How to deal with the failure of transmission parts in motor assembly line?

The core of fault treatment of transmission parts in motor assembly line is "stop the machine first, then accurately repair, and finally verify and restore", and it is necessary to follow the four-step process of "safety-diagnosis-repair-test" to avoid fault expansion or secondary damage.

1. Emergency shutdown and safety protection: cut off the risk source.

Faults of transmission components (such as chains, belts and gears) may be accompanied by jamming, abnormal noise or even parts being thrown out. The first step must be to ensure the safety of personnel and equipment.

Stop immediately and cut off power: press the emergency stop button of the production line to cut off the power supply and air supply (if pneumatic transmission is involved) in the fault area to prevent the components from being stuck or broken due to continuous operation.

Set safety warning: put warning signs around the fault area, prohibit irrelevant personnel from approaching or trying to start the equipment, and wear protective gloves, goggles, etc. at the same time to avoid being scratched by oil or metal debris during maintenance.

2. Fault diagnosis: locate the type and cause of the problem.

Accurately judging the fault type is the premise of efficient maintenance, and it needs to be checked in three ways: "seeing, listening and checking".

Visual inspection: check whether there is obvious damage to the transmission parts, such as broken/disconnected chain, cracked/skidded belt, worn/cracked gear tooth surface, oil leakage/abnormal sound of bearing, etc.

Cause tracing: According to the fault phenomenon, the root causes are analyzed, and the common causes include insufficient lubrication (dry grinding of components), overload (exceeding the rated torque of transmission), alignment deviation (components installed on different shafts) and aging loss (fatigue of components caused by long-term use).

Tool-aided detection: use a wrench to check the fastening of components, use a multimeter to detect the current of the drive motor (to judge whether it is overloaded), and use a micrometer to measure the clearance of gears or bearings (to judge the degree of wear).

3. Targeted maintenance: according to the fault type.

There are great differences in maintenance methods for faults of different transmission components, so it is necessary to classify operations to ensure the repair effect.

Chain/belt fault: if the chain is out of line, it is necessary to adjust the tightness of the tensioner and re-engage; If the chain is broken or the belt is cracked, it is necessary to directly replace the new parts of the same model. After replacement, it is necessary to calibrate the parallelism of the driving wheel to avoid running deviation again.

Gear fault: If the gear is slightly worn, the grease can be added after cleaning the oil on the tooth surface; If the tooth surface is cracked or seriously worn, it is necessary to remove and replace the new gear, and ensure the coaxiality of the gear shaft during installation, and the error should be controlled within 0.1 mm.

Bearing failure: If the bearing is abnormal or hot, it is mostly lubrication failure or ball wear, so it is necessary to remove the bearing and clean it (with kerosene or special cleaning agent). If the ball is worn, replace it with a new bearing, and apply proper amount of grease (the filling amount is 1/3-1/2 of the inner space of the bearing) during installation.

Motor transmission failure: if the motor output shaft is loosely connected with the transmission parts, the coupling or keyway needs to be tightened again; If the motor is overloaded, it is necessary to check whether the load exceeds the standard, and adjust the operation parameters of the production line if necessary (such as reducing the conveying speed).

4. Commissioning and acceptance: ensure normal operation.

After maintenance, it needs to be tested step by step to avoid the failure recurrence caused by direct full-load operation.

No-load test run: first disconnect the transmission parts from the load (such as disconnecting the conveyor belt), start the motor to drive the transmission parts to idle for 10-15 minutes, and check whether there are any problems such as abnormal sound, jamming and heating (bearing temperature does not exceed 60℃).

Load test run: After no-load is normal, restore the load connection, gradually test according to the rated load of 50%, 80% and 100%, observe the running state of transmission parts, and record the motor current, transmission speed and other parameters to ensure consistency with normal operation.

Follow-up tracking: within 1-2 hours after resuming production, patrol the fault area regularly. After confirming that there is no abnormality, update the equipment maintenance account, record the fault reasons, maintenance measures and replacement parts models, so as to facilitate subsequent preventive maintenance.