Gear reducers are generally used for low-speed and high torque transmission equipment. The longer the working time, the more severe the wear of its internal transmission device, leading to various malfunctions. Today, we will share preventive measures for common faults in gear reducers, as well as some tips for installation and maintenance.

Common faults of gear reducers

1. Abnormal heating of the gearbox

① Abnormal heating of the gearbox refers to severe heating of the bearing or housing parts of the gearbox, exceeding the normal temperature range. The most common type is heating of the bearing parts.

② Possible reasons: Overloaded operation of the reducer, bearing wear, improper assembly of bearings, gears, shafts and other parts, high or low voltage, excessive starting and stopping in a short period of time, poor lubrication, etc.

③ In steel rolling production, overloading operation may cause frequent failures of multiple reducers, and bearing wear is the most common.

2. Abnormal vibration and sound of the gearbox

① It refers to the significant increase in vibration and sound of the gearbox, exceeding the normal allowable range, or abnormal noise and vibration.

② Possible reasons: There are many reasons for abnormal vibration and noise in the gearbox, mainly including: damaged gears and bearings, foreign objects stuck in the gear meshing area, large coaxiality error between the gearbox and the motor, poor gear meshing during assembly, loose bolts, unclean lubricating oil with impurities, etc.

3. Oil leakage

① Mainly due to lubricating oil leakage at the position of the reducer bearing end cover, sealing surface, or housing joint surface.

② Possible reasons: poor sealing, deformation of the casing, damage to the shell, etc; It is also possible that in gear transmission, friction generates heat, leading to an increase in oil temperature, thinning of oil, and easy leakage.

③ The failure of the reducer is related to too many factors, and any problem in any link can lead to the failure of the reducer. Therefore, the quality of daily maintenance and repair after equipment failure is crucial.

④ But at the same time, maintenance of the gearbox is difficult because the factors that cause gearbox failures are often inside the gearbox housing, which is difficult to inspect during production and operation. It is very important to detect problems early and prevent accidents from escalating.

preventive measures

1. Selection of gearbox

The quality of equipment directly affects its usage status and determines its service life. Select the appropriate specifications and models of reducers based on the working conditions and load requirements on site, and choose manufacturers with good quality, good reputation, and corresponding technical advantages to ensure the quality of the reducers.

2. Installation and commissioning of gearbox

Improper installation of the gearbox can affect its normal use. When installing the gearbox, attention should be paid to:

(1) The reducer must be installed on a sturdy and flat base, and the anchor bolts must be sturdy and shock resistant;

(2) It is necessary to ensure the coaxiality between the motor, reducer, and working machine;

(3) After installation, it is necessary to check the lubrication system to ensure that all key positions are lubricated appropriately, and to ensure that the cleanliness of the lubricating oil meets the requirements. It can only be put into trial use after being tested according to regulations.

3. Maintenance and upkeep of the gearbox

The daily maintenance of equipment is the key to preventing faults and preventing accidents from escalating. The daily maintenance of reducers needs to pay attention to the following aspects:

1) Strengthen the training of equipment maintenance personnel.

Many equipment maintenance personnel lack theoretical foundations and have unclear understanding of common sense, which may lead to violations and reckless behavior. Therefore, it is necessary to strengthen regular training for on-site maintenance personnel, and the training should be simple, easy to understand, and operable. Avoid vague and theoretical discussions without substance, and enhance their professional knowledge and skills.

2) Strengthen daily inspections.

According to the "Five Determinations" principle of lubrication work, lubrication and maintenance work should be carried out for the reducer, ensuring that each reducer is regularly inspected by a responsible person. Experienced personnel should also be arranged for regular spot checks. Once any abnormal phenomena are found in the reducer, work should be stopped immediately and timely maintenance should be carried out to avoid the escalation of accidents. At the same time, after each inspection and maintenance, make records to have a comprehensive and clear understanding of each reducer.

The main contents of the inspection include:

⑴ Check whether the oil temperature of the reducer and the temperature of the bearing parts are within the allowable range, and adjust the allowable range appropriately according to the external temperature;

⑵ Check for any abnormal vibration or noise during the operation of the gearbox;

⑶ Check whether there is oil leakage on the upper and lower joint surfaces of the reducer and the position of the bearing end cover. If there is, it should be dealt with in a timely manner;

Regularly check the cleanliness of lubricating oil;

When the reducer stops running, check the condition of internal components such as gears and shafts through the observation hole.

Due to bearing damage being a common factor causing gearbox failures, and the difficulty in detecting the bearing parts (which requires disassembling the bearing end cover after stopping the machine and taking a lot of time to inspect), an observation hole can be opened on the gearbox bearing end cover for easy inspection at any time. Check the external hygiene of the gearbox to ensure it operates in a better environment as much as possible.

3) Perform maintenance and installation work on the gearbox after the malfunction.

After the gearbox malfunctions, it is necessary to conduct a detailed observation and analysis of the site, clarify the cause of the malfunction, and keep records of the inspection results. At the same time, replace the damaged parts and repair the parts that need to be repaired. Do not force to use the parts that can still be used in a short period of time. During assembly, strictly follow the regulations to ensure the cleanliness of the box and adjust the gaps.

In addition, the sealing glue should be applied appropriately to the joint surface of the box and the bearing end cover. Do not think that more is better. Excessive application may cause the bearing to run out of the outer ring, wear the bearing seat hole of the box, and block the oil hole, affecting lubrication and causing major failures.

Proper installation and operation, regular maintenance, and ensuring the quality of maintenance personnel can greatly reduce the frequency of failures and ensure smooth production.