Reasons and prevention methods for gear reducer failures

Adddate：2014/4/1　Views：1901

The most common faults in gear reducers are gear damage, followed by bearing failure, and then gear failure. This indicates the importance and significance of gear problems in reducers. In general, when repairing a gear reducer, it is necessary to shut down the machine for maintenance, which is relatively troublesome. Therefore, conducting research on maintenance and fault diagnosis of gear reducers without disassembly or shutdown can have extremely important technical and economic benefits. The transmission shaft, gears, and bearings of the gear reducer will produce vibration regardless of whether there is a fault during operation. If a malfunction occurs, the amplitude of the vibration produced will increase, and the energy distribution of the vibration signal will change. Therefore, using vibration analysis to diagnose faults in gear reducers is one of the more effective methods. Tooth surface wear, pitting, shaft bending, and tooth breakage are typical faults that can be analyzed from the vibration characteristics of gear reducers. The main reasons for gear reducer failures are:
1. Defects in the structural design of the reducer, the cycloidal pinwheel reducer has an input speed of 980 revolutions per minute and an output speed of 88 revolutions per minute.
2. There are issues with the lubricating oil model and viscosity used in the gearbox. As for lubricating oil, viscosity is its main performance indicator, which reflects the internal friction force of the oil and is an indicator of the oil's oiliness and fluidity. Without adding any functional additives, the higher the viscosity, the higher the oil film strength, and the poorer the fluidity. Random data from the gearbox shows that in the selection of lubricants, gearboxes with speeds below 300r/min and torques below 600n can be lubricated with grease, while gearboxes with speeds above this and torques greater than this can generally be lubricated with lubricating oil.
3. The lubrication method of the gearbox is not reasonable enough. The lubrication method of this cycloidal pinwheel reducer is also one aspect that causes poor lubrication. The splash lubrication method is mainly used in high-speed situations, and it is obviously not suitable for medium loads and low-speed situations. Before formal use, the reducer must be rotated flexibly by hand without any jamming phenomenon, and then run without load. The time shall not be less than 2 hours. The operation should be smooth. There should be no impact, vibration, noise, or oil leakage, and any malfunctions should be promptly resolved.
When the reducer is used for the first time, it must be replaced with new lubricating oil after 20 days of operation. In future use, the quality of the oil should be regularly checked. If impurities or aged or deteriorated oil are found, it must be replaced at any time. At the same time, the oil level should be checked regularly. If it is lower than the specified height, it should be replenished in a timely manner. In general, gearboxes that work continuously for a long time must have their oil changed every three months. For reducers that work no more than eight hours a day, the oil must be replaced every six months. When the oil temperature significantly rises to 60 degrees or exceeds 85 degrees, or abnormal noise is generated during use, the use should be stopped and the cause checked. If it is caused by tooth surface adhesion or other reasons, it must be repaired, the fault must be eliminated, and the lubricating oil must be replaced before use. If severe oil leakage or leakage is found on the joint surface during use, open the hood and apply 601 sealant. If oil leakage is found on the oil seal, please replace it with the original oil seal model.