In filling machinery, the reducer is the "power center" that ensures the synchronous operation of all components. The fault location can usually be determined through the three main dimensions of "listening to identify the location", "touch sensing" and "running test":
1. Analysis from the perspective of sound (identifying the position by listening to the sound)
Different abnormal sounds often correspond to different internal damages:
Scratching noise: Usually indicates a problem with the gears. It may be due to insufficient lubricating oil that the gears are dry grinding, or the tooth surface is seriously worn and roughened.
Periodic knocking sounds: Regular "dong-dong" sounds often point to bearing failure. This may be caused by worn bearing balls, broken cage, or improper installation resulting in uneven eccentric force.
High-frequency whistling sound: Most of the time it is because the lubrication system is not working well, such as using the wrong type of lubricating oil, the oil is too dirty, or the oil line is clogged.
Sudden breaking sound: This indicates that the gear may have broken teeth or serious cracks, resulting in a high-frequency impact sound.
2. Perception from the perspective of vibration and temperature (follow the clues)
Observing the external status of the reducer through touch and vision can also quickly locate hidden dangers:
Abnormal vibration: If you touch the shell with your hand and feel obvious abnormal vibration or numbness, it may indicate that the gear is eccentric, broken teeth or the mating surface gap is too large (if the gap is >0.05mm, it needs to be repaired). If conditions permit to use a vibrator, be highly vigilant when the vibration speed exceeds 8 mm/s.
Excessive temperature: When the gearbox oil temperature exceeds 90°C, it will accelerate lubricant degradation and shorten bearing life. This is usually caused by excessive/low oil levels, oxidative deterioration of lubricating oil, or frictional heating caused by improper meshing clearance between bearings and gears.
Oil leakage phenomenon: Oil leakage is the most intuitive visible fault. Commonly seen are aging and damage of the output shaft oil seal, failure and cracking of the sealant on the box joint surface, or damage to the sealing gaskets at the sight hole cover and oil drain plug.
3. Function comparison testing method
In order to further confirm whether the fault lies in the reducer itself, you can perform the following verification operations:
Comparison between no-load and load: disconnect the load and perform no-load operation. If the abnormal noise disappears, it means that the problem is on the load side; if the noise remains, it can basically be determined that the internal gears and other components of the reducer are damaged.
Torque fluctuation observation: When operating under rated load, normal torque fluctuation should be ≤ 5% of the rated torque. If the fluctuation exceeds 15% and is accompanied by vibration, there is a problem with the gear mesh.
Maintenance suggestions: Once the fault location is initially identified through the above method, it is recommended to stop the machine for inspection in time. For minor wear and tear, you can grind and repair it or replenish/replace special lubricating oil; if you find serious gear pitting, peeling, or bearing damage, it is recommended to contact the manufacturer directly to obtain replacement parts with accurate specifications, and have a professional team repair or replace them to avoid secondary damage caused by installation errors.
