How to repair the broken shaft of the servo planetary reducer by welding

Broken shaft is a common fault of servo planetary reducer.Many users don't know what to do with a broken shaft.After a large number of actual cases, the broken shaft of the servo planetary reducer can be repaired by welding.Today, the editor will introduce to you the welding method.Welding is divided into three stages: pre-weld preparation, welding and post-weld treatment.The specific operation is as follows:

Servo planetary reducer

1. Preparation before welding

1. Design of welding groove and gap.The fractured part of the servo planetary reducer should be processed and leveled before welding, and the design of the welding groove should also take corresponding measures to reduce the stress.The U-shaped groove is designed according to the fracture situation and the diameter of the part.The groove has an upper width of 20 mm and a depth of 37 mm.After the end surface of the fracture is processed flat, use a forming turning tool to cut the end surface of the fracture to make it consistent in shape.In order to avoid stress concentration, all parts of the groove should be rounded to reduce the proportion of the base metal melted into the weld metal and prevent cracks.The welding gap also has an important influence on the quality of the weld.If the gap is too small, defects such as incomplete penetration or excessive accumulation of weld seams will easily occur, and if the gap is too large, it will be easy to burn through.

2. Clean up before welding.Before welding, the rust, oil, moisture and scale on the groove and blunt edge surface of the servo planetary reducer shaft must be removed.First bake it with a flame to remove water and oil, and then polish it with a hand-made emery cloth or a sander to remove rust.The scale can be removed directly with a grinder, and some difficult-to-clean oil stains can be cleaned with acetone or ethanol.

2. Welding

During the welding process of the servo planetary reducer, in order to prevent welding deformation, a positioning block is added at the groove to ensure equal spacing welding.The positioning point welding position is selected on both sides of the positioning block to avoid shaft welding deformation.At the same time, reduce the cooling rate of the entire welding area to prevent cracks.The weld seam should be evenly welded with the rotation of the shaft.After completion of each layer of welds, the welds shall be visually inspected.If there are pores, slag inclusions, cracks, etc., use carbon arc gouging to remove weld defects, and continue welding after repair welding.When the welding seam cooling temperature is not lower than 200°C, weld to the height of the positioning block, knock off the positioning block and continue welding.The surfacing height should be greater than the diameter of the original shaft, leaving enough machining allowance.

3. Post-welding treatment and machining

Use asbestos insulation after welding to reduce hardenability and avoid embrittlement.In order to eliminate the welding stress, the weld area can be heated to 350-550°C with a flame, and then buried in hot sand or lime and slowly cooled to normal temperature.The appearance of the solder joints of the servo planetary reducer should be neat and beautiful, the weld seam is uniform, and there are no pores, slag inclusions, poor melting, splashes and undercuts.After passing the visual inspection, turn the outer circle and end face of the output shaft according to the required size.

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