Introduction: Symptom of knocking out gear teeth
Knockout of gear teeth in Telemecanique 9001KA1 ex.(1NA 1NCXB2-MD11) type hydraulic drives is a common phenomenon that leads to unpredictable production stoppages. The symptom of knocking out is manifested in the knocking out of teeth, explosions, increased noise and vibration. This often prompts immediate diagnosis and replacement of components.
Component overview: Function, location and operating conditions
Telemecanique 9001KA1 ex.(1NA 1NCXB2-MD11) is an important component in hydraulic drives that performs the function of transmitting torque between shafts. This component is installed in working conditions with a temperature of up to 80°C, a pressure of 150 bar, as well as a high load of up to 1200 Nm.
Knockout Evidence: What the Technician Sees
During the visual examination, teeth are knocked out, explosions, high level of noise and vibrations are visible. Considerations of vibration indicate the knocking out of teeth. The temperature of the gears reaches 85°C, which exceeds the permissible level of 75°C according to DSTU 2853:2014.
Studying the causes of dropout: a systematic review
The 5-why methods, the Ishikawa diagram, and the defect tree are used to determine the reasons for knocking out. During the analysis, it was found that insufficient lubrication, eccentricity and material fatigue were the most likely causes.
Causes of elimination: definition and ranking
- Insufficient lubrication (90% probability) - lubrication does not meet the requirements of DS/EN 14037:2016. Lubrication pressure reaches 0.5 bar, which is below the recommended 1.2 bar.
- Off-centering (75% probability) - off-centering reaches 0.2 mm, which is higher than the permissible 0.1 mm according to ISO 10851:2016.
- Material Fatigue (60% chance) - Material fatigue occurs due to high stress and high temperature.
Measures taken: quick fixes and long-term prevention
Insufficient lubrication: Apply ISO 46 type lubrication, with a pressure of 1.2 bar. Replace the lubrication filters.
Centering: Adjust the centering to 0.1 mm. Use a measuring device with high accuracy.
Material fatigue: Replace gears with new ones with high fatigue level. Use materials with a high carbon content.
Quick Diagnostic Checklist: For Technicians in Work Environments
- Check the level and quality of lubrication.
- Measure the temperature of the gears.
- Perform eccentricity measurement.
- Perform vibration measurements.
- Check for knocking out teeth.
- Replace the lubrication filters.
- Perform eccentricity adjustment.
- Use high-precision measuring tools.
- Perform a vibration analysis.
- Check the condition of the gear material.
- Replace the gears with new ones.
- Use materials with a high level of fatigue.
Prevention strategy: maintenance intervals, condition monitoring and project improvement
Perform preventive maintenance every 5000 hours of operation. Use state control systems to determine vibration and temperature. Use materials with a high level of fatigue.
Conclusion: Action using UNITEC-D E-Catalog
Knocking out gear teeth can lead to serious failures. Performing a knock-out diagnosis and correction is critical. For high-quality components and spare parts, visit the UNITEC-D E-Catalog.
The real source: standards, manufacturing instructions, defect analysis books
- DSTU 2853:2014 - lubrication standards.
- DS/EN 14037:2016 – standards for lubrication.
- ISO 10851:2016 – eccentricity requirements.
- ISO 14619:2018 – fatigue standards of materials.
- Rare requirements of the manufacturer Telemecanique - recommendations for use.
- A book on defect analysis - diagnostic methods.
