In-depth explanation of the causes and maintenance methods of reducer failure

Whether it is a planetary gear reducer or a worm gear reducer, it may fail during long-term use. Reducer failure refers to various problems that occur during the use of the reducer, which may cause the reducer to fail to work properly or deteriorate in performance. If the reducer fails to work, it is generally caused by the failure of some parts that make up the reducer.

So, what are the common reducer failures and maintenance methods?

1. Oil leakage fault

Oil leakage is one of the most common speed reducer failures. Speed ​​reducers require lubricating oil to reduce friction between gears and other moving parts and to help dissipate heat during operation. During operation, lubricating oil may leak from the inside of the speed reducer to the outside.

The main causes of oil leakage are:

(1) Improper assembly. The centering accuracy of the main shaft and the transmission mechanism is not high during the assembly of the main shaft, causing wear of the oil seal and bearing, resulting in leakage;

(2) Due to damage to the O-ring and the meshing surface;

(3) At the end of the output shaft of the speed reducer, the oil seal is damaged, or the outer circumference of the fixed ring is severely damaged;

(4) The screws on the connection surface are loose;

(5) The engine oil contains a large amount of impurities, which will accelerate the aging of the engine oil;

(6) The amount of lubricating oil is too large, so a high stirring temperature will be generated during operation, and finally the engine oil will leak from the sealing part.

The maintenance method includes:

(1) calibrate the joints several times to ensure correct positioning and update the frame rubber seal;

(2) adjust according to specific needs;

(3) replace the new oil seal, or remove the original fixing ring or even replace it;

(4) make good connections between screws and spring gaskets;

(5) completely remove the old oil, clean the equipment, and replace the engine oil and oil;

(6) add appropriate oil according to the oil level specified by the oil gauge, and adjust the oil reasonably, and there must be no excessive oil.

2.Reducer overheating

Gearbox overheating refers to the overheating phenomenon that occurs when the gearbox is overloaded for a long time, has insufficient lubrication, poor heat dissipation, improper assembly, etc. Gearbox overheating will not only accelerate the aging of the lubricant, but may also cause damage to parts.

Solutions include:

(1) Ensure that the gearbox operates within the maximum load limit specified by the manufacturer to avoid overloading;

(2) Regularly check the status of the lubricant, including oil level, color and viscosity, and add or replace the lubricant as needed;

(3) Provide good ventilation conditions for the gearbox to ensure the normal operation of the cooling system;

(4) During the installation of the gearbox, strictly follow the manufacturer’s instruction manual for correct installation and commissioning to ensure that all components are in the best condition.

3. The temperature of the lubricating oil rises too high

The temperature of the lubricating oil rises too high, which may be because the characteristics of the lubricating grease do not meet the requirements, or the support of the reducer rotating arm is not sufficiently lubricated, resulting in a sharp rise in local temperature. High temperature will accelerate the aging process of the lubricating oil, change its viscosity, and may even cause oxidation and deterioration, forming sediments and colloid substances, further deteriorating the lubrication effect.

Solution:

(1) Purchase lubricating fluid according to the instructions of the reducer manufacturer, and select the appropriate lubricating oil according to the product model to ensure that the amount added is sufficient;

(2) Add oil according to the specified oil level to ensure the operation of the lubricating oil pump and the smooth flow of the oil channel.

4. Abnormal sound of the reducer

The reducer makes a sound different from that in normal working state during operation, which is usually an obvious fault signal.

The main reasons for abnormal sound of the reducer include: the centering error during installation makes it impossible for the gears to achieve smooth contact during meshing and rotation, thus generating abnormal sound; when the reducer is used for a long time, some parts inside the reducer (such as gears, bearings, etc.) may be damaged due to long-term use or improper operation, resulting in clicks, buzzing or other unusual sounds.

Maintenance suggestions:

(1) Stop the machine and carefully check whether each connection point is correctly aligned, recalibrate the equipment, and accurately adjust the coupler according to the manufacturer’s instruction manual to effectively solve the noise problem caused by misalignment;

(2) When it is suspected that there is damage to a component, thoroughly disassemble and inspect the equipment to determine which parts need to be repaired or replaced, and repair and replace the components in a timely manner.