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Analysis of common failures of reducer and troubleshooting measures

Updated:2020-10-20
Summary:Failures that may occur during the use of the reducer include: oil leakage, overheating of the beari...

Failures that may occur during the use of the reducer include: oil leakage, overheating of the bearing parts, high noise, excessive temperature of the oil sump of the reducer (above 70 degrees), abnormal noise of the reducer, drive shaft shifting, bearing cracks, gear damage And so on, now analyze its causes and preventive measures.
1. Oil leakage of reducer
Cause Analysis:
There are many ways of oil leakage, but the most common one is oil leakage at the seals of the driving and driven shaft heads, especially the most serious oil leakage at the sealing ring of the driving shaft. In addition to the above cases, there are the following 3 oil leaks.
a. Oil leakage along the box surface of the reducer;
b. Oil leaks along the sight hole cover on the reducer;
c. Oil leakage along the oil drain hole at the bottom of the reducer;
The oil leakage at the sight hole cover and the oil drain hole is mainly caused by the fixing bolts not being tightened completely or the sealing gasket is not installed.
In some reducers, when assembling the box, there are iron filings on the box surface, which makes the box surface not tight and leaks oil. In addition to the above-mentioned factors, the reason for oil leakage on the sealing surface is that the housing of the reducer is deformed after a period of use, causing the sealing surface to be uneven and not tightly fitted to cause oil leakage.
Prevention and elimination methods:
a. The sealing ring gland adopts easy disassembly structure.
b. The sealing ring adopts an open structure.
c. The oil return hole at the input shaft bearing should be appropriately enlarged.
d. The aging treatment of the reducer housing can prevent deformation of the housing and avoid oil leakage along the box surface. There are currently three aging methods, one is natural failure; the other is artificial aging; the third is vibration aging. Can be selected and processed according to actual conditions.
e. An annular oil groove is cast or machined on the joint surface of the reducer base, and there are multiple oil return holes communicating with the annular oil groove. When the reducer is working, once oil penetrates into the joint box surface, it will enter the annular oil groove, and then flow into the oil tank through the oil return hole, and the lubricating oil will not leak out of the reducer housing along the joint box surface.
f. When assembling the reducer, apply a layer of sealant (such as D05 silicone rubber sealant) on the box joint surface to effectively prevent oil leakage at the box joint surface.
g. The oil level of the reducer is too high, which not only increases the power loss of the gear agitating oil, the splash of lubricating oil increases the chance of oil leakage, but also causes the oil temperature to rise, especially in summer, the high ambient temperature will increase the oil temperature and lubricate Decrease in oil viscosity, reduce lubrication performance, increase oil fluidity and leakage, directly affect the lubrication of gears and bearings, and reduce service life. For this reason, the normal oil level must be maintained during use.
h. Install gaskets at the sight hole cover and the oil drain hole, and tighten the bolts.
l. Enlarge the oil return hole of the output shaft to prevent oil leakage from the output shaft.
j. Improve the ventilation cap and inspection hole cover. The internal pressure of the reducer is greater than the outside atmospheric pressure is one of the main reasons for oil leakage. If the pressure inside and outside the machine is balanced, the oil leakage can be prevented. Although the reducer has a vent cap, the vent hole is too small, it is easy to be blocked by dust and oil, and the inspection hole cover must be opened every time the oil is refueled. Once opened, the possibility of oil leakage will increase once, so that the original leak-proof place Leaks also occurred. The vent hole can be enlarged to equalize the pressure inside and outside.

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