During the pre-tightening force test of the connecting bolts in the reducer, a torque setting of 760 Nm was applied (which required special approval due to its high value). The torque wrench was manually pulled from its farthest end until the first audible click was heard. At this point, the bolt cap should not rotate, indicating that the torque has been properly applied. The test results confirmed that all three bolts met the required specifications.
The nut at the bottom of the connecting plate was removed, and the bolt was manually pulled to check if it could be easily removed. The bolt hole was also inspected for any misalignment. It was observed that the axial bushing of the coupling inner gear sleeve may have been affected by axial forces.
One of the primary causes of increased axial force is the use of a drum-type gear coupling between the first and second reduction gears. This type of coupling allows limited axial movement, which helps to reduce the small axial forces caused by minor misalignments in the horizontal or axial direction. As a result, during operation, the sleeve tends to move axially along the shaft due to centrifugal force and these minor axial forces.
A second contributing factor is the impact and vibration generated during the start-up and shutdown of the main lifting system. These forces can increase the existing misalignment, thereby increasing the axial force acting on the components.
The deviation in the alignment of the connecting shaft between the primary and secondary reduction gears can occur during design, manufacturing, transportation, or installation. The primary reducer is a synchronous unit, meaning the center distance between the two output shafts is fixed and cannot be adjusted. The secondary reducer is designed with three fixed support points, making it impossible to adjust the horizontal alignment or eliminate installation errors. To address this, an inspection platform was added to facilitate maintenance and ensure timely equipment checks. Additionally, baffle plates were welded at both ends of the coupling to prevent excessive movement or dislocation of the coupling housing.
This comprehensive approach ensures that the system remains stable and reliable, minimizing the risk of failure due to misalignment or excessive axial forces. Regular inspections and proper maintenance are essential to maintaining the integrity and performance of the reducer over time.
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