Solution to how to repair shaft wear in Flanders reducers

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Equipment Name: Flender Type 4 Reducer
Equipment Parameters: Operating temperature: 40°C–60°C; Bearing housing wear: 0.5–2.5 mm varies. Country of origin: Germany. Material of reducer: Cast iron. Bearing housing dimensions: Ø260, Ø380, Ø480. Bearing models: SKF 2324EC, FAG NU2336-EX-M1A-C3, SKF 23064 CC/W33. Total equipment weight: 13 tons. Areas to be repaired: Lower bearing housing of shaft 2, upper bearing housing of shaft 3, upper bearing housing of shaft 4. Material used for repair: Sorex high-performance polymer material.

Traditional methods (patch welding and machining): Repair time – around 20 days. Using external casting and surfacing followed by machining: Results include welding stress, defects, cracks, etc. Traditional method (inserting steel sleeves): Repair time – around 15 days. Repair procedure: Drilling to expand the hole, heat treating the steel sleeve, and then fitting it with an interference fit. Outcome: The steel sleeve tends to deform, creating gaps that lead to further wear.

Sorex technology: Repair time – around 3 days. Repair procedure: On-site repair, curing, followed by machining to the required dimensions. No mechanical stress is generated, and the force distribution is adjusted to effectively prevent further wear.

Case study: A desulfurization company experienced wear in the bearing housings of its reducers, with wear levels ranging from 0.5–2.5 mm. The company’s technical engineers rushed to the site of the enterprise and developed solutions based on the equipment’s operational data and the issues encountered. By assisting enterprises in repairing the worn bearing housings of reducers at their machining sites, it solves major equipment problems for them as quickly and effectively as possible, earning high praise from cooperative customers. (The diagram is on the 2nd floor) Steps for repairing wear in the reducer bearing chamber: 1. Degrease the surface ； 2. Pre-process by treating the worn surface and cleaning it with anhydrous ethanol. 3. Harmonize SD7101 material ； 4. Apply the material and use it up within the specified time ； Use a scraper to scrape repeatedly to ensure full adhesion to the metal ； And use a template ruler to restore it to the standard size. 5. Cure ； (If starting up quickly is necessary, the material can be heated using an iodotungsten lamp; a temperature of around 80°C for 2 hours will suffice.) 6. After the SD7101 metal-polymer repair material has cured, simply treat the repaired surface and then assemble the gears for installation.