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ABSTRACT: By analyzing the common faults and causes of reducer, this paper puts forward solutions, emphasizing the importance of installation and debugging technology, lubrication maintenance and human responsibility in reducing the faults of reducer.
Reducer is an independent component consisting of gear transmission, worm transmission and gear-worm transmission enclosed in a rigid case. It is often used as a reducer between the original part and the working machine. It matches the speed and transfers the torque between the prime mover and the worker or actuator. The purpose of using it is to reduce the speed and increase the torque. It is widely used in modern machinery.
When choosing reducer, the most suitable reducer should be selected according to the selection conditions of the working machine, technical parameters, performance and economy of the power machine, comparing the outer dimensions, transmission efficiency, carrying capacity, quality and price of different types and varieties of reducers. However, in the actual selection and use process, due to economic and technical reasons, the reducer can not be fully selected and installed in accordance with technical requirements, which greatly increases the probability of failure of the reducer. Because of its heavy load, high manufacturing accuracy, difficult maintenance and high cost, it has a great impact on the normal production of factories and enterprises. Therefore, it is one of the key points of equipment daily management to do well in the daily management of reducer, improve the maintenance technology level and maintain its good mechanical performance and normal operation. In order to reduce the occurrence of faults and solve them better and faster when they occur, the common faults and their causes in the use of reducer are analyzed as follows:
The common faults of reducer can be divided into the following categories:
Leakage oil
This fault reducer will appear after a long time operation. Sometimes the newly installed reducer will appear after a short time operation. Generally, it is easy to appear at the joint of input or output shaft and reducer, observation window and other parts.
Causes:
(1) The coaxial precision of the reducer and the drive or driven device is low, resulting in oil seal and bearing wear, thus causing oil leakage.
(2) Damage combined with gasket and O-ring.
(3) The bolts on the joint surface are loose.
(4) The quality of lubricating oil is poor and contains more impurities, which accelerates the wear of oil seals.
(5) Excessive lubricating oil and excessive stirring heat in operation result in oil leakage through oil seals.
Methods of treatment:
(1) Strengthen the training of technicians, ensure coaxiality during installation and debugging, and replace skeleton oil seals for worn oil seals.
(2) Replacement of gaskets and O-type seals.
(3) fastening bolts.
(4) Exhaust lubricants and replace high-quality lubricants and seals after cleaning with gasoline as far as possible.
(5) Refueling according to the factory's oil standard, avoid excessive.
2. Too High Temperature Rise of Reducer
Causes:
(1) The quality of lubricating oil or grease is not good.
(2) The lubrication of the rotating shaft is not good.
(3) Rotary bearing damage.
Methods of treatment:
(1) Recommend the brand of lubricating oil or grease according to the manufacturer's instructions and add notes as required.
(2) Fill the lubricating oil in accordance with the regulations to ensure the normal operation of the lubricating oil pump and smooth oil passage.
(3) replace bearings.
3. Abnormal Vibration of Retarder Running
Causes:
(1) The large clearance between the mounting shaft and the bearing or gear of the reducer causes wear and tear.
(2) When the chain is driven, the chain is too tight.
(3) The parts of the reducer are damaged.
(4) Damage of bearings at both ends of transmission shaft or excessive series of shaft clearance
(5) Loosening of the base bolt of the reducer and the connecting bolt of the reducer
(6) poor lubricating oil
(7) The gearbox of the reducer falls into other foreign bodies, the gears are damaged and foreign bodies are stuck.
Methods of treatment:
(1) Adjust and replace axles, bearings and gears.
(2) Adjust the chain tightness.
(3) Inspection and replacement of dismantling machines.
(4) adjust and update
(5) Fastening bolts to increase lubricating oil
(6) replace lubricating oil.
(7) Remove the foreign body and clean the reducer box.
4. Peeling, pitting, blocking and breaking of gear teeth
Low-speed gears have the most frequent phenomenon of block falling and broken teeth. Under the normal conditions of oil supply quality, oil quantity, oil pressure and transmission load, the output big gear of the reducer has the lowest speed, the largest bearing torque, the largest force, the largest diameter and weight of the gear, and the main points of forging, mechanical processing, heat treatment and installation of the blank. It is also the most difficult to find, if the technology, control, quality inspection and other processes are not strictly checked, it may cause problems in the use of the gear. After the gear reducer has broken teeth, it is difficult to repair, expensive and long cycle, which has a great impact on the production of the factory.
Causes:
(1) Defects or excessive harmful residual stresses may be induced by inclusions, micro-grinding cracks or local fracture caused by improper heat treatment.
(2) It may be that the material inclusion and the forging of the blank have problems.
(3) The poor quenching and carburizing process or other reasons cause the quality problems of the gears themselves.
Methods of treatment:
Choose the decelerator manufactured by the regular manufacturer, and follow up the record, contact the manufacturer for maintenance of such problems in time. In order to make the reducer run efficiently, it is necessary to have advanced technology as the guarantee. In view of specific faults, choosing reasonable solutions is the prerequisite for the safe and stable operation of the reducer. Quite a large part of the common faults of reducer belong to human factors, which can be avoided. In order to execute them well, it is necessary to do:
1. Strengthen the training of technicians, enhance the technical level, and ensure the accuracy of installation and commissioning.
2. Establish a lubrication maintenance system, select qualified lubricants, and strictly implement the oil change cycle and oil injection standards.
3. Strengthen the inspection, enhance the sense of responsibility, find problems in time and deal with them in time, and maintain them.
Do not drop foreign bodies into the box of the reducer. In the normal use process, the warehouse should purchase the spare parts of reducer according to the ratio of 5:1. At the same time, we should make a good plan for the reducer which frequently breaks down. When the reducer breaks down, it can be replaced in time to ensure the normal operation of the equipment in the shortest time. Then, the maintenance unit dismantles the reducer to observe and analyze it in detail, find out the fault situation, purchase appropriate spare parts for damageable parts such as sealing rings, etc. to retain; contact the manufacturer to identify the replacement or maintenance because of the quality problems of the product itself; according to different fault situations, according to the above methods, deal with them comparatively.
