually flush and the section is usually perpendicular to the length of the axle.Shaft breaks on belt conveyors on mobile machinery and grounded belt conveyors. 1. The main external causes of shaft failure should include the following aspects: 1.1 The bearing capacity of the selected belt conveyor reducer is insufficient, that is, the driving reducer of the belt conveyor is too small.When the actual power of the reducer exceeds the bearing capacity of the reducer, the shaft of the belt conveyor driving the reducer will be damaged within a certain period of time; 1.2 The hydraulic coupling and brake wheel are usually installed between the motor shaft and the reducer shaft.When the dynamic balance of the brake wheel and the hydraulic coupling is poor and the eccentricity is serious, it will cause a lot of vibration during the operation of the belt conveyor.When the vibration load reaches a certain level, the output shaft of the reducer is too stressed and broken; 1.3 The concentricity deviation of the installation is too large.If the hydraulic connection and brake wheel between the motor and the reducer are installed, the concentricity between the reducer and the motor shaft should be carefully adjusted.If the deviation is too large, the connection and brake wheels will generate excessive vibration during operation and damage the shaft. 1.4 Due to the defect in the design of the reducer, the input shaft is broken.This situation occurs when the belt conveyor is designed, and the reducer is selected according to the requirements of the reducer supplier.Although the selected reducer meets the requirements of the reducer supplier, the shaft is still damaged. 2. The internal factors of the shaft fracture of the reducer mainly include the following aspects: 2.1 Excessive stress of shaft fracture during reducer design; 2.2 The shaft shoulder on the input shaft of the reducer does not carefully consider the radius of curvature and change curve of the transition fillet, resulting in serious stress concentration and fatigue failure; 2.3 The reducer adopts the form of a vertical shaft, and the main input shaft is a bevel gear shaft.Severe stress concentration occurs at the transition shaft shoulder at the bevel gear support bearing, and fatigue failure occurs; 2.4 The reducer is a hard tooth surface reducer, and the diameter of the input shaft of the reducer is relatively small.Although the strength is calculated, the shaft itself is very thin, so the stress concentration is severe, and fatigue failure occurs under the change of shaft diameter; 2.5 The heat treatment quality of the input shaft is unqualified; 2.6 Incorrect material selection of input shaft. 3 Methods and measures to avoid and reduce the shaft damage of the reducer shaft 3.1 Modify the design of the reducer; 3.2 During installation and maintenance, pay attention to adjusting the concentricity of the motor and reducer to meet traditional requirements; 3.3 When a reducer with a parallel shaft can be used, it is better not to use a reducer with a vertical shaft; 3.4 When selecting a reducer, consider or calculate the allowable radial load of the reducer; 3.5 When selecting the motor speed, a six-pole motor should be selected as much as possible, that is, a motor with a synchronous speed of 1000 r/min should be used as the driving motor, thereby reducing the vibration of the coupling and brake wheels during high-speed rotation, especially for those with For high-power belt conveyors, such as belt conveyors with power greater than 90kW, it is best to choose a low-speed motor. At this time, the price of the motor is correspondingly higher than that of a four-pole motor; 3.6 Attempt to reduce or control the unbalanced torque of hydraulic couplings and brake wheels. Through the above method, the problem of shaft disconnection of the input shaft of the drive reducer of the belt conveyor can be basically found or solved.In the frequently operated belt conveyor system, the necessary spare part of the reducer should be properly equipped and replaced in time to avoid affecting normal production.
