Common faults and troubleshooting methods of speed reducer

Common faults and troubleshooting methods of speed reducer

 

Abstract: By analyzing the common faults and causes of the reducer, we emphasize the importance of installation and commissioning technology, lubrication and human responsibility in reducing the reducer fault.

The reducer is an independent component composed of gear transmission, gear transmission and gear-worm transmission enclosed in the rigid housing. It is commonly used as a deceleration transmission device between the actuator and the working machine.It acts as a matching speed and transfer torque between the original motor and the working machine or actuator, with the purpose of being used to reduce the speed and increase the torque.It is extremely widely used in modern machinery.

When choosing the reducer, according to the work machine selection conditions, technical parameters, power machine performance, economy and other factors, etc., compare the outer profile size, transmission efficiency, carrying capacity, quality, price, etc., and choose the most suitable reducer.However, in the actual selection and use process, due to economic and technical reasons, the reducer failed to fully choose and install according to the technical requirements, which makes the probability of reducer failure greatly improved.Due to its heavy load, high manufacturing accuracy, high maintenance difficulty and high cost, it has a great impact in the normal production of factories and enterprises.Therefore, it is one of the key points of the daily management of the equipment to improve the reducer daily management, improve the maintenance technical level, and maintain its good mechanical performance and normal operation.In order to reduce the occurrence of faults and the better and faster solution of faults, now for the common faults and causes of the reducer, the exclusion method is analyzed as follows:

Common faults of speed reducer can be divided into the following categories:

First, leakage oil

This fault reducer will occur after a long time of operation, sometimes the newly installed reducer will not run for a long time, generally easy to appear in the input or output shaft and reducer connection, observation window and other parts.

IMG_257The reducer is leaking oil

Causes:

(1) The coaxial accuracy of the reducer and the drive or drive device is low, causing oil seal and bearing wear, thus forming oil leakage.

(2) Damwith pad and O seal.

(3) Loose the bolts on the binding surface.

(4) lubricating oil is of poor quality, contains more impurities, and can accelerate the oil seal wear.

(5) lubricating oil, too high mixing heat in operation, causing oil leakage through oil seal.

Processing method:

(1) shall strengthen the training of technical personnel, ensure the coaxial degree during installation and commissioning, and replace the frame oil seal for the wear oil seal.

(2) Replace the sealing pad and the O-type seal.

(3) Fastening the bolts.

(4) Remove lubricating oil and replace high quality lubricating oil and oil seal as much as possible.

(5) refueling according to the factory oil standard provisions, avoid too much.

Two, The reducer temperature rise is too high

Causes:

The (1) lubricant or grease is of poor quality.

The (2) rotating shaft has poor lubrication.

The (3) rotary shaft bearing is damaged.

IMG_258The oil temperature of the reducer is high

Processing method:

(1) recommends lubricating oil or grease plate number according to manufacturer instructions and fill as required.

(2) Fill lubricating oil according to regulations to ensure normal operation of lubricating oil pump and smooth oil road.

(3) Replace the bearings.

III. Operation of abnormal sound and vibration of the reducer

Causes:

The (1) reducer has a large gap between the mounting shaft and bearing or gear and gear causing wear.

(2) Chain transmission, the chain is too tight.

(3) Damage to the speed reducer components.

(4) bearing at both ends of transmission shaft is damaged or shaft gap is large string

Loose anchor bolts of (5) reducer and loose reducer connection bolts

(6) has a bad lubricating oil

(7) reducer box falls into other foreign bodies, gear damage, foreign body stuck

Processing method:

(1) Adjust and replace the axafts, bearings and gears.

(2) adjusts the chain tightness.

(3) disassembly inspection and replacement.

(4) adjustment update

(5) fastening bolts to increase lubricating oil

(6) Replace the lubricating oil

(7) removes the foreign body and cleans the deceleration box.

Four, wheel teeth peeling, dot corrosion, block loss and broken teeth

Low speed gear, block, tooth phenomenon is the most frequent, in the oil quality, oil quantity, oil pressure, transmission load, the reducer output large gear speed, the largest torque, the biggest force, gear diameter and single weight, blank forging, machining and heat treatment, installation requirements, if the most difficult in the technology, control, quality inspection and other process is not strict, may cause the gear in use.After the reducer occurs tooth break, the repair is difficult, high cost and long cycle, which has a great impact on the production of the factory.

IMG_259Reducreducer teeth pastry

Causes:

(1) defects induced by, or excessive harmful residual stress, may be local breaks caused by inclusions, microabrasive cracks, or inappropriate heat treatment

(2) may be material mixed, blank forging problems;

(3) Poor quenching and carbonization process, or other reasons cause quality problems of the gear itself.

Processing method:

Select the reducer produced by regular manufacturer, track and contact the manufacturer for such problems and timely maintenance.In order to make the efficient operation of the reducer, advanced technology must be used as the guarantee. For specific faults, choosing reasonable solutions is the premise of the safe and stable operation of the reducer.A considerable part of the common reducer faults are human factors, which can be avoided, and to implement it well, it must be done:

1. strengthens the training of technical personnel, enhance technical level and ensure the accuracy during installation and commissioning.

2. shall establish a lubrication maintenance system, select qualified lubricating oil, and strictly implement the oil change cycle and oil injection standards, not exceeding it.

3. strengthen inspection, enhance the sense of responsibility, timely find problems in time, in maintenance

Avoid dropping foreign objects into the box.In the normal use process, the warehouse should purchase the reducer spare parts in the ratio of 5:1, and make good plans for the frequent fault reducer. When the reducer fails, it can be replaced in time to ensure that the equipment is restored to normal operation in the shortest time.Disassemble the reducer in detail in the maintenance unit, find out the fault situation, purchase the damaged parts such as seal ring; contact the manufacturer to identify the replacement or repair, according to the above method