Gear reducers are generally used in low-speed, high-torque transmission equipment. The longer they operate, the more severe the wear on their internal transmission components, leading to various malfunctions. Today, we'll share preventative measures for common gear reducer failures, as well as some installation and maintenance tips.
Common faults of gear reducers
1. Abnormal overheating of the speed reducer
Abnormal overheating of a speed reducer refers to severe overheating of the bearings or housing, exceeding the normal temperature range. Overheating of the bearings is the most common cause.
Possible causes: Overloading of the speed reducer, bearing wear, improper assembly of bearings, gears, shafts and other parts, excessively high or low voltage, too many starts and stops in a short period of time, poor lubrication, etc.
In steel rolling production, overload operation may cause multiple speed reducers to malfunction frequently, with bearing wear being the most common cause.
2. Abnormal vibration and noise from the speed reducer
This refers to a significant increase in the vibration and noise of the speed reducer, exceeding the normal allowable range, or abnormal noise and vibration.
Possible causes: There are many reasons why a speed reducer may produce abnormal vibration and noise, including: damaged gears and bearings, foreign objects stuck in the gear meshing parts, large coaxiality error between the speed reducer and the motor, poor gear meshing during assembly, loose fixing, loose bolts, and unclean lubricating oil containing impurities.
3. Oil leak
The main issue is lubricating oil leakage at the bearing end cover, sealing surface, or housing mating surface of the gearbox.
Possible causes: poor sealing, deformation of the housing, damage to the shell, etc.; it may also be that in the gear transmission, friction generates heat, causing the oil temperature to rise and the oil to become thinner, making it easy to leak.
Gearbox failures are related to many factors, and problems in any link can lead to gearbox failures. Therefore, routine maintenance and the quality of repairs after equipment failure are of paramount importance.
However, maintaining a speed reducer is difficult because the factors causing speed reducer failures are often inside the speed reducer housing, which is difficult to inspect during production operation. Therefore, early detection of problems and prevention of escalation of accidents are crucial.
Preventive measures
1. Selection of speed reducer
The quality of equipment directly affects its performance and determines its lifespan. Selecting the appropriate specifications and model of speed reducer based on on-site working conditions and load requirements, and choosing a reputable manufacturer with high-quality products and corresponding technical advantages, will ensure the quality of the speed reducer.
2. Installation and commissioning of the speed reducer
Improper installation of a speed reducer can affect its normal operation. The following precautions should be taken when installing a speed reducer:
(1) The speed reducer must be installed on a solid and flat base, and the anchor bolts must be strong and shockproof;
(2) The coaxiality between the motor, reducer, and working machine must be guaranteed;
(3) After installation, the lubrication system must be checked to ensure that all critical parts are adequately lubricated and that the cleanliness of the lubricating oil meets the requirements. It can only be put into trial operation after being tested according to regulations.
3. Maintenance and upkeep of the speed reducer
Routine maintenance of equipment is crucial for preventing malfunctions and escalating accidents. The following aspects should be considered during the routine maintenance of a speed reducer:
1) Strengthen the training of equipment maintenance personnel.
Many equipment maintenance personnel lack theoretical foundation and have a poor understanding of some common sense, which may lead to violations and reckless actions. Therefore, it is necessary to strengthen regular training for on-site maintenance personnel. At the same time, the training should be simple, easy to understand, and practical, avoiding vague discussions that are purely theoretical without substance, in order to enhance their professional knowledge and skills.
2) Strengthen daily inspections.
In accordance with the "five fixed" principles of lubrication work, proper lubrication and maintenance of speed reducers should be carried out. Each speed reducer should be assigned a responsible person for regular inspections, and experienced personnel should conduct regular spot checks. If any abnormal phenomena are found in the speed reducer, operation should be stopped immediately, and timely repairs should be carried out to prevent the escalation of accidents. Furthermore, records should be kept after each inspection and repair to ensure a comprehensive and clear understanding of each speed reducer.
The main contents of the inspection include:
Check whether the reducer oil temperature and bearing temperature are within the allowable range. The allowable range should be adjusted appropriately according to the ambient temperature.
Check the speed reducer for any abnormal vibrations or noises during operation;
Check the upper and lower mating surfaces of the reducer and the bearing end cover for any oil leakage. If any is found, deal with it promptly.
Regularly check the cleanliness of the lubricating oil;
When the speed reducer stops running, inspect the internal components such as gears and shafts through the inspection hole.
Since bearing damage is the most common cause of gearbox failure, and the bearing area is difficult to inspect (it requires stopping the machine and removing the bearing end cover for inspection, which takes a lot of time), an inspection hole can be made on the gearbox bearing end cover for easy inspection at any time. Check the cleanliness of the external environment of the gearbox to ensure it operates in the best possible condition.
3) Perform proper repair and installation of the speed reducer after a malfunction.
After a speed reducer malfunctions, a detailed on-site inspection and analysis should be conducted to determine the cause of the failure, and the inspection results should be recorded. Damaged parts should be replaced, and any components requiring repair must be repaired. Do not force the use of parts that are only temporarily usable. Assembly should be performed strictly according to regulations, ensuring the inside of the gearbox is clean and that clearances are properly adjusted.
In addition, the amount of sealant applied to the mating surfaces of the housing and bearing end caps should be appropriate. Do not think that more is better. Too much sealant may cause the bearing to run off its outer ring, wear the bearing housing bore, or clog the oil holes, 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 malfunctions and ensure smooth production.
