How to inspect and maintain the reducers regularly?- Shanghai SGR Heavy Industry Machinery Co., Ltd.

For industrial and mechanical companies, after purchasing the reducer, in addition to correctly installing and using the reducer, these companies also need to regularly inspect and maintain the reducer.

Reducers maintenance refers to the process of regular or irregular inspection, maintenance, repair and replacement of parts of the reducers, which aims to ensure that the reducers can operate normally, safely and efficiently, extend the service life of the equipment, and prevent the unexpected shutdown or safety accidents caused by equipment failure.

So, what is the maintenance cycle and maintenance content of the reducer? How to perform maintenance? How to perform daily maintenance on the reducer? In this article, SGR will share these experiences.

(1) What are the main tasks involved in the maintenance cycle and maintenance?

Generally speaking, when the reducers run continuously for 6 months, it needs to be shut down for maintenance. The maintenance content mainly includes:

a. External inspection: Check whether the reducers’ housing, fasteners, cooling system, lubrication system, sealing condition, etc. are intact, and whether there are cracks, deformation, oil leakage and other problems;

b. Inspection of internal components: After disassembling the reducers, carefully inspect the core components such as gears, bearings, shafts, couplings, etc. to check whether the gears are worn, pitted, broken teeth, etc., and whether the bearings are worn, rusted or fatigued.

c. Performance test: Measure vibration and noise levels, detect whether the temperature rises abnormally, and confirm the smoothness and efficiency of the reducers’ operation.

d. Lubricant analysis: Check the condition of the lubricant, such as oil quality, oil quantity, degree of contamination, etc. Replace the lubricant and clean the lubrication system if necessary.

e. Reassembly and debugging: After completing the repair or replacing parts, reassemble the reducers in accordance with the assembly technical standards, and conduct no-load and load test runs to ensure that all performance indicators meet the requirements.

Regular maintenance work to reducers mainly includes:

a. Before starting the machine, turn the main shaft to make the gear rotate slowly for one circle, and then start the machine.

b. During the operation, check whether the bearing temperature is normal, whether the reducer is vibrating, and whether the shaft seal is leaking oil. If the temperature is too high and the reducer vibrates greatly, the machine should be stopped for inspection and treatment.

c. Check that if the oil level in the gearbox is within the specified mark and the pressure is normal. Add oil regularly. The lubricating oil brand should comply with the regulations.

d. Check that the screws are not loose. If they are loose, tighten them in time.

e. Listen to the sound of the machine body for abnormal noise.

f. Always keep the machine body and operating environment clean.

(2) Inspection and repair quality standards for major components

a. Gears and gear bodies

(1) Gear teeth must be replaced when their thickness is worn to 30%.

(2) The burrs caused by the extrusion of the gear teeth should be removed and made smooth. The gear teeth must be replaced if they are cracked or broken.

(3) The joint surface between the upper cover and the housing flange should be smooth to ensure tightness after installation. Check every 100 mm with red oil.

b. Rolling bearings

1.Measure the clearance of the ball (roller). The maximum clearance allowed by wear should generally comply with industry regulations.

2. The fit between the inner diameter of the rolling bearing and the shaft, and the fit between the outer diameter and the housing should comply with regulations.

3.When there are defects on the surface of the ball or roller that cannot be eliminated, such as pitting, black spots, rust marks and stratification, it should be replaced.

4. When the clearance between the bearing housing and the bearing of an inseparable bearing exceeds the specified size, the bearing should be replaced, or the outer diameter of the bearing should be enlarged and inserted into the sleeve. The inner diameter of the sleeve should be processed according to the size required for the bearing. For the separable bearing housing, the mating surface can be appropriately filed off.

5. No gasket is allowed between the bearing and the bearing housing.

6. When removing or installing the bearing, when press-fitting, the bearing can be preheated with hot oil at 80℃~90℃, and then it is easy to remove or install. When installing, the inner hoop of the bearing must be evenly knocked with a sleeve and a cushion. It is strictly forbidden to hit the bearing directly or apply force to the balls or rollers.

c. Shaft

1. Check the auxiliary and auxiliary neck for damage, cracks and other defects. Repairs can be made with a fine file and polished with oil-soaked fine sandpaper.

2. The ovality and taper of the shaft neck should not exceed 0.05 mm.

The surface finish:

(1) Rolling bearings should not be lower than VVV8.

(2) Sliding bearings should not be lower than VVVV10.

3. The curvature of the shaft is allowed to be no more than 0.08-0.10 mm. If it exceeds the specified value, the shaft should be straightened.

(3) What are the benefits of regular maintenance?

a. Ensure reliability and safety of the mechanical equipment: timely discover and solve potential problems to prevent safety risks and production interruptions caused by sudden failures in mechanical equipment.

b. Maintain production efficiency: through the maintenance and overhaul of the reducers, the mechanical equipment can be kept running in the best condition, unplanned downtime caused by mechanical equipment failure can be reduced, and production efficiency can be improved.

c. Extend service life: regular maintenance can effectively slow down the wear rate of key components, thereby extending the overall service life of the reducers.

d. Save costs: preventive maintenance is cheaper than emergency repairs, avoiding the high cost of overhaul or replacement of new equipment due to serious failures.(Author: SGR, Angie Zhang)

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