What are the key inspection points for daily maintenance of non-standard reducers

1. Running status monitoring (listening, touching, measuring)

Abnormal noise and vibration: Listen to the sound of the gearbox running. If there is high-frequency whistling, dull impact, or periodic abnormal noise, it is usually a signal of gear damage, bearing damage, or improper assembly; Simultaneously feel the vibration of the box with your hands or a vibration meter. Increased vibration often indicates the presence of imbalance, misalignment, or internal damage.

Temperature inspection: closely monitor the temperature changes of the gearbox and motor. Under normal circumstances, the shell temperature should not exceed 85 ℃ (temperature rise of 45 ℃), and the oil temperature should not exceed 80 ℃. Currently in the scorching heat of August, the high temperature environment can accelerate the oxidation of lubricating oil. It is recommended to use an infrared thermometer to accurately measure key parts daily. If the temperature rises abnormally, the machine should be stopped immediately for troubleshooting.

2. Lubrication and sealing system inspection

Oil level and quality: After stopping the machine or waiting for the oil to stabilize, check the oil level gauge/oil level mirror to confirm whether the oil level is between the specified upper and lower limits (or 2/3 of the window). Low oil level can lead to insufficient lubrication, while high oil level can easily cause heating and oil leakage. At the same time, observe whether the oil has turned black, emulsified (milky white), or contains metal debris. If the oil quality deteriorates, it should be replaced immediately.

Leakage and sealing components: Carefully inspect the shaft seal, box joint surface, bearing end cover, and oil drain plug for any oil leakage or dripping at the sealing points. Seals are prone to aging under high temperatures in summer, and if oil leakage is found, the cause should be promptly identified and repaired.

Respirator status: Observe whether the breathable plug/respirator is unobstructed. Blockage can cause abnormal pressure inside the box, leading to oil leakage or inhalation of external pollutants.

3. Fasteners and visual inspection

Bolt tightening: Regularly (such as monthly) use a wrench to check and tighten the box connection bolts, bearing end cap bolts, and foundation bolts in diagonal order. Under high temperature and vibration conditions, bolts are prone to loosening, which is also one of the main causes of early damage to the gearbox.

Cleaning and heat dissipation: Keep the gearbox and its surrounding environment clean, and promptly remove surface dust and oil stains. Especially in summer, it is necessary to ensure good ventilation conditions to avoid dust accumulation affecting heat dissipation and even causing potential short circuits in power lines.

4. Load and Electrical System

Load monitoring: Ensure that the gearbox operates within the rated load range to avoid prolonged overload. It can be indirectly judged by observing the current and voltage readings of the motor. If it exceeds the rated value, it should be adjusted in a timely manner.

Electrical inspection: Confirm that the motor wiring is correct, the grounding is good, the insulation resistance meets the requirements, and the setting values of protective devices such as thermal relays are appropriate.

Establishing a comprehensive daily inspection system, with detailed records of the data and problems discovered during each inspection, can effectively achieve preventive maintenance and avoid equipment running with problems causing greater economic losses.