For the KAF87-27.88-Y7.5KW gear reducer, the core of failure prevention lies in matching, standardized installation, regular maintenance and real-time monitoring. Specific measures are as follows:
1. Selection matching
Load and speed matching: Select the appropriate model according to actual working conditions (such as load type, speed range) to avoid overload operation.
Manufacturer Selection: Give priority to brands with reliable quality and excellent technology to ensure the basic performance of the equipment.
2. Standardized installation
Base and Bolts: It must be installed on a solid and flat base, and the anchor bolts must be tightened to prevent shock.
Coaxiality: Ensure that the motor, reducer and working machine are coaxial, and the error is controlled within the allowable range.
Lubrication system: Check the lubrication system after installation to ensure sufficient oil and clean oil quality, and test run according to regulations.
3. Regular maintenance
1. Lubrication management:
Select oil according to load and speed. For heavy loads, it is recommended to use oil containing extreme pressure additives.
Change the oil after the first 300 hours of operation, and then every 5,000 hours or half a year.
2. Fastener inspection: Use a torque wrench to recheck the anchor bolts every month. The pretightening force must reach ±5% of the design value.
3. Daily inspection: record oil level, noise and other parameters, conduct vibration testing every quarter, and conduct oil physical and chemical index testing every year.
4. Spare parts reserve: Consumable parts (such as oil seals and bearings) are kept in stock, and core components such as gears are ordered 3 months in advance.
4. Real-time monitoring
Temperature monitoring: Regularly check the oil temperature and bearing temperature, and adjust the allowable range according to the ambient temperature.
Vibration and Sound: Pay attention to abnormal vibration and noise, and promptly troubleshoot problems such as gears, bearings, and foreign objects stuck.
Oil level and seal: Check the oil level and sealing surface to prevent oil leakage.
5. Other matters needing attention
Environmental Control: Keep the working environment clean, avoid dust from entering, and stay away from strong vibration and humid environments.
Maintenance safety: Cut off the power supply and lock and tag out before maintenance. Large reducers need to release the residual pressure of the brake.
Record Management: Record maintenance contents in detail to facilitate subsequent fault tracing.
Through systematic preventive measures, the life of the reducer can be effectively extended and the occurrence of failures can be reduced. In actual operation, the manufacturer's technical specifications must be followed to avoid secondary damage caused by empiricism.
