Spring passive disk failure analysis

Analysis of the Failure Condition of the Spring Passive Disc The failure of a spring passive disc typically occurs when it fails to shift automatically according to the pressure exerted by the spring—commonly referred to as "sticking" or "jamming." This issue can lead to operational inefficiencies and even system failure if not addressed. Possible causes include: 1. One-way Rotation (e.g., in food processing, packaging, woodworking, electronics cable, and band saw machinery) - During installation, the shaft hole may be too tight or misaligned, making it difficult to install the shifting disc smoothly. According to national standards, the diameter tolerance for the shaft should be -0.021. - *Solution:* Replace the component. However, this is generally not covered under warranty and is often due to improper installation by the user. - Prolonged use without following the manufacturer's guidelines can cause parts like the umbrella disc and its wheel, or the wheel and the shaft center, to rust due to lack of lubrication or maintenance. This can result in permanent sticking. - *Solution:* Disassemble the unit, clean off any rust, apply fresh grease, and reassemble. 2. Bidirectional Rotation (common in printing and dyeing machines, occasionally used in food mixing equipment) - The same issues as in one-way rotation may occur, such as improper installation or insufficient maintenance. - In some cases, the materials used in the product are not suitable for the intended application. For example, machines that require bidirectional operation should use cast iron with a minimum Brinell hardness of 180. If the materials are substandard, the fixed round shaft and flat steel key may become stuck, leading to an enlarged keyway and inability to shift. - *Solution:* Replace the faulty components. - When the machine frequently switches between forward and reverse, the belt may rub against the disc during the transition, generating heat. This heat can cause the factory-lubricated grease to lose its viscosity, reducing the clearance between internal parts and causing corrosion on metal surfaces. This is especially common in high-humidity environments where rust is more likely. - *Solution:* Disassemble the unit, remove rust, reapply grease, and reassemble. Ensure that the issue from point 3 has been ruled out before proceeding. Regular maintenance, proper installation, and adherence to usage guidelines are essential to prevent these failures and extend the lifespan of the spring passive disc.

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