XWEDV4/4 - 8160C - 104 The output shaft shoulder of the cycloidal pinwheel reducer is a key part of stress concentration. If cracks appear here and are not dealt with in time, the damage will gradually spread from the shaft itself to the entire machine and related equipment, and even cause safety accidents. The details are as follows:
Power transmission failure interrupts the production process : the output shaft is the core component of the reducer that transmits power to the load end of textile machinery, conveying equipment, etc. Shoulder cracks will reduce the torque carrying capacity of the shaft. With the action of alternating loads during the operation of the equipment, the cracks will continue to expand and may eventually cause the output shaft to break. At this time, the reducer cannot effectively transmit the power corresponding to 5.5KW to the downstream equipment, directly causing the production line to shut down. For continuous production scenarios, this downtime will bring significant production efficiency losses and economic losses.
Exacerbating the wear of the entire machine components and causing cascading failures : cracks in the shaft shoulder will destroy the coaxiality of the output shaft, causing the shaft to oscillate eccentrically during operation. On the one hand, it will cause abnormal fit clearance between the shaft and the bearing, and the bearing will bear uneven radial force, which will intensify the wear of the rolling elements and raceways. In severe cases, it will cause the bearing to get stuck and the balls to break. On the other hand, the eccentric operation will also affect the meshing accuracy of the cycloidal wheel and the pin teeth inside the reducer. The original uniform force on multiple teeth will become a localized force concentration, leading to tooth surface wear, pitting corrosion and even tooth chipping. At the same time, this abnormal force may also be transmitted to the input end, causing the motor load to increase abnormally, causing the motor to overheat, shortening the service life of the motor, and even burning the motor in severe cases.
Deterioration of operating stability and generation of vibration and noise : Cracks will cause asymmetric stiffness of the output shaft and produce nonlinear vibration during operation. This vibration will not only intensify the vibration of the reducer itself, but will also be transmitted to the entire equipment unit through the mounting base. Moreover, vibration and crack propagation promote each other. The more severe the crack, the more severe the vibration, which in turn accelerates the crack propagation. In addition, vibration will be accompanied by abnormal noise, which will not only interfere with the normal working environment of the workshop, but also cover up the signals of other potential faults of the equipment, which is not conducive to the daily operation and maintenance monitoring of the equipment.
Causing potential safety hazards and threatening the safety of personnel and equipment : If the crack continues to expand and the output shaft suddenly breaks, shaft fragments may fly and connected load components may fall off during high-speed operation, which may easily hit peripheral equipment and operators, causing equipment damage and personal injury. At the same time, the impact force at the moment of breakage may destroy the housing sealing structure of the reducer, causing internal lubricating oil to leak. This not only results in a waste of oil, but the leaked oil may also cause secondary safety hazards such as slipping. If it is in special working conditions with a flammable environment, it may also increase the risk of fire.
Increase maintenance costs and expand economic losses : If cracks are treated in time in the early stages, maintenance costs will be lower. However, once the cracks expand, not only the output shaft must be replaced, but also bearings, cycloidal wheels, pin teeth and other components damaged by vibration and abnormal force must be repaired. The difficulty and cost of repairs increase significantly. If the downstream load equipment is damaged due to shaft fracture, such as the deformation of the roller shaft of the textile machinery, the offset of the transmission roller of the printing equipment, etc., it will further expand the scope of repair and economic losses, and subsequent equipment debugging and recovery will also require additional time and cost.
