Broken shaft is a common fault of the servo planetary reducer. Many users do not know how to deal with the broken shaft. After a large number of practical cases, the broken shaft of the servo planetary reducer can be repaired by welding. Today I will introduce you how to weld. The welding is divided into three stages: pre-welding preparation, welding and post-welding treatment. The specific operations are as follows:
Servo planetary reducer
1、 Preparation before welding
1. Design of welding groove and gap. The fracture part of the servo planetary reducer shall be processed and leveled before welding, and corresponding measures shall be taken for the design of the welding groove to reduce the stress. The U-shaped groove is designed according to the fracture condition and part diameter. The upper width of the groove is 20 mm and the depth is 37 mm. After the fracture end surface is machined flat, cut the fracture end surface with formed turning tool to make its shape consistent. In order to avoid stress concentration, all parts of the groove shall be rounded to reduce the proportion of base metal melting into the weld metal and prevent cracks. The welding gap also has an important impact on the weld quality. Too small gap is easy to produce defects such as incomplete penetration or excessive weld accumulation, while too large gap is easy to burn through.
2. Cleaning before welding. Before welding, the rust, oil stain, moisture and oxide skin on the groove and the blunt edge surface of the servo planetary reducer shaft must be removed. First, use flame baking to remove water and oil, and then use manual abrasive cloth or grinder to polish for rust removal. The oxide scale can be removed directly by grinding machine, and some oil stains that are difficult to clean can be cleaned by acetone or ethanol.
2、 Welding
In the welding process of servo planetary reducer, in order to prevent welding deformation, positioning blocks shall be added at the groove to ensure equal spacing welding. The welding position of the locating point is selected on both sides of the locating block to avoid welding deformation of the axis. At the same time, the cooling rate of the whole welding area is reduced to prevent cracks. The weld shall be welded evenly with the shaft rotation. After each layer of weld is completed, the weld shall be visually inspected. If there are pores, slag inclusions, cracks, etc., the weld defects shall be removed by carbon arc gouging, and the welding can be continued after repair welding. When the cooling temperature of the weld is not lower than 200 ℃, weld to the height of the locating block, knock off the locating block and continue welding. The surfacing height shall be greater than the diameter of the original shaft, so as to leave enough machining allowance.
3、 Post-weld treatment and machining
After welding, asbestos shall be used for insulation to reduce hardenability and avoid embrittlement. In order to eliminate the welding stress, the weld area can be heated to 350~550 ℃ by flame, and then buried in hot sand or white ash to cool slowly until the temperature is normal. The appearance of the welding points of the servo planetary reducer shall be neat and beautiful, and the welds shall be uniform, without pores, slag inclusion, poor melting, spatter and undercut. After the appearance inspection is qualified, the outer circle and end face of the output shaft shall be turned again according to the required size.
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