English (UK) 
简体中文 (Scratch my head.) I don't know if you have ever encountered such a situation: the drum motor conveyor line in the workshop, bought back only three months on the squeaking, disassembled to see the gears are grinding bald? Last week, the old king and I complained that their warehouse newly installed line body, froze because of the wrong type of gear selection, the motor burned two, the conveyor belt running to the grandmother's home...I'm telling you, this drum motor thing looks simple, but there's a lot of gearing in it!Today we will break open the kneaded talk, from the parameter calculation to the installation and maintenance, package you listen to the end of the pits can avoid 90%.
First, the first step of gear selection: to understand how "heavy" you move the goods
Newbies are most likely to fall prey to load estimation -It's not all about the weight of the material.!
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It's the dynamic load that counts.
For example, your factory passes the carton (≤20kg), the actual calculation must be multiplied by a1.5 times safety factorIf you are moving car wheels (80kg each), you will have to pay for them as follows2xTo count! Why? The cardboard box is light and has no impact, but the metal part bangs down, and the force is more than three times as strong. -
The torque formula must be understood.
How do you calculate torque? Remember this life-saving formula.Torque (N-m) = 9550 × motor power (kW) / drum speed (r/min) × efficiency (0.85~0.9)
Take a chestnut 🌰:
- Your motor power 3kW
- Roller speed 60 rpm
- Take the transmission efficiency 0.88
Put it in and do the maths: 9550 x 3 ÷ 60 ÷ 0.88 ≈543N-m-Remember this number, select gear bearing capacity below this value quasi-accident!
- Heavy-duty scenarios plus "extras"
When a single gear load exceeds500kg(the equivalent of five strong men pressed up against it), and honestly use theDouble sprocket + planetary gear structureLast year, we changed the line for the auto parts factory. Last year for the auto parts factory to change the line, single gear load from 800kg to 2.4 tonnes, life from half a year to four years.
Second, the ratio: do not let the motor as the "wrong kind"
I've seen too many people blindly match gear ratios and hold the motor alive until it smokes ......
(Slaps thigh) Two iron laws of ratio distribution:
- Don't let the high-speed class be the "carrier."
In the case of a secondary reduction, the ratio of the high-speed stage ≈ √ the total ratio (bad maths is a direct copy of the homework):
- Gross ratio 15: 3.87 for the first stage and 3.88 for the second stage.
- Gross ratio 20, 4.47 for primary and 4.47 for secondary.
Distribute 60% loads to low-speed stages, high-speed gears are lightly loaded for durability!
- Oil bath lubrication should be "flooded in place".
Large gears in the oil tank immersed in oil depth ≥ 1.5 times the height of the tooth (for example, module 5mm gears, immersed down at least 7.5mm). Last year, a logistics warehouse gear holding dead, disassembled and found that the oil just did not reach the tip of the tooth - high-speed gear directly dry grinding waste!
Third, gear selection: 45 steel in front of high temperature is "war five dregs".
(Sighs) How many factories planted on the material, saving thousands of material costs, lost hundreds of thousands of downtime losses...
Red and black list of materials for different scenes
| working condition | Recommended Materials | Processing | case in point |
|---|---|---|---|
| Normal temperature light load (carton sorting) | 45 steel | Tempering HB220-250 | It's enough and it saves money. |
| Medium load impact (metal parts transport) | 40Cr | Surface hardened to HRC50-55 | A power plant uses 45 steel, gears are scrapped quarterly |
| High temperature steam (food sterilisation line) | 20CrMnTi | Carburising and hardening HRC58-62 | Plant with stainless steel, three months corrosion cracking |
| Strong acid environment (plating workshop) | 316L stainless steel | nitriding | Ordinary alloy steel won't last a week. |
Tears of blood lessons: food factory Zhang non-stainless steel "high", the results of the steam room gear intergranular corrosion, the whole line downtime overhaul - for 20CrMnTi carburised gears, three years without a moth.
Fourth, the installation of precision: difference of 0.1mm, sorting error rate soared 30%
You think it'll work just because you put it on?Gear mesh accuracy is the key!
Three axes of precision control
- The province and the flower.
- Logistics Sorting LineGrade 8 precision gears(Price Save 30%)
- Automotive assembly lines mustClass 6 accuracy + tooth trimming(Positioning error ≤0.3mm)
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Shaft Bore Fitting Seize Size
Shaft Bore Fitting OptionsH7/k6(Surplus 0.01~0.03mm) - Can't stuff it? Boil gears in hot water! Automatic tightening when cold. -
"Leave a way out" for thermal expansion.
Summer workshop 40°C? Gear clearance left0.12 x modulus(e.g. leave 0.6mm for module 5)
(Sudden excitement) know why a courier sorting centre in Foshan has a high error rate? Is the gear backlash exceeds the standard 0.5mm, parcels dancing on the drum!
V. Maintenance tips: 3-minute gear change is not a dream
What do repairmen hate the most? Having to remove half a line to remove a gear!Now the quick release construction really smells good...
The Sleazy Operation That Cuts Maintenance Costs in Half
- The right grease for half a year's work
- Ambient workshop.Molybdenum disulphide lithium grease(6-monthly supplement)
- Food and medicine line: a mustNSF H1 certified food grade fats and oils
- Quick release design saves lives
- Traditional bolting: 1 hour for dismantling ↑
- Spring loaded snap-on rollers: Press down on the handle and extract the gears in 3 minutes! (Gear change time reduced from 53 minutes to 4 minutes as measured by a car company)
- Putting an EKG on the gears.
Stickers on the bearing housingVibration sensors, mobile phone to see the spectrogram - appeared1.5 times the engagement frequency spikeWhat's that? Immediate warning of gear wear!
(Knock on the blackboard) Finally dump a practical programme table, according to the choice is correct:
| Line type | Gear configuration programme | return on investment (ROI) |
|---|---|---|
| E-commerce light load sorting line | Helical gear + timing belt drive | Low cost and easy maintenance |
| Heavy industry casting transport | Planetary gear + double sprocket | ¥High丨Life × 4 |
| Pharmaceutical clean room | 316L stainless steel gear + fully sealed | ¥Central丨Zero Pollution |
Gear selection is not about filling out a parameter list, it's about predicting the mines that will be carried by the production line in the next ten years.. Think about it, when the middle of the night burst of express parcels rumbled into the drum, while the gears are still turning silently - this is the real pride of engineers. We can't afford a repeat of the old Wang's motor-burning crap!
