Daily operation and maintenance of gearbox

Daily operation and maintenance of gearbox
During the daily operation and maintenance of the gearbox, a comprehensive inspection plan should be developed based on the actual working condition of the machine, which is beneficial for the normal and stable operation of the equipment. In daily work, staff need to pay full attention to the daily operation of the reducer, and develop a comprehensive maintenance plan based on specific situations, which is conducive to fully realizing the application value of the reducer itself.

1. Analyze the fault diagnosis methods in the daily operation of the gearbox

In the process of inspecting the working condition of the machine, it is necessary to develop a comprehensive inspection plan, which is a crucial part of preventive maintenance work and can provide reliable guarantee for the stable operation of the equipment. The staff need to promptly detect any abnormal situations that occur during the operation of the machine, and handle the problems in a timely manner based on the specific situation to prevent mechanical failures. During the operation of the gearbox, the staff should use the point inspection instrument reasonably, pay attention to measuring the temperature and vibration of the gearbox, and scientifically judge the actual operating status of the gearbox based on relevant parameters.

The inspection should be timely, accurate, and strictly follow the inspection procedures. The staff need to make complete records during the inspection work. If there are no relevant testing instruments, it is necessary to make scientific judgments on the actual operation of the equipment and understand the sealing performance of the equipment through various methods such as touch, observation, and listening, based on the experience of maintenance workers and job workers.

Pay attention to observation. Observe if there is any wear on the bearings. When there is oil leakage, it is necessary to check whether the oil seal is damaged and whether the oil plug is loose. Check if there is any blockage in the ventilation port and if the oil level is normal. Inspect by opening the cover, and after stopping the machine, open the top cover for the staff to conduct a thorough inspection. Secondly, touch. During the actual cloud like period, the gearbox is prone to malfunction and equipment shutdown due to high temperatures.

The staff needs to have a comprehensive understanding of the bearing temperature. Generally, the staff can identify abnormal temperature conditions in the gearbox through touch, which is beneficial for reducing the probability of faults. Afterwards, listen. During normal operation, there may be some low noise inside the gearbox. If there is any abnormal situation during operation, it is easy to produce irregular noise and squeaking sound.

Common faults and troubleshooting measures of reducers

For reducers, as a transmission device, in practical work, due to external working environment and internal factors, it is easy to encounter some fault problems. During the use of the gearbox, the main faults that occur include: bearing parts, oil leakage, high temperature in the gearbox oil pool, bearing breakage, gearbox abnormal noise, gear damage, etc. Analyze the actual situation and develop comprehensive preventive measures based on the causes of the malfunction.

2.1 Oil leakage

The gearbox has a serious oil leakage problem at the sealing ring of the active shaft during operation. The solution to this problem is to replace the seals, clean the assembly, and reapply the sealant. During the application process, it is important to pay attention to the correct application position and ensure even application. Secondly, there is an issue of oil leakage on the various contact surfaces of the gearbox housing. The solution to this problem is for the staff to tighten or replace the bolts in a timely manner and remove the old sealant. Then reapply the sealant. During the application process, it should be applied to the correct position, evenly applied to prevent breakpoint issues, and refueling should be done in moderation. At the same time, for the gearbox oil window, there is oil leakage at the drain hole. The solution is to check whether the oil plug is loose or damaged. If this phenomenon occurs, it should be replaced or tightened in a timely manner. Afterwards, in response to the oil leakage problem at the bottom of the gearbox, the main solution adopted by the staff was to inspect the actual damage of the gearbox and carry out reasonable treatment or repair according to the actual situation.

2.2 High temperature

During the operation of the gearbox, if there is a problem of high temperature, the specific solution is that the staff should make reasonable adjustments to each gap and adjust the amount of fuel added. On this basis, attention should be paid to reasonable control of the high temperature of the reducer, while also paying attention to online monitoring of the actual operation of the reducer.

2.3 Overheating or noise issues in the bearing area of the reducer

When the lubrication oil level of the gearbox is not added enough or the gearbox oil leakage does not meet the above height requirements, it is easy to cause noise or high temperature in the gearbox bearing area. Friction occurs in the sealing part, and prolonged use can cause the gap between the bearing and the end cap to continuously increase. The main solution to this problem is to pay attention to checking the oil level and adding lubricating oil reasonably. Secondly, tighten the bearings properly and connect them with some bolts, while conducting a comprehensive inspection of the actual safety of the seals. Afterwards, for bearings, a comprehensive inspection should be carried out, and when damage occurs, timely replacement is necessary.

2.4 Excessive vibration of the reducer and loosening of the foundation screws

When the reducer is in operation for a long time, the foot screws are prone to loosening, which directly affects the normal operation of the reducer. Gear damage, tooth breakage, and other issues may be caused by excessive vibration in the gearbox, resulting in shaft deformation and loss of balance. If the strength and hardness of the shaft are lower than the actual requirements, the gearbox will experience aging problems during long-term operation, which will cause shaft deformation. The main solution to these problems is to tighten the foot bolts properly. Secondly, inspect the cause and location of the damage to the coupling, and carry out timely maintenance work on the coupling. Thirdly, pay attention to tightening the loose screws of the motor. Fourthly, pay attention to timely replacement of bearings.