Failure System Solutions: Multi-level Engineering Strategies for Disc Spring and Wave Spring Failure

When disc springs or wave springs fail, simple replacement often only addresses the surface issue. Jiangsu Sunzo, guided by systems engineering principles, provides a comprehensive fault management framework that spans from immediate response to root cause resolution, helping you establish a long-term reliability assurance mechanism.

1、Systematic Solution to Disc Spring Failure

1. Immediate response measures (within 24 hours of failure)

Security Isolation and Assessment:

Stop the device immediately and perform a security isolation mark

Assess the impact of the fault on adjacent components

Record fault phenomena and environmental parameters

 

Temporary Disposal Plan:

Use equivalent stiffness alternatives (such as temporary replacement with helical springs of the same specification)

Implementing load reduction operation mode

Start the standby device switch program

2. Short-term remediation measures (within 17 days)

Failure component analysis:

Macroscopic Morphology Photographing and Recording of Failed Disc Spring

Measure key dimension changes (thickness, height, taper angle)

Perform hardness gradient testing

 

Exact match replacement:

Ensure the batch and heat treatment status of the new disc spring material match those of the original component.

Perform pre-load matching test (with deviation controlled within ±5%)

Implement the principle of grouped replacement (replace disc springs in the same working group simultaneously)

3. Long-term preventive measures (systemic improvements)

Design optimization plan:

Revise the design safety factor based on the actual load spectrum (recommended increase from 1.5 to 2.0)

Optimizing the Geometric Structure of Stress Concentration Area

Introduction of finite life design concept

 

Process improvement measures:

Establish Critical Process Control (CP) points

Implementation of Statistical Process Control (SPC)

Improve the material traceability system

2、Special Solution of Wave Spring Fault

1. special measures for vibration control

Identification and Control of Emission Sources:

Perform vibration spectrum analysis to identify the main excitation frequency

Increase the dynamic balance accuracy requirement (G2.5 grade) in motor design

Install vibration isolation devices (rubber vibration pads or spring isolators)

 

Structural dynamics optimization:

Adjust the natural frequency of the wave spring (avoiding ±15% of the primary excitation frequency)

Optimize the clearance between the wave peak and the installation groove (controlled within 0.05-0.1 mm)

Multi-layer Wave Spring Phase Displacement Arrangement Scheme

2. Precision Control Scheme of Pre-tensioning Force

Measurement and adjustment system:

Establishing an Axial Pre-tightening Force Online Monitoring System

Establish a pre-tightening force decay warning standard (trigger an alarm when it exceeds 20% of the initial value)

Implement a periodic calibration system for preload (once per quarter)

 

Optimization design of matching:

Determine the Optimal Pre-tension Range Based on Bearing Type

Adaptation of Variable Stiffness Wave Spring to Different Working Conditions

Design of adjustable pre-tensioning force mechanism

3、Upgrade of Maintenance Management System

1. intelligent monitoring system

Sensor configuration:

Installation of Displacement Sensor to Monitor Spring Deformation

Measurement of Actual Stress by Strain Gauge

Monitor working temperature using a temperature sensor

 

Data Analysis Platform:

Establishing a Spring Health Status Database

Development of life prediction algorithm model

Enable automatic alarm for abnormal status

2. standardized operational procedure

Maintenance standards:

Create a checklist (including 15 key indicators)

Specify the lubrication cycle and lubricant specifications

Clarify the criteria for determination

 

Personnel Training System:

Establish an operator certification system

Conduct regular skills training (every six months)

Implementation of Case Teaching and Experience Sharing

4、Three groups of technology integrated solution services

We provide end-to-end support, from troubleshooting to system optimization:

1. emergency response service

24-hour technical hotline: provides immediate technical guidance

Emergency spare parts supply: Common specifications available within 72 hours

On-site support team: Engineers will arrive within 48 hours

2. technical improvement service

Design review: Systematic review of existing designs

Process Optimization: Providing Manufacturing Process Improvement Solutions

Test Verification: Provides comprehensive performance testing services

3. advisory services to management

Design of Maintenance System: Customized Maintenance Management System

Personnel training: provide standardized training courses

Sustained improvement: establish a mechanism for sustained improvement

5、Implementation Effectiveness Evaluation System

1. short term effect indicator

Fault resolution time reduced by over 30%

The spare parts matching accuracy reaches 99%

Reduce the failure rate by 50%

2. long term effect indicator

MTBF increased by 40%

Maintenance costs reduced by 25%

Device availability increased by 15%

A systematic solution not only resolves immediate issues but also establishes a long-term preventive mechanism. We employ professional engineering expertise to build a robust reliability assurance system for your equipment.