What are the common faults and troubleshooting methods of JZQ200-15.75-1 reducer with soft tooth surface

ZQ200 reducer is a common involute cylindrical gear reducer. The following are its common faults and troubleshooting methods:

Gear wear

Fault phenomenon: Wear, pitting, bonding and other phenomena occur on the gear tooth surface, resulting in increased noise, reduced transmission efficiency and intensified vibration of the reducer.

Cause analysis: Poor gear material, improper heat treatment, poor lubrication, excessive load, harsh working environment, etc.

Solution: Select appropriate gear materials and heat treatment processes to ensure the strength and hardness of the gears; Strengthen lubrication management, regularly replace lubricating oil, and maintain clean oil quality; Reasonable selection to avoid overload operation of the gearbox; Improve the working environment and regularly clean the dust and debris around the gearbox. For gears with severe wear, they should be replaced in a timely manner.

Bearing damage

Fault phenomenon: Bearing heating, increased noise, and intensified vibration can cause the gearbox to malfunction in severe cases.

Cause analysis: Improper bearing selection, insufficient installation accuracy, poor lubrication, excessive load, bearing quality issues, etc.

Solution: Select the appropriate bearing model based on the load and speed of the reducer; Improve the installation accuracy of bearings and ensure that they are installed in place; Strengthen the lubrication of bearings and regularly replenish or replace lubricating grease; Avoid overloading the gearbox during operation; Choose bearing products with reliable quality. Damaged bearings should be replaced promptly.

Oil leakage

Fault phenomenon: Oil stains appear on the joint surface, shaft end, oil gauge hole and other parts of the gearbox body, and the oil level drops.

Cause analysis: Poor sealing of the box joint surface, damaged shaft seal, poor sealing of the oil gauge hole, excessive addition of lubricating oil, etc.

Solution: Apply sealant to the joint surface of the box to ensure good sealing; Replace the damaged shaft seal; Check the seal of the oil gauge hole and replace it promptly if it is damaged; Add lubricating oil according to the prescribed oil level to avoid excessive oil level.

Overheating of gearbox

Fault phenomenon: The temperature of the gearbox is too high during operation, exceeding the specified temperature rise range.

Cause analysis: excessive load, poor lubrication, poor heat dissipation conditions, poor gear meshing, etc.

Solution: Reasonably adjust the load to avoid long-term overload operation of the reducer; Check the quality and oil level of the lubricating oil, and promptly replenish or replace the lubricating oil; Clean the dust and debris on the surface of the reducer to improve the heat dissipation conditions; Check the meshing condition of the gears and adjust or repair them promptly if there are any problems.

Excessive noise

Fault phenomenon: The gearbox emits abnormal noise during operation, which affects the working environment and normal operation of the equipment.

Cause analysis: gear wear, bearing damage, poor gear meshing, unstable installation of reducer, poor lubrication, etc.

Solution: Take corresponding measures for different reasons, such as replacing worn gears and damaged bearings, adjusting the meshing clearance of gears, tightening the installation bolts of the reducer, and strengthening lubrication.