Substituindo uma caixa de engrenagens de rosca para a indústria: O que manter e o que reavaliar

A replacement industrial worm gearbox may seem like a simple task: duplicate the ratio, get a motor with the same horsepower and place an order for the same housing. The question is if the original specification is still applicable to the machine. The production hours, Carregamento, space and stopping requirements might have been altered since the installation.

The challenge for maintenance managers and replacement buyers is to maintain the interfaces required while not necessarily performing the same, wrong interface. This guide focuses on the Mingye's RV and S-series products to provide instructions on how to conduct that review and determine if a drive can be replaced or if another drive should be considered.

Set up reasons for the replacement of the existing gearbox.

Start with the circumstances – not the purchase order. Write down if there is leakage or noise or damaged interfaces or problems with starting or frequent times of shutdown. Record the time when it took place and whether or not production conditions varied previously. A symptom is a part of the investigation that helps identify it, but is not by itself an indication of the failed component.

Mingye's conveyor restart troubleshooting guide covers machine resistance, acceleration demand, traction and drive capability. That is a distinction that is important prior to upgrading the motor size or ordering another reducer. Another reason for a replacement to experience loads is if a mechanism is obstructed or if the transmission tension is not correct.

If it is necessary to inspect equipment, isolate equipment according to the site procedure. Maintain the current nameplate, maintenance records, installation pictures and any operating data that has been measured and made available to the supplier for more that a verbal description.

Determine the Worm Drive Configuration that is installed

Mingye's Motor de engrenagem sem-fim da série RV features a small square housing and right angle worm gear transmission. It offers a relevant starting point for finding a matching compact industrial drive on its product page, however the exact input and output and mounting arrangement must be exactly specified in the final specification.

Motor de engrenagem helicoidal S-Series is a hybrid of a stage with helical stage and worm stage. Consider it as an independent architecture and do not take it for granted that it can be substituted for an RV unit and the housing section as well. Their own review is required for motor position, overall size, available ratios and connections.

Check if the replacement scope consists of the motor, input adapter, output accessories and the brake. Even if a gearbox quotation and a complete gear-motor quotation are similar in terms of the series used to describe the supply, they can actually be different.

Get Interfaces That Can't Easily Change

Make use of the existing machine as dimensional reference. Measure the shaft / hollow bore, Keyway, engagement length, Padrão de montagem, locating register and shaft center position. Document the location of the motor and guards, terminals, cables and service tools.

Mingye's right angle gear motor replacement guide doesn't only focus on nameplate information, it also focuses on orientation. Determine output direction and rotation based on a specified viewing direction and good photos. An identical unit on a bench may have the motor or out on the opposite side of the installed unit.

Discuss an accepted dimensional drawing prior to ordering. If an adapter plate or coupling change is to be proposed, review alignment, support and maintenance clearance with the change. Don't consider machining work required after delivery as an insignificant issue that doesn't impact downtime.

Repeat if Process Has Changed: Speed and Torque

An increased production rate can alter the output speed required and a heavier product or increase in process resistance can alter torque. Don't assume that the previous motor rating is the current running demand and the loaded start.

Por exemplo, if the input speed is 1,440 rpm, a velocidade de saída (nominal) changes from 36 rpm to 48 rpm when the ratio is changed from 40:1 a 30:1. That calculation is just to determine speed. Também, the torque of the motor, the efficiency of the gearbox and the allowable torque of the replacement will affect the available output torque.

If the motor is to be retained when the gearbox ratio is changed, a new compatibility check needs to be done. Indicate the speed, Suprimento, control range, starting demand and continuous duty. A mechanically sized flange does not ensure the existing motor is capable of providing the performance of the revised machine.When sizing the flange mechanically, this does not confirm that the existing motor will be able to provide the performance of the revised machine.

Useful Outputs to compare Service Cost.

While the purchase price is important, operating hours will determine the impact of efficiency on the operating cost. When comparing candidates drives for continuous service, compare the drives at the same useful output torque and speed. Otherwise what appears to be a savings may be due to different work being performed.

For illustrative purposes only: If a gearbox-only comparison is made and the input to the gearbox is assumed to be 75% and 90% efficient, 2.00 kW and 1.67 kW will be required, respectively, to deliver 1.5 kW. Então, the difference is approximately 1333 kWh over 4,000 loaded hours. These efficiencies assumed are not the same as the product rating of the Mingye and electrical savings also rely on the losses of the motors and controls.

Mingye's worm/helical-bevel comparison provides a starting point to discuss other architectures. Along with energy, add adaptation cost, access to services, spares and predicted downtime. Considering another setup may still be practical for a small, intermittent duty machine, but for longer duty cycles, it may be worth considering the worm replacement.

Keep the mounting and holding functions during substitution.

The replacement should maintain the desired reaction/torque path and reaction support. If a hollow-shaft installation is to be used, ensure that the reaction arrangement has been approved. Do not rigidly fix all available interfaces for foot or flange mounting; follow manufacturer's instructions.

Verify the lubricant specification, quantity and service requirements for the installed orientation. Don't assume that a maintenance period and/or old oil is applicable to a different series. Any arrangements for venting and services points by the chosen design also need to be checked for an orientation change.

Look at holding behaviour in isolation. An industrial worm gearbox is NOT always a holding brake and a different gear setup can change back driving characteristics. If gravity or stored energy will cause the machine to move, verify that the necessary restraint and stopping devices are needed before making substitutions, such as existing brake and control sequence.

Generate an Order with an Installation Plan to hand out to customers.

Request Mingye to mark confirmed matches, proposed deviations and unresolved inputs, in the quotation. Mutual agreement on motor inclusion, Acessórios, supply of the lubricant, drawings and inspection documents to be used. Document any adapters, electrical changes or guarding work prior to arranging for shut down.

At the time of commissioning check installation, Rotação, normal loading and required starts with an agreed procedure. Make observations in similar conditions to allow the maintenance team to have a baseline to use. Have complete ordering code and approved drawings for future replacements.

Industrial Worm Gearboxes replacement is the right way to preserve the requirements of the machine and cater to the modifications. When you have something documented for review, it becomes an engineering decision to replace it or make changes to the architecture.

Perguntas frequentes

Q1. Are match ratio and motor power the only important parameters to consider for replacement?

Also the dimensions, Disposição do eixo, Orientação, ratings and scope of supply must be the same. Check installed configuration on approved drawing.

Q2. Is it possible to directly replace an RV gearbox with an S series helical-worm unit?

Not automatically. There are differences in the architectures and interfaces. Check full dimension, output duty and motor arrangement and then suggest substitution.

Q3. When changing gearbox ratio can the existing motor be retained?

Possibly, after review. Verifique o torque, Velocidade, Início, thermal duty and motor interface with the updated machine requirement.

4º trimestre. Does a more efficient gearbox mean it's a more affordable replacement?

Não. Factor in energy use as compared to adaptation cost, Horário de funcionamento, Manutenção e tempo de inatividade. The economic outcome will vary depending upon the application.

Pergunta 5. Is worm gearing enough to ensure that the machine will stay in place?

Não. Back-driving behaviour is dependent on design and operating conditions. Verify appropriate holding solution whenever when movement is not desired.