Failure of gear reducer caused by lubrication and countermeasures

February 20, 2024

Failure of gear reducer caused by lubrication and countermeasures

Gear reducer lubrication is an important part of the maintenance of the gear reducer, when we choose to use lubricating oil in the gear reducer, we need to know which lubricating oil is appropriate when the gear reducer is used.

01 gear reducer lubricating oil selection

1, gear reducer lubricating oil, should be based on the gear reducer operating environment, load size, movement characteristics and friction form to choose the appropriate type of lubricating oil, high-speed motion gear should choose low viscosity, good mobility Gear Oil, low speed motion gear should choose good anti-wear lubricating oil, low temperature running gear should choose low condensing gear oil.

2, gear reducer lubrication is an important reducer maintenance ring hundred, low speed closed gear transmission, usually employ periodic lubrication, the lubricant used for lubricating oil or grease.

3, for the low speed heavy load of large reducer, should be as much as possible to choose the viscosity of the extreme pressure heavy load gear oil, because it has better extreme pressure wear resistance, thermal oxidation stability, corrosion and rust resistance and excellent anti-emulsification performance than the medium load gear oil, so that it is easy to form a chemical film on the meshing surface of the gear, thereby protecting the tooth surface. Minimize gear wear.

4, do not change the original lubrication scheme of the gear reducer, such as the original oil lubrication, and then changed to grease lubrication, lubrication is not in place or the heat can not be dissipated, resulting in insufficient thermal power of the reducer, it is easy to break.

02 The reducer is faulty due to lubrication

(1) Poor lubrication will cause noise and vibration of the metal, causing environmental pollution

After the reducer starts, it emits a continuous and large harsh sound, which may be foreign matter stuck, gear wear serious or bearing damage; Sometimes, the reducer has a large jitter, which may be due to bearing, gear wear or poor transmission configuration. In the above cases, it will cause a certain degree of environmental pollution, making the production site there are safety risks, affecting the normal operation of the reducer.

(2) The oil temperature is too high, and the reducer parts are damaged

Because the reducer is overloaded or the amount of lubricating oil is insufficient during the working process, the oil temperature in the body will rise rapidly, so that some parts in the body are damaged; Some parts due to thermal deformation, reduce the precision of the reducer; Some parts due to high temperature caused by the material strength decline, causing parts damage, resulting in serious power loss of the reducer, malfunction and other equipment problems. In this case, the transmission parts may be stuck, and problems such as uneven mechanical operation may occur.

(3) Oil leakage of the box, causing environmental pollution

The parts with oil in the reducer have oil leakage in the box because the screws are loose or the sealing ring is damaged during operation. Sometimes because the oil level is too high or foam is produced, it will also cause oil leakage at the ventilation plug and pollute the environment.

(4) The lubrication effect of the gear pair is not good, and the tooth surface wear and other problems occur

The reducer operates in a harsh environment, and it is difficult to form a stable and good oil film between the meshing surfaces, so that problems such as pitting and wear occur on the surface, resulting in tooth surface failure and affecting the normal operation of the reducer.

03 Reducer lubrication fault prevention and solution

(1) Reasonable selection of lubricating oil

The lubricating oil should be selected scientifically and reasonably according to the working load, friction form and operating environment of the reducer. Because different types of lubricating oil, its lubrication performance is different. The details are as follows:

① For the high-speed reducer gear, the gear oil should have low viscosity and good fluidity.

② For gears with low speed movement, which are often heavy-duty gears, it is necessary to choose lubricating oil with good wear resistance when considering gear impact.

③ For the reducer running at low temperature, in order to ensure the effective operation of the gear, low condensing gear oil should be selected, so as to ensure the smooth flow of lubricating oil. And the gear oil freezing point should be lower than the working temperature of about 5℃. At the same time, pay special attention to the viscosity of the lubricating oil, the viscosity is too low, can not form a good oil film, easy to cause the friction pair to be burned.

(2) The correct use of lubricating oil

First of all, before adding lubricating oil, be sure to ensure that the oiler is clean and strictly avoid impurities in the tank. Then, the oil configuration of the lubricating oil should be appropriate. When operating, you can check the filling of lubricating oil according to the relevant instructions to ensure the appropriate amount of oil. Finally, the lubricating oil should be detected at irregular intervals, and the abnormal indicators in the oil measurement should be identified in time to take effective measures to prevent the oil from being further polluted. Of course, the lubricating oil needs to be replaced if necessary.

(3) Ensure that the lubricating oil is in a stable and good environment

The root cause of the problem of the reducer equipment is often the contamination of the lubricating oil system, so it is necessary to ensure that the lubricating oil is in a stable and good environment, especially to avoid problems such as water leakage and oil leakage. At the same time, the lubricating oil is susceptible to pollution from the external environment, so the lubricating oil system needs to be sealed for protection, and is tested from time to time, such as detecting the sealing friction surface to avoid small deformation or damage affecting the stability of the oil film, so as to avoid the oil leakage problem of the reducer. Therefore, check the lubricating oil system irregularly and clean the filter device in the system to ensure the good performance of the system. In addition, the lubricating oil system needs to be maintained, especially the replacement of components, troubleshooting, etc., which are the key to the normal operation of the system.

(4) Ensure that the lubricating oil is in a stable and good environment

The root cause of the problem of the reducer equipment is often the contamination of the lubricating oil system, so it is necessary to ensure that the lubricating oil is in a stable and good environment, especially to avoid problems such as water leakage and oil leakage. At the same time, the lubricating oil is susceptible to pollution from the external environment, so the lubricating oil system needs to be sealed for protection, and is tested from time to time, such as detecting the sealing friction surface to avoid small deformation or damage affecting the stability of the oil film, so as to avoid the oil leakage problem of the reducer. Therefore, check the lubricating oil system irregularly and clean the filter device in the system to ensure the good performance of the system. In addition, the lubricating oil system needs to be maintained, especially the replacement of components, troubleshooting, etc., which are the key to the normal operation of the system.

(5) Do a good job of early fault diagnosis

In daily work, it is necessary to effectively prevent the failure of lubricating oil, carry out early fault diagnosis in depth, and ensure that the reducer has a good operating environment. At the same time, timely troubleshooting, strengthen the maintenance of related equipment, reduce the wear and tear of parts, in order to improve the utilization rate of reducer equipment. Some of the faults of the reducer generally occur before the abnormal state, so it is necessary to have a comprehensive understanding of the operating state of the relevant equipment (such as noise, vibration, temperature, etc.), and compare with the parameters of the fault detection, so that the problem can be found more effectively and in a timely manner.

The reducer is mainly composed of transmission shaft, bearing, gear pair and other parts, and its occurrence is mostly lubricating oil failure. Lubricating oil failure often leads to gear wear, equipment malfunction, environmental pollution and other problems. Therefore, in actual work, it is necessary to reasonably select lubricating oil, correctly use lubricating oil, and do an early fault diagnosis work to prevent problems before they occur and ensure that the reducer works normally.

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