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Common sense of reducer maintenance and emergency handling methods encountered in production

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Common sense of reducer maintenance and emergency handling methods encountered in production

1. The reducer heats up and leaks oil. In order to improve efficiency, worm gear reducers generally use non-ferrous metals as worm wheels, and worms use harder steel. Because it is a sliding friction drive, more heat will be generated during operation, which will cause differences in thermal expansion between the parts and seals of the reducer, thereby forming gaps in each mating surface, and the lubricating oil will become thinner due to the increase in temperature, which will easily cause leakage . There are four main reasons for this situation. One is the unreasonable combination of materials; the second is the poor quality of the friction surface; the third is the incorrect choice of lubricant; the fourth is the poor assembly quality and use environment. Solution: Ensure assembly quality. You can buy or make some special tools. When disassembling and installing the parts of the worm gear reducer, try to avoid hitting with other tools such as hammers; when replacing gears and worm gears, try to use original parts and replace them in pairs; when assembling the output shaft, Pay attention to tolerance matching; use anti-sticking agent or red lead oil to protect the hollow shaft to prevent wear, rust, or dirt on the mating area, which is difficult to disassemble during maintenance.

2. Worm gear wear. The worm wheel is generally made of tin bronze, and the matched worm material is hardened with 45 steel to hrc4555, or 40cr hardened hrc5055, and then ground to a roughness of ra0.8μm by a worm grinder. The reducer wears very slowly during normal operation, and some reducers can be used for more than 10 years. If the wear rate is fast, it is necessary to consider whether the selection is correct, whether it is overloaded, and the material of the worm gear, assembly quality or use environment. Solution: selection of lubricants and additives. Worm gear reducers generally use 220# gear oil. For reducers with heavy loads, frequent starts, and poor use environments, some lubricating oil additives can be used to make the gear oil still adhere to the gear surface when the reducer stops running, forming protection Membrane to prevent heavy load, low speed, high torque and direct contact between metals when starting. The additives contain seal ring regulator and anti-leakage agent to keep the seal ring soft and elastic, effectively reducing lubricating oil leakage.

3. The small drive helical gear is worn. It usually occurs on the reducer installed vertically, mainly related to the amount of lubricant added and the oil variety. When installed vertically, it is easy to cause insufficient lubricating oil. When the reducer stops running, the transmission gear oil between the motor and the reducer is lost, and the gears cannot get the proper lubrication protection. When the reducer is started, the gears are not effectively lubricated, causing mechanical wear and even damage. Solution: the choice of the installation location of the reducer. Where the location permits, try not to use vertical installation. In vertical installation, the amount of lubricating oil added is much larger than that in horizontal installation, which may cause heat generation and oil leakage of the reducer.

4. Worm bearing is damaged. When a failure occurs, even if the gearbox is well sealed, it is often found that the gear oil in the reducer is emulsified, and the bearings are rusted, corroded, and damaged. This is because the condensed water produced by the worm gear reducer is mixed with water after the gear oil temperature rises and cools after running for a period of time. Of course, it is also closely related to bearing quality and assembly process. Solution: Establish a lubrication maintenance system. The reducer can be maintained according to the principle of lubrication work \"five fixed\", so that every reducer has a responsible person to check regularly, and it is found that the temperature rise is obvious, if the temperature exceeds 40 ℃ or the oil temperature exceeds 80 ℃, the quality of the oil decreases If too much copper powder is found in the oil and abnormal noise is generated, stop using it immediately, check and repair in time, troubleshoot, and replace the lubricating oil. When refueling, pay attention to the amount of oil to ensure that the worm gear reducer is properly lubricated.

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