How to improve the service life of reducer

The friends who contacted the reducer know that the service life of the reducer depends on the external load and internal wear rate. 

Excessive load on the surface and inside of the reducer may lead to tooth fracture, shaft fracture and wear of moving parts, and the wear of moving parts may cause difficulty in forming smooth oil film. Therefore, when the reducer is in the first shape and a hardened gear is used, the methods to improve its service life are as follows:

First, the components driven by the reducer must be protected from excessive external loads.

Secondly, the wear of the internal bearing or gear of the reducer shall be controlled within a reasonable range.

Third, we should try our best to ensure that the bearing interior and gear meshing surface conform to hydrodynamic smooth oil film.

1 Install the reducer correctly to avoid excessive force

The reducer device must meet the corresponding device requirements to avoid large additional force (i.e. increasing external force) due to poor alignment, insufficient matching accuracy, excessive vibration and other reasons, thus accelerating the damage of the reducer. retarder. Such faults shall be found and handled in time in the early stage or during the work, otherwise it will cause load vibration and abnormal conditions, such as accelerated wear or bearing slip ring, thus shortening the service life of the bearing. retarder.

2 Repair the driven parts and the reducer in time to avoid excessive load of the reducer.

The components driven by the reducer will bear excessive external load due to wear, fracture, breakage or damage of the bearing. Therefore, in the daily maintenance work, it is necessary to formulate and implement targeted spot check and maintenance specifications to avoid excessive external load, thus reducing the service life of the reducer. For example, the reducer itself can be monitored by five sensing, vibration monitoring, smooth oil ferrite analysis and other detection methods (such as smooth oil, vibration, temperature, noise, etc.), so as to find out the existing problems or dangers in time, Timely check, correct or replace damaged parts, ensure that the operation of the reducer itself meets the requirements of the plan, and avoid or avoid excessive internal load.

3. Ensure that the bearing and tooth surface structure conform to hydrodynamic smooth oil film.

The composition of all fluid dynamic smooth oil film is the basis for improving the service life of the reducer. How to do this:

First of all, reasonable selection of smooth oil is the key to ensure sufficient smoothness. When selecting lubricating oil, linear speed, limit load, working temperature, working environment and other factors shall be considered first, and lubricating oil shall be selected reasonably.

There is no doubt that it is unreasonable to import oil products recommended by gear reducer manufacturers, but a small amount of lubricating oil recommended by domestic gear reducer manufacturers. At the same time, it is improper to replace imported varnish with domestic varnish. This situation is very unfavorable to the service life of the reducer. In a short time (1 year), it is impossible to see the serious consequences caused by improper use without fluent oil analysis skills. Therefore, people should pay attention to the selection of smooth oil.

4. Ensure the cleanliness of the oil

When the reducer, smooth oil and external load are determined, the thickness of all hydrodynamic smooth oil film of gear and reducer is also stable. Most oil film thicknesses range from a few microns to tens of microns. Abrasive particles and external pollutants during normal operation of the reducer will damage the oil film state and accelerate the wear of relevant moving parts (this state is that under the speed of movement, high temperature and high pressure will accelerate the conversion of smooth oil. Therefore, the number of abrasive particles in the oil and the improvement of the cleanliness of the oil can greatly improve the sliding surface parts and smoothness

The service life of the oil. For example, after many tests, SKF bearing manufacturers have deeply studied the influence of load, oil viscosity, particulate pollutants and other factors on bearing life. They concluded that by eliminating 2-5 μ M solid particles, the fatigue life of rolling bearings can be extended to 10-50 times of the original life. Therefore, reducing or controlling the amount of foreign matters in the oil can not only reduce the wear of equipment, but also extend the service life of smooth oil.

The specific method is as follows: The newly added smooth oil shall be free of pollution. Avoid external pollutants (dust, water, etc.) from entering the engine oil when using the engine oil; Clean the oil tank thoroughly when changing oil; For important equipment or large and medium-sized reducer, oil filter can be installed to filter smooth oil online; For equipment requiring high cleanliness or equipment inconvenient to install oil filter, high-precision oil filter equipment can be used to filter oil regularly. Use smooth oil.

5. Avoid stable accident of reducer

The reducer will burn dry due to oil leakage, and wear will be increased due to water, dust, mud, etc., resulting in the problem of smoothness. Therefore, it is necessary to regularly check the dynamic sealing points, exhaust plugs, oil level changes and other conditions in the spot check to prevent external pollutants from entering the reducer, which may lead to poor lubrication and dry burning due to lack of oil. For reducers that use cooling water to cool the smooth oil or work in the open air steam, it is necessary to strengthen the inspection of the water inlet of the smooth oil to avoid the smooth problem caused by the water inlet.

6.Regularly monitor the quality of lubricating oil to achieve "oil change according to quality"

In use, the smooth oil will not only cause dust, water and other external pollutants to enter Hunan Province, but also lead to aging and deterioration due to the constant deceleration of internal abrasive particles, leading to the early failure of lubricating oil I}, and the improvement of cleanliness can also extend the life of Sichuan Province. Therefore, the specified oil change gauge cannot meet the needs of the design department.