Gear breakage is a serious failure during reducer operation, which directly affects equipment safety and production continuity. For the ZLYJ146-12.5 reducer, judging the degree of gear fracture requires a combination of direct damage characteristics and abnormal operation signals, and a graded assessment from micro cracks to macro broken teeth, so that repair or replacement measures can be taken in a timely manner.
1. Direct observation method: judge the degree of fracture through disassembly and inspection or observation holes
1. Crack stage (early damage)
Symptoms : Small cracks appear on the tooth root or tooth surface, visible to the naked eye or identified with the help of a magnifying glass.
Judgment Criteria :
Once visible cracks (regardless of length) are found in the tooth root area, great attention must be paid. The tooth root is a stress concentration area where cracks propagate quickly and can easily lead to tooth breakage.
Colored penetrant testing or magnetic particle testing can be used to further confirm the depth and direction of cracks.
2. Partially broken tooth (moderate damage)
Performance : The edge or part of the tooth body of a single tooth is broken, and the fracture area is less than 1/3 of the tooth width.
Judgment Criteria :
If the broken tooth does not damage the tooth root and there is no obvious sign of crack expansion, it can be operated under load for a short period of time, but close monitoring is required.
If there are sharp burrs in the broken tooth area, it may scratch the matching gear and requires grinding.
3. Completely broken teeth or multiple broken teeth (severe damage)
Symptoms : The entire tooth falls off or multiple teeth are broken, and the gear outline is obviously incomplete.
Judgment Criteria :
Complete breakage of a single tooth is considered a serious failure and the entire set of gears must be replaced.
Multiple tooth fractures will cause transmission interruption, sharp increase in vibration, and even damage to bearings and shafting systems.
2. Indirect judgment method of operating status: on-site diagnosis without dismantling the machine
1. Abnormal vibration and noise
There are periodic 'clicking' and 'clunking' sounds, accompanied by obvious vibration, which usually corresponds to the impact at the moment of broken teeth.
Use a vibration meter to test. If the radial vibration speed exceeds 11.2mm/s and the bearing failure is eliminated, it can be determined that the gear mesh is abnormal.
2. Abnormal increase in temperature
Broken teeth lead to uneven meshing, increased friction, and the temperature of the gearbox may quickly rise above 70°C, especially when operating under load.
3. Lubricating oil contamination
Large metal fragments (>0.5mm) or massive abrasive grains are found in oil samples, which are usually the product of tooth surface peeling or broken teeth.
Ferromagnetic particles can be quickly detected through magnet adsorption. If the adsorption amount is large and the particles are coarse, it indicates that serious internal damage has occurred.
3. Non-contact detection technology (suitable for early warning)
Although ZLYJ146-12.5 is not directly mentioned in the literature, you can refer to the detection method of the same series of ZLYJ reducers:
Vibration signal analysis method
Install an acceleration sensor to collect the vibration signal of the box, and identify the sideband changes of the meshing frequency through spectrum analysis to determine whether there are broken teeth or cracks.
Acoustic emission detection method
It captures the elastic waves released when gear cracks expand. It is highly sensitive to early micro-cracks and is suitable for online monitoring.
Infrared Thermography
By scanning the temperature distribution on the surface of the box, broken teeth or severely worn areas will show local high-temperature areas due to increased friction, allowing for visual positioning.
