Loom reducer wears out too quickly? Avoid these 5 common usage mistakes

1、 Error 1: Directly pulling full speed when starting up, the gearbox "bears" the impact load hard

When the loom is started, if it is directly turned to the highest speed, the internal gears and bearings of the reducer will instantly bear a huge impact load. Especially for old-fashioned weaving machines, the transmission system has a high inertia, and this "violent start" can cause micro cracks on the gear tooth surface, which can eventually lead to pitting, peeling, and even tooth breakage.

Correct practice: Before starting up, jog the machine 1-2 times to confirm that there is no jamming or abnormal noise. Then, run it at low speed without load for 3-5 minutes, and gradually increase the speed to the working speed. The same applies when shutting down, slow down the speed first and then turn off the power. It is strictly prohibited to stop immediately.

2、 Error 2: Lubricating oil is added without checking the quality and level of the oil

Many operators think that 'adding oil will make everything fine', but in reality, there are many flying flowers and large amounts of dust in the weaving machine room, and the lubricating oil is easily contaminated. After metal debris is mixed into the oil, it becomes "grinding paste", accelerating the wear of gears and bearings. In addition, excessive oil volume can cause the box to heat up and expand, and the oil seal to be damaged and leak oil; If the oil level is too low, direct dry friction can have more serious consequences.

Correct practice: Check whether the oil level is between 1/2 and 2/3 of the window in each shift; The new gearbox must have its oil changed and any metal shavings generated during the break in period removed after approximately 300 hours of operation; Afterwards, it should be replaced every 2000-4000 hours according to the working conditions, and the cycle should be shortened in high temperature and high dust environments. It is best to drain the oil when the oil temperature is between 40-60 ℃, and then add new oil after draining the old oil.

3、 Error 3: "Violent knocking" during installation, making it difficult to detect internal damage to bearings and oil seals

When replacing couplings and pulleys, some maintenance technicians are accustomed to using hammers to directly hit the output shaft. With this hammer, the internal bearing raceway may have been dented and the oil seal lip may have been knocked over, which was not visible at the time, but oil leakage and abnormal noise would occur within a few days of running.

Correct method: When installing the coupling or pulley, use a copper rod to cushion it and strike it, or use a screw to push it in. The coaxiality deviation between the input shaft and the motor shaft should be controlled within 0.1mm, and it is best to calibrate with a dial gauge or laser alignment instrument. The anchor bolts should be tightened diagonally and evenly to avoid deformation of the box.

4、 Error 4: Overloaded 'hard support', weaving machine continues to run 'with illness'

During the weaving process, some operators encounter problems such as yarn jamming and warp breakage. In order to meet production demands, they forcefully operate without stopping the machine for inspection, and even remove protective covers to continue production. The gearbox will operate beyond the rated load for a long time, and the gear contact stress will exceed the standard. The tooth surface will quickly peel off, and the bearing raceway will also undergo plastic deformation.

Correct approach: In case of any abnormalities such as wire breakage, jamming, abnormal noise, or severe vibration, immediately press the emergency stop button, stop the machine and cut off the power before handling. It is strictly prohibited to operate at excessive speed or load, and it is strictly prohibited to remove protective covers for production with defects.