speed reducer fault diagnosis and solution

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Speed Reducer Fault Diagnosis and Solution

Introduction

Speed reducers are a vital component of mechanical systems used in various industrial production applications such as automobiles, boats, heavy equipment, and factory assembly lines. They work by interlocking gears of different specifications to decrease the acceleration from the input shaft. The acceleration is then reduced to the mechanical device through the output shaft. The main function of a reducer is to convert power and provide the right power for efficient mechanical operation.

Common Reducer Faults

1. Parts High Temperature Leaking

Most reducer manufacturers choose non-ferrous components to produce the turbine of the reducer, and the material for the production of the worm is harder steel. This leads to constant rubbing and slipping between the parts during operation, which generates a great deal of heat. Since the internal components of the reducer have different degrees of thermal expansion, the parts' primary mounting distance becomes smaller, which leads to constant wear and tear. Additionally, the lubricating oil between the parts is affected by the rise in temperature and becomes thin, resulting in oil leakage failure of the reducer.

2. Turbine Wear Failure

The materials used to produce the are generally nonferrous metals such as tin bronze alloy, and the worm is made of 45 steel, which is quenched to reach a hardness of HRC45-55. During operation, the worm's high hardness causes permanent friction with the turbine, resulting in the severe wear and tear of the turbine. The use of the turbine can result in reduced life span of the reducer.

3. Drive Little Helical Gear Wear

This failure mainly occurs in vertical reducer equipment. It is due to certain issues in the type and amount of lubricant. When the reducer is installed, a certain amount of lubricant is added to the inside. However, when the reducer is in operation, due to usage or leakage, the lubrication of the parts is lost. This leads to the lubricating oil dropping to the bottom of the reducer due to gravity, causing wear and tear to the reducer's parts.

4. Worm Bearing Damage

Moisture produced by the sudden cooling of the oil during the operation of the reducer is agglomerated. Even if the sealed package is well-protected in the course of failure of the reducer, the gear oil may be emulsified, resulting in damage, corrosion, and rust of the .

Effective Methods to Resolve Reducer Issues

1. Improve the Working Environment

Dirt and fine particles in the working environment of the reducer can enter the machine through its casing. These particles adhere to the lubricating oil, which is transmitted to all parts of the reducer as the equipment rotates. This increases the friction of the reducer parts, leading to equipment failure. Thus, it is necessary to pay attention to the reducer's working environment and add a protective cover to the reducer casing to decrease particle entry and prevent dust from entering the machine.

2. Improve the Machining Precision of the Reducer

The fundamental issue of oil leakage of the chassis is mainly caused by the problem of machining precision in the processing process of the reducer. Therefore, maintenance workers can enhance the machining accuracy of the reducer, and cut the machining precision when the reducer fails. This ensures that the casing of the casing can become tightly engaged.

3. Improve the Assembly Quality of the Reducer

The unreasonable installation phase of the reducer is one of the biggest causes of its failure. Thus, it is essential to pay attention to the installation process of the reducer to ensure its reliability. Use advanced measuring instruments for comprehensive inspection of the parts and the proportions of the reducer's parts to improve their precision. Additionally, the assembly and inspection strength of the reducer should be increased, and the performance should be tested before starting up.

4. Standards of Installation and Repair Practices

To ensure the installation or repair quality of the reducer, purchase the parts individually, and avoid directly striking the parts with a hammer or other tools. When replacing parts, pay attention to the components that match the mechanical model. In the process of assembling the result bearing, use red Dan oil and anti-adhesive agent to protect the hollow shaft and prevent the use and rust of the parts.

Promotion

Ever-Power Group offers high-quality replacement parts for speed reducers that are available at a favorable price and are customizable based on pictures or samples. Our team provides considerate service, and we welcome customers to visit the company to learn more about our products.

FAQs

1. What are speed reducers?

Speed reducers are essential mechanical systems used in various industrial production applications such as automobiles, boats, heavy equipment, and factory assembly lines. They work by interlocking gears of different specifications to decrease the acceleration from the input shaft.

2. How do I resolve the issue of parts high temperature leaking in reducers?

To resolve the issue of parts high temperature leaking in reducers, it is necessary to pay attention to the working environment of the reducer and add a protective cover to the reducer casing. Additionally, enhance the machining accuracy of the reducer and improve the assembly quality of the reducer.

3. How do I improve the assembly quality of the reducer?

To improve the assembly quality of the reducer, use advanced measuring instruments for comprehensive inspection of the parts and the proportions of the reducer's parts to improve their precision. Additionally, increase the assembly and inspection strength of the reducer, and test the performance before starting up.

4. What is the main function of a reducer?

The main function of a reducer is to convert power and provide the right power for efficient mechanical operation.

5. What does Ever-Power Group offer for speed reducer replacement parts?

Ever-Power Group offers high-quality, customizable replacement parts for speed reducers that are available at a favorable price. Our team provides considerate service, and we welcome customers to visit the company to learn more about our products.

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