When abnormal noise or vibration occurs in the reducer, there is a high probability of mechanical failure, which requires comprehensive judgment based on sound characteristics, vibration data and operating status. Here are practical ways to quickly identify faults based on noise and vibration:
1. Preliminarily locate the fault location through Noise Type
1. Continuous "buzzing" sound
Possible reasons: Insufficient lubrication, deterioration of lubricating oil, or coaxiality deviation between the motor and reducer, resulting in poor transmission.
Verification method: Check whether the oil level is at 1/2~2/3 scale and whether the oil quality is black and turbid; observe whether the coupling is aligned and whether the bolts are loose.
2, sharp "piercing sound" or "screeching sound"
Possible reasons: The bearing is short of oil, the raceway is pitted or the roller is broken, and it is in a dry friction state.
Verification method: Touch the bearing end cover after stopping the machine. If the temperature exceeds 80°C, or there is a stuck feeling during manual rotation, it can basically be determined that the bearing is damaged.
3. Periodic "click" or "clunk" impact sound
Possible reasons: Broken gear teeth, tooth surface peeling, pitting corrosion or excessive meshing clearance.
Verification method: Abnormal noise still exists during no-load operation, and appears synchronously with the speed change. You can use a stethoscope close to the box to determine whether the frequency of the abnormal noise is consistent with the gear speed.
4. High-frequency "hissing" sound
Possible reasons: Poor tooth surface lubrication or too small meshing clearance, resulting in increased friction.
Response: Check whether the lubricating oil model matches, replace if necessary and adjust the meshing accuracy.
2. Determine the severity of the fault through vibration amplitude
Normal range: Vibration speed ≤ 2.8mm/s (ISO standard), some equipment can be relaxed to 4.5mm/s.
Early warning interval: 4.5~7.1mm/s, indicating that the gear or bearing has been slightly worn.
Exceeding standard alarm: >7.1mm/s, the machine needs to be shut down immediately for maintenance. Moderate to severe wear or loose parts may have occurred.
