How to check for faults when Flender reducer is running

Electrical system inspection

• Power check: Check whether the power switch is tripping. If it is tripping, check whether there is short circuit overload and other reasons that cause tripping. Use a multimeter to measure the power supply voltage to confirm whether the voltage is within the rated voltage range of the reducer, whether the voltage fluctuates too much. Whether the three-phase voltage is balanced. If it is unbalanced, it may be a problem with the power supply line.

• Motor inspection: Check whether the motor winding is short-circuited and open. You can use an insulation resistance tester to measure the insulation resistance of the motor winding. If the insulation resistance is too low, it means that the motor may have insulation damage. At the same time, check whether the motor wiring is loose. If the wiring is loose, it will cause poor contact and make the motor unable to operate normally.

• Control circuit inspection: Check whether the components such as the relay contactor that controls the operation of the reducer are working normally, whether there are contact ablation and adhesion, etc. to see if the fuse in the control circuit is blown. If it is blown, the cause needs to be found and replaced to check whether the output signal of the PLC and other controller is normal. If the signal is abnormal, it may be that the controller has a fault.

Mechanical system inspection

• Load inspection: Check whether the load driven by the reducer suddenly increases or is stuck. If the load is too large, it exceeds the load carrying capacity of the reducer, which will cause the reducer to be overloaded and stopped. For example, whether there are foreign objects on the conveyor belt stuck, resulting in a sudden increase in load.

• Coupling inspection: Check whether the coupling is damaged or the connection is loose. If the coupling is damaged and the torque cannot be transmitted normally, it will cause the reducer to stop check whether the coupling connection bolts are loose or broken, and whether the elastic components of the coupling are worn and aging.

• Bearing inspection: By listening to sound or using a vibration tester to determine whether the bearing is damaged. If the bearing is damaged, abnormal noise and vibration will occur. In severe cases, the reducer will stop and touch the bearing part with your hands to feel whether the temperature is too high. If the temperature is too high, it may cause poor lubrication or serious wear of the bearing.

• Gear inspection: Open the inspection hole of the reducer to observe whether there are any damages such as wear, pitting, broken teeth, etc. If the gear is damaged, it will affect the normal transmission of the reducer, resulting in shutdown. At the same time, check whether the gear meshing clearance is normal. You can use a feeler gauge for measurement.

Lubrication system inspection

• Oil level check: Check whether the oil level of the reducer is within the normal range, which will cause poor lubrication of gears and bearings, resulting in overheating and wear, and even causing shutdown. If the oil level is too low, appropriate lubricating oil must be added.

• Oil quality inspection: Take lubricant oil samples to check the color, odor and viscosity of the oil. If the oil becomes dark, there will be odor or the viscosity changes significantly, it means that the lubricant oil has deteriorated. It needs to be replaced and check whether the oil contains impurities such as metal chips. If there is, it may be severely worn by gears or bearings.

• Lubrication pump inspection: Check whether the lubrication pump is working normally, whether the impeller of the pump is damaged, and whether the inlet and outlet pipes of the pump are blocked. If the lubrication pump fails, the lubricating oil cannot be delivered to various lubricating parts, which will cause the reducer to stop due to poor lubrication.