What are the common faults in the internal gear transmission system of CJY160-160-LZ-5.5KW reducer?

CJY160-160-LZ-5.5KW is an integrated gear reduction motor model (adapted to 5.5KW motors, LZ vertical installation). Its internal gear transmission system is mainly based on involute cylindrical gears. Faults are mostly concentrated in the three core parts of the gear body, meshing pair, and shaft system, and are mostly caused by installation deviation, lubrication failure, abnormal load, and fatigue wear. The following is a summary of high-frequency faults, their characteristics, and incentives, and is presented in a structured plain text:

1. Gear tooth surface wear (abrasive wear/adhesive wear)

Characteristics: Uniform wear marks and grooves appear on the tooth surface. In severe cases, the tooth thickness becomes thinner and the meshing gap is too large, accompanied by increased operating noise and reduced transmission efficiency. Adhesive wear will cause tooth surface adhesive, metal peeling, and local high-temperature ablation marks.

Causes: Insufficient grease/lubricating oil level, deterioration of oil quality (mixed with iron filings/dust), mismatched lubrication model; rupture of the oil film on the tooth surface under low speed and heavy load; poor cleanliness of the box during installation, and residual impurities entering the meshing pair.

2. Gear tooth surface pitting corrosion (fatigue pitting/early pitting corrosion)

Characteristics: Needle-shaped and pitted pits appear on the tooth surface (mainly at the pitch circle). As the fault develops, the pits expand and become connected. Periodic high-frequency noise is accompanied during operation. The metal particles shed by pitting corrosion will aggravate the wear of other parts.

Inducing factors: Insufficient heat treatment hardness of gear material and excessive tooth surface roughness; tooth surface contact fatigue under long-term alternating load; too large/too small meshing clearance, resulting in local contact stress concentration; shaft deflection and excessive bearing clearance causing tooth surface eccentric load.

3. Gear tooth root cracks/broken teeth

Characteristics: Transverse cracks appear at the tooth root, or even the entire tooth breaks. After the tooth is broken, the equipment will vibrate violently, hit the sound, or even get stuck and shut down; cracks mostly occur at the transition fillet of the tooth root (stress concentration area).

Inducing factors: low processing accuracy of tooth root fillet, sharp corners/knife marks; sudden overload, impact load (such as frequent starts, sudden increase in load); excessive installation coaxiality deviation, causing a single tooth to bear excessive load; fatigue pitting corrosion is not treated in time, and cracks extend to the tooth root.

4. Poor gear meshing (eccentric meshing/abnormal tooth side clearance)

Features: The operating noise is 'whispering', the difference between no-load/load noise is large, the tooth surface wear is uneven (severe tooth surface wear on one side), abnormal heating occurs at the bearing end cover; when the clearance is too small, the tooth surface is squeezed and stuck, and when the clearance is too large, the transmission impact is obvious.

Causes: The coaxiality and parallelism deviation of the input/output shaft exceeds the standard; the machining accuracy of the box bearing hole is low and the bearing installation is skewed; the coupling alignment error is too large, transmitting radial/axial force to the gear pair; the keyway fit is loose during gear assembly, and the gear moves on the shaft.