Micro gear pumps are widely used in various fields such as precision machinery, automotive electronics, and pharmaceutical equipment due to their advantages of compact structure, small volume, stable output pressure, and high transmission precision. However, in long-term operation, affected by factors such as working conditions, medium characteristics, and installation and maintenance levels, micro gear pumps are prone to various faults, which directly affect the normal operation of the entire system. Therefore, mastering the common fault causes and corresponding troubleshooting methods of micro gear pumps is of great significance for improving equipment operation efficiency, reducing maintenance costs, and ensuring production continuity.
One of the most common faults of micro gear pumps is insufficient or no discharge pressure. After investigation, the main causes of this fault are diverse. Firstly, the inlet pipeline is blocked or leaking. Due to the small flow channel of the micro gear pump, even small impurities in the medium can easily block the inlet pipeline, resulting in insufficient suction of the pump; while the leakage of the inlet pipeline will cause air to enter, destroying the vacuum environment required for suction, and thus the pump cannot generate normal discharge pressure. Secondly, the wear of the gear pair is serious. The gear pair is the core component of the micro gear pump. After long-term meshing operation, the tooth surface will be worn, resulting in an increase in the gap between the gears. When the gap exceeds the allowable range, the medium will leak back between the gears, making it impossible to establish effective discharge pressure. In addition, the insufficient filling of the medium in the pump cavity, the failure of the one-way valve at the outlet, and the too low speed of the driving motor can also lead to insufficient or no discharge pressure.
For the fault of insufficient or no discharge pressure, targeted troubleshooting methods should be adopted. First, check the inlet pipeline: clean the pipeline to remove impurities, and replace the aging seals at the pipeline connections to eliminate leakage. If the pipeline is severely corroded, it should be replaced in time. Secondly, inspect the gear pair: disassemble the pump body, measure the wear of the gear tooth surface and the gap between the gears. If the wear exceeds the limit, replace the gear pair with a new one. At the same time, check the bearing condition of the gear shaft. If the bearing is stuck or worn, it should also be replaced. In addition, ensure that the medium is fully filled in the pump cavity before starting the pump; check the one-way valve at the outlet, clean or replace the valve core and seal to ensure its normal opening and closing; check whether the driving motor speed meets the design requirements, and adjust or repair the motor if there is a speed deviation.
Another common fault of micro gear pumps is abnormal noise and vibration during operation. The main causes of this fault include unbalanced gear meshing, excessive bearing wear, loose fasteners, and cavitation in the pump cavity. When the gear pair is installed incorrectly or worn unevenly, the meshing gap will be uneven, resulting in impact during operation and generating abnormal noise; the excessive wear of the bearing will cause the gear shaft to deflect, leading to eccentric operation of the gear, which not only produces noise but also causes vibration; the loose fasteners such as the pump body and the base will cause the pump to shake integrally during operation, amplifying noise and vibration; cavitation occurs when the local pressure in the pump cavity is lower than the vaporization pressure of the medium, and the generated vapor bubbles burst suddenly, resulting in severe noise and cavitation damage to the gear and pump body.
To solve the problem of abnormal noise and vibration, the following measures can be taken. First, check the gear meshing condition: re-adjust the installation position of the gear pair to ensure uniform meshing gap; if the gear is worn unevenly, replace the gear pair. Secondly, inspect the bearing: disassemble the pump to check the bearing wear, and replace the bearing if necessary. At the same time, add an appropriate amount of lubricating oil to the bearing to ensure smooth operation. Thirdly, check all fasteners and tighten them if there is any looseness. For the pump base, it is necessary to ensure that it is firmly fixed on the foundation to avoid integral shaking. Finally, solve the cavitation problem: improve the inlet pressure of the pump, reduce the flow rate of the inlet pipeline to avoid excessive local flow velocity, and ensure that the medium temperature does not exceed the limit, so as to prevent the vaporization of the medium.
In addition, oil leakage of micro gear pumps is also a frequent fault. The main leakage parts include the joint between the pump body and the end cover, the shaft extension seal, and the pipeline connection. The causes of leakage are mainly the aging, damage or improper installation of seals, the deformation of the pump body or end cover due to uneven stress, and the excessive tightening of fasteners leading to the damage of the sealing surface. For oil leakage faults, first, check the seals at each leakage part, replace the aging or damaged seals, and ensure that the seals are installed correctly. Secondly, check the flatness of the pump body and end cover sealing surfaces. If there is deformation, repair it by grinding or replace the damaged parts. At the same time, adjust the tightening torque of the fasteners to avoid excessive or insufficient tightening, ensuring that the sealing surface is closely fitted.
In conclusion, the common faults of micro gear pumps are mostly related to core components such as gear pairs and bearings, as well as installation, maintenance and working conditions. In the process of using micro gear pumps, regular inspection and maintenance should be carried out, including cleaning the medium, checking the wear of components, adding lubricating oil, and tightening fasteners. When a fault occurs, it is necessary to accurately judge the fault cause according to the fault phenomenon, and adopt targeted troubleshooting methods to quickly restore the normal operation of the pump. Only in this way can the service life of the micro gear pump be prolonged, and the stable and reliable operation of the related systems be guaranteed.
