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        Common Problem

        Welcome!In order to allow you to better experience the product, our products have been through thousands of reliability tests before finally reaching your hands.I hope the following problems can be helpful to you.

        01

        There are usually several reasons for oil leakage of reducer

        1, reducer, both inside and outside differential pressure: reducer operation process, movement vice friction heat and influenced by environmental temperature, the temperature rise of the gearbox, if there is no breather hole or blockage in a breather hole, is increasing pressure on machine, machine the higher the temperature, pressure difference with the outside world, the greater the oil under the action of pressure difference, the leakage from the gap.
        2. The structural design of the reducer is unreasonable
        1) Check that the hole cover plate is too thin, and it is easy to deform after tightening the bolt, which makes the joint surface uneven and leaks oil from the contact gap;
        2) in the manufacturing process of the deceleration mechanism, the casting is not annealed or aged, and the internal stress is not eliminated, which will inevitably lead to deformation, clearance, and leakage;
        3) there is no oil return groove on the box body, and the lubricating oil accumulates in the shaft seal, end cover, joint surface and so on. Under the action of pressure difference, it leaks outward from the gap;
        4) the shaft seal structure design is unreasonable. Early reducer adopts oil groove, felt ring type shaft seal structure, assembly of felt by compression deformation, and the joint surface gap sealed up. If the contact between the shaft journal and the seal is not ideal, the seal will fail in a short time due to the poor compensation performance of the felt. Although there are oil return holes on the oil groove, they are easy to be blocked and the oil return function is difficult to play.
        3, too much oil: reducer in the process of operation, the oil pool is stirred very badly, lubricating oil splashing everywhere in the machine, if the amount of oil is too much, so that a large amount of lubricating oil accumulation in the shaft seal, joint surface, etc., resulting in leakage.
        4. Improper maintenance process: when the equipment is overhauled, oil leakage will also occur due to incomplete removal of dirt on the combined surface, improper selection of sealant, reverse installation of seals, and delay in replacing seals.
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        02

        Installation and maintenance of reducer

              1) for the installation of the reducer, the ground shall be flat and the ventilation conditions shall be good as far as possible. The installation site has a great impact on the use of the reducer in the future.

              2) the daily maintenance of reducer includes: use and replacement of lubricating oil, check whether the installation foundation, seal, transmission shaft, etc. are normal, and the maintenance of important parts such as housing removal. The gearbox cleaning and maintenance machine uses the original oil supply and drainage system of the gearbox and the filtered old oil to realize the functions of gearbox cleaning, fast filtration of waste oil, filling of new oil, etc. the operation process does not change the hardware facilities, do not add cleaning agent, so as to ensure the safe operation of the gearbox and extend the service life.

              3) during the idle period of the reducer, it is necessary to check and maintain it regularly according to the requirements of the manual. Only when it is reused can it be ensured that it can be used immediately without any unexpected failure.
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        03

        Common causes of main shaft heating of reducer

            Whether it is rolling bearing or sliding bearing, from the bearing assembly reason, the clearance adjustment of the sliding bearing is too small, the preload of the rolling bearing is too large, it will increase the resistance in the bearing rotation, resulting in the bearing heating. For the internal reasons of the bearing, if the surface roughness and shape of the sliding bearing are not correct, and the manufacturing accuracy of the rolling bearing is low, the bearing will work at low accuracy and high speed, and the rotating resistance will also be increased, so that the bearing will generate heat. From the point of view of the influence of matching parts, it is mainly due to the influence of external forces that the main shaft is bent, the coaxiality of the front and rear bearing holes of the box body is out of tolerance, or the drive belt on the main shaft is adjusted too tight, or the manufacturing of heavy rotating parts installed on the main shaft is inaccurate, the external forces are deformed, and the internal organization is not uniform, resulting in the situation that the coaxiality error between the center of gravity and the rotating axis is too large Too large centrifugal force will also make the shaft bear a large abnormal force, which will cause the bearing to heat up. From the working environment, one of the reasons for bearing heating is the poor lubrication conditions. For example, the supply of lubricating oil is not smooth; the amount of lubricating grease added is not enough; the use brand of lubricating oil and grease is not correct and clean, etc. Second, the protection measures are not good, so that the working environment of dirt, dust into the bearing.
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        04

        The general elimination method of bearing heating in worm gear reducer

              1) first, check whether the lubrication conditions of the bearing are met.

              2) check whether the bearing is subjected to excessive centrifugal force.

              3) check whether the clearance of bearing is adjusted properly.

              4) after the above inspection and adjustment, if the bearing is still hot, it can be considered to dismantle the main shaft, check the internal quality of the bearing, and repair and update. When the equipment is affected by abnormal external force or is damaged accidentally, the deformation of the main shaft and box bearing hole shall also be considered. Check whether the main shaft is bent and whether the front and rear axle holes are coaxial. If a problem is found, it must be repaired.
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        05

        Service factor and working condition factor of German McDonnell reducer

              1) service factor of reducer (FB): FB = rated power of reducer ÷ motor power of reducer

             2) rated power of reducer: under the standard working condition (working condition factor FB total = 1), ensure the service life of the reducer (generally 10000 hours), and the maximum power that the reducer can be configured is the rated power of the reducer. The rated power of the reducer is determined by the weakest part of the reducer. For example, the minimum gear shaft of gear reducer, the motor shaft or eccentric bearing of cycloid reducer, etc.

             3) standard working condition (FB total = 1): it refers to the working condition with stable load, no impact vibration, no more than 10 hours of daily operation, less than 10 starts per hour, ambient temperature of about 20 ℃, good lubrication, and sufficient running in of the reducer. At this time, the service factor FB is 1.

           4) working condition coefficient: it is determined by the working nature and environment, and it is an important parameter that the reducer must refer to when using.

            5) the total condition coefficient (FB total) includes: 1. The condition coefficient determined by load nature, working time and starting frequency, also known as the necessary condition coefficient (FBL). The detailed parameters can be inquired from the table of working machine coefficients in the manual of use of McDonnell products; 2. Working condition coefficient determined by the ambient temperature (FB1); 3. Working condition coefficient determined by the hourly operation time (FB2); fbtotal = FBL × FB1 × FB2

            6) product selection conditions: in order to ensure the normal service life of the reducer under different working conditions, the following conditions must be met: the service factor FB of the product is greater than the total service factor FB of the product. Therefore, under normal circumstances, when selecting products, we must make sure that the service factor of the selected products is greater than 1.0 under the condition of the motor power and speed ratio.
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        06

        How to operate the decelerator correctly

        Reducer is very common today. No matter what kind of reducer has good performance in use, it can help people achieve the desired effect. Reducer is a very common mechanical equipment, people should pay more attention to it when operating.


             1) before unpacking, we should check whether the package of the deceleration equipment is in good condition, and ensure that it is not affected with damp or other problems. In the process of operation, it is necessary to avoid tilting or overturning, otherwise it is easy to damage its motor, and its performance will be reduced.


              2) the inspection of the reducer before use should not be ignored. People need to check whether there is any damage, to ensure that its accessories are intact, and the fasteners should not be loose. Otherwise, the reducer will vibrate violently during use.

            3) people should pay more attention to the installation of reducer. It is better to ensure that the installation complies with relevant regulations and that the installation of the host is reliable.

             4) the use of reduction equipment is to ensure good ventilation conditions and cooling conditions, otherwise it will affect the use of the reducer.
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        07

        There are usually several reasons for oil leakage of reducer

        1, reducer, both inside and outside differential pressure: reducer operation process, movement vice friction heat and influenced by environmental temperature, the temperature rise of the gearbox, if there is no breather hole or blockage in a breather hole, is increasing pressure on machine, machine the higher the temperature, pressure difference with the outside world, the greater the oil under the action of pressure difference, the leakage from the gap.

        2. The structural design of the reducer is unreasonable
        1) Check that the hole cover plate is too thin, and it is easy to deform after tightening the bolt, which makes the joint surface uneven and leaks oil from the contact gap;
        2) in the manufacturing process of the deceleration mechanism, the casting is not annealed or aged, and the internal stress is not eliminated, which will inevitably lead to deformation, clearance, and leakage;
        3) there is no oil return groove on the box body, and the lubricating oil accumulates in the shaft seal, end cover, joint surface and so on. Under the action of pressure difference, it leaks outward from the gap;
        4) the shaft seal structure design is unreasonable. Early reducer adopts oil groove, felt ring type shaft seal structure, assembly of felt by compression deformation, and the joint surface gap sealed up. If the contact between the shaft journal and the seal is not ideal, the seal will fail in a short time due to the poor compensation performance of the felt. Although there are oil return holes on the oil groove, they are easy to be blocked and the oil return function is difficult to play.

        3, too much oil: reducer in the process of operation, the oil pool is stirred very badly, lubricating oil splashing everywhere in the machine, if the amount of oil is too much, so that a large amount of lubricating oil accumulation in the shaft seal, joint surface, etc., resulting in leakage.

        4. Improper maintenance process: when the equipment is overhauled, oil leakage will also occur due to incomplete removal of dirt on the combined surface, improper selection of sealant, reverse installation of seals, and delay in replacing seals.

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        08

        Structure composition of reducer

        What is the structure of the reducer?

        Reducer structure is composed of: gear box, transmission motor, transmission shaft, output shaft
        1, gear box: gear set, transmission shaft, box, gasket composition.
        2, gear series: reducer has single stage, double stage, three, but there are some large reduction ratio can reach four, the larger the series reduction transmission efficiency is lower.
        3, Drive motor: brushless DC motor, brushless DC motor, stepping motor, hollow cup motor, motor, permanent magnet motor can be used.
        4, drive shaft: sintered bearing, rolling bearing.
        5, output shaft: metal output shaft, plastic output shaft.

        Function of reducer:
        1, the reducer is installed between the prime mover and the working machine to reduce the speed, increase the torque of the device, is widely used in production, the common gear reducer, worm gear reducer and so on.
        2, the reducer will be a higher speed into a lower speed device.
        Due to the input shaft and output shaft gear tooth gear mesh together, and the input shaft wheel tooth number is less than the output shaft of the big gear wheel gear, according to the inverse of the gear ratio and speed ratio when the power source, such as machine or other transmission mechanism of high-speed movement, through the input to the output shaft, gear shaft and output shaft got lower than the input shaft of low-speed movement, so as to achieve reduction purposes. Although the shape of the reducer is varied, the basic structure is composed of shafting parts, box and accessories.
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        09

        The cause of broken shaft of planetary reducer

        If the output shaft of the planetary reducer is broken, in addition to the planetary reducer due to the assembly of the output end of the different heart caused by the planetary reducer broken shaft, nothing more than the following two reasons:
        1, the wrong selection of planetary reducer output torque is not enough.
        Some users in the selection, as long as the selected planetary reducer rated output torque to meet the requirements of the work can be mistaken, in fact, one is the motor rated output torque multiplied by the reduction ratio, the numerical value is less than the product sample provided by the similar planetary reducer rated output torque in principle. The second is to consider the overload capacity of the driving motor and the greater working torque required in practice.
        2, in the process of acceleration and deceleration, the planetary reducer output shaft on the instantaneous torque more than 2 times of its rated output torque, and the deceleration and too frequently, 朂 will make the reducer shaft broken.
        In theory, the user needs greater working torque must be less than 2 times the rated output torque of planetary reducer, especially some applications must strictly abide by this criterion. This is not only the protection of planetary reducer, but also the main thing is to avoid the output shaft of the reducer being twisted off. Mainly because, if the equipment is installed in question, the output shaft of the planetary reducer and its load are stuck, the overload capacity of the driving motor will still make it continue to increase the output force, which may make the output bearing of the planetary reducer more than 2 times its rated output torque and torsion off the output shaft of the planetary reducer.

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