Gear reducer is generally used for low speed and high torque transmission equipment. The longer the working time, the more serious the wear of the internal transmission device, and then there are various failures. Today share the gear reducer common fault prevention measures, as well as some installation and maintenance skills.

Common faults of gear reducer

1. Abnormal heating of reducer

Abnormal heating of reducer means that the bearing part or shell part of reducer has serious heating, which is beyond the normal temperature range. The common one is the bearing part.

Possible causes:Reducer overload operation, bearing wear, improper assembly of bearing, gear, shaft and other parts, too high or too low voltage, too much start and stop in a short time, poor lubrication, etc.

In rolling production, overload operation may cause frequent failure of multiple reducers, and bearing wear is the most common.

2. Abnormal vibration and sound of reducer

It means that the vibration and sound of the reducer increase obviously, which is beyond the normal allowable range, or there is abnormal noise and vibration.

Possible causes:There are many reasons for the abnormal vibration and noise of the reducer, such as: the gear and bearing are damaged, the foreign matter is stuck in the gear meshing part, the coaxiality error between the reducer and the motor is large, the gear meshing is not good, the fixing is not firm, the bolts are loose, the lubricating oil is not clean and has impurities, etc.

3.Oil leakage

The main reason is the leakage of lubricating oil at the bearing end cover position, sealing surface or shell joint surface of the reducer.

Possible causes:Poor sealing, deformation of box, damage of shell, etc; It may also be that in gear transmission, due to the heat generated by friction, the oil temperature rises, the oil becomes thinner and easy to leak.

The failure of the reducer is related to too many factors. Any problem in any link may lead to the failure of the reducer. Therefore, the daily maintenance and the quality of maintenance after the equipment failure are very important.

But at the same time, the maintenance of the reducer is very difficult, because the cause of the failure of the reducer is often in the gearbox box, and in the production and operation of the reducer box is very difficult to check. It is very important to find out the problem as soon as possible and prevent the accident from expanding.

preventive measure

1. Selection of reducer

The quality of equipment directly affects the use condition of the equipment and determines the service life of the equipment. Select the reducer of the right specification and model according to the working condition and load requirements on the site, and select the manufacturer with good quality, good reputation and corresponding technical advantages to supply the reducer, so as to ensure the quality of the reducer.

2. Installation and debugging of reducer

Improper installation of the reducer will affect the normal use of the reducer

(1) The reducer must be installed on a firm and flat base, and the anchor bolts must be firm and shockproof;

(2) The coaxiality of motor reducer working machine must be ensured;

(3) After the installation, the lubrication system must be checked to ensure that all key positions are properly lubricated and the cleanliness of the lubricating oil meets the requirements. It can be put into operation after commissioning according to regulations.
3. Maintenance of reducer

The daily maintenance of equipment is the key to prevent failure and accident expansion. The daily maintenance of reducer needs to pay attention to the following aspects:

1) Strengthen the training of equipment maintenance personnel.

Many equipment maintenance personnel do not have a theoretical basis, and they do not have a clear understanding of some common sense, which may lead to violations and recklessness. Therefore, it is necessary to strengthen the regular training for on-site maintenance personnel. At the same time, the training should be simple and easy to understand, operable, and avoid talking about pure theory without substance, so as to enhance their professional knowledge and skills.

2) Strengthen daily inspection.

According to the "five fixed" principle of lubrication work, do a good job in lubrication and maintenance of the reducer, so that each reducer has a responsible person to carry out regular inspection, and arrange experienced personnel to carry out regular spot check. Once it is found that there are some abnormal phenomena in the reducer, the work should be stopped immediately, and timely maintenance should be carried out to avoid the expansion of the accident. At the same time, after each inspection and maintenance, make a good record, so as to have a comprehensive and clear understanding of each reducer.

The main contents of the inspection are as follows:

Check whether the oil temperature and bearing temperature of the reducer are within the allowable range, and the allowable range should be adjusted according to the external temperature;

Check the reducer for abnormal vibration and noise during operation;

Check whether there is oil leakage between the upper and lower joint surface of the reducer and the bearing end cover, and deal with it in time if there is any;

Regularly check the cleanliness of lubricating oil;

When the reducer stops running, check the internal parts such as gear and shaft through the observation hole.
As bearing damage is the most common cause of reducer failure, and the bearing part is difficult to detect (it takes a lot of time to shut down and remove the bearing end cover for inspection), an observation hole can be opened on the bearing end cover of the reducer to facilitate inspection at any time. Check the external environment sanitation of the reducer to make it work in a better environment as far as possible.

3) Do a good job in the maintenance and installation of the reducer after failure.

After the reducer fails, it is necessary to observe and analyze the site in detail, find out the cause of the failure, and record the detection situation. At the same time, the damaged parts should be replaced, and the parts that need to be repaired must be repaired. The parts that can still be used in a short time should not be used reluctantly. The assembly should be carried out in strict accordance with the regulations to ensure the cleanliness of the box and adjust the gap.

In addition, the joint surface of the box and the end cover of the bearing should be applied with proper amount of sealant. Don't think the more the better. Too much sealant may cause the bearing to run out of the outer ring, wear the bearing seat hole of the box, and block the oil hole, which will affect the lubrication and cause major faults.

Correct installation and operation, regular maintenance, ensure the quality of maintenance personnel, can greatly reduce the frequency of failure, ensure the smooth progress of production.