Working principle: Gear reducers use gear transmission at various stages to achieve speed reduction. A reducer is composed of gear pairs at various stages. For example, using a small gear to drive a large gear can achieve a certain speed reduction. By using a multi-stage structure, the rotational speed can be greatly reduced.
Overview: Gear reducers are generally used in low-speed, high-torque transmission equipment. Even ordinary reducers for electric motors use several pairs of gears operating on the same principle to achieve the desired speed reduction. The ratio of the number of teeth on the large and small gears is the transmission ratio. With the continuous development of the reducer industry, more and more companies are using gear reducers.
Gear reducer
1. The R-series coaxial helical gear reducer is manufactured in accordance with international technical requirements and has a high level of technological content.
2. Space-saving, reliable and durable, with high overload capacity and a power output of up to 132KW.
3. Low energy consumption, superior performance, and reducer efficiency of over 95%.
4. Low vibration, low noise, and high energy efficiency.
5. Made of high-quality forged steel, with a rigid cast iron housing, and gear surfaces treated with high-frequency heat treatment.
6. Through precision machining, ensuring shaft parallelism and positioning bearing requirements, the reducer of the helical gear transmission assembly is equipped with various types of motors, forming a mechatronic system that fully guarantees the product's quality characteristics.
Troubleshooting:
During long-term operation, speed reducers often experience failures such as wear and leakage. The most common types are:
1. Wear of the gearbox bearing housing, including wear of the housing bearing box, the inner bore bearing housing of the housing, and the gearbox bearing housing.
2. Wear on the gear shaft diameter of the reducer, mainly at the shaft end and keyway.
3. Wear on the bearing seat of the reducer drive shaft.
4. Leakage at the gearbox mating surface.
Traditional solutions for wear and tear include welding or electroplating followed by machining. However, both methods have drawbacks: the thermal stress from welding cannot be completely eliminated, potentially damaging the material and causing bending or breakage; electroplating is limited by coating thickness and prone to peeling. Furthermore, both methods involve metal-on-metal repair, failing to address the inherent "hard-on-hard" contact, leading to further wear under combined forces. Large bearing manufacturers often cannot resolve these issues on-site and rely on outsourcing. Modern Western countries frequently utilize polymer composite materials for repair, leveraging their superior adhesion, compressive strength, and other comprehensive properties. Polymer repair eliminates the need for disassembly and machining, avoids the thermal stress of welding, and has no limitations on repair thickness. Its inherent resilience, absent in metal materials, absorbs impacts and vibrations, preventing further wear and significantly extending the lifespan of equipment components. This saves companies considerable downtime and generates substantial economic value.
Traditional methods for addressing leakage issues require disassembling and opening the gearbox to replace gaskets or apply sealant. This is not only time-consuming and labor-intensive but also difficult to guarantee a proper seal, leading to recurring leaks during operation. High-polymer materials, on the other hand, can effectively address leakage on-site. Their superior adhesion, oil resistance, and 350% elongation overcome the effects of gearbox vibration, providing a significant solution for gearbox leakage problems for businesses.
Maintenance and upkeep:
Use, maintenance and precautions for gear reducers
1. The reducer uses 460# medium-load industrial gear oil, and the working environment temperature is 0~40℃.
2. After the first 100 hours of use, the inner cavity should be cleaned and the gear oil replaced. Thereafter, the oil should be changed every 2000 hours.
3. When disassembling and assembling the speed reducer, hammering should be avoided as much as possible to prevent damage to normal machine parts.
4. If oil leakage is found at the shaft extension or connection during use, the oil seal and other sealing components should be replaced in time.
