How to judge whether a ZD30-4.5-I soft tooth surface reducer needs to be modified

To determine whether the ZD30-4.5-I soft tooth surface reducer needs to be modified, a comprehensive evaluation must be combined with its technical characteristics and actual operating conditions. The following are the specific basis and methods for judgment:

1. Assessment based on gear wear and damage

1. ‌Tooth surface wear‌When the tooth thickness wear of the
   soft tooth surface gear exceeds 20% of the original tooth thickness, replacement or modification needs to be considered‌. If the actual measured tooth thickness decreases by more than 10% compared to the original value (for example, the original tooth thickness is 10mm, the measured tooth thickness is ≤9mm), it is judged to be severely worn.

2. ‌Tooth surface damage type‌

• ‌Pitting corrosion‌ : Dense pits (diameter >0.5mm) appear on the tooth surface and the area exceeds 30%‌.

• ‌Gluing /Welding‌ : The tooth surface adheres to high temperatures to form tear marks or welding lesions‌.

• ‌Spinning‌ : The hardened layer on the tooth surface falls off in chunks (area >10mm²)‌.
  If any of the above damage occurs, it must be replaced or modified immediately.

• ‌Tooth structure damage‌tooth
  root cracks, broken teeth or gear deformation (tooth direction deviation>0.1mm/m) must be replaced‌.

2. Indirect judgment based on operating performance

1. ‌Abnormal Vibration and Noise‌Vibration
   speed >11.2mm/s or periodic abnormal noise (such as 'clunking' sound) occurs, indicating poor gear meshing.

2. ‌Transmission efficiency decreases‌The
   output torque decreases or the motor current continues to be high, indicating that gear wear leads to energy loss‌.

3. ‌Lubricating oil pollution‌Metal wear particles in
   the oil are >0.5mm or there are too many ferromagnetic substances, indicating severe wear of the tooth surface.

3. Additional conditions for modification decisions

1. ‌Working condition matching‌If the equipment load fluctuates frequently or the impact load is large (such as rotary
   kiln transmission), it is necessary to evaluate whether the gear strength meets the requirements.

1. ‌Maintenance costs‌If it operates
   beyond its service life (such as over 8,000 hours under heavy load conditions) or if it continues to malfunction repeatedly after repairs, it is recommended to modify it directly‌.

2. ‌Technical upgrade requirements‌If
   you need to improve transmission accuracy or load-bearing capacity, you can consider replacing it with a hard tooth surface gear (tooth surface hardness >350HBS).

4. Detection Tools and Methods

• ‌Appearance inspection‌ : Observe signs of uniform wear, pitting, gluing and other signs on the tooth surface‌.

• ‌Dimensional measurement‌ : Use tooth thickness caliper and common normal micrometer to quantify the amount of wear‌.

• ‌Operation monitoring‌ : Collect data through vibration meters and temperature sensors to compare with standard values‌.

In summary, if the ZD30-4.5-I reducer shows any of the above severe wear or performance failure signals and cannot be restored through routine maintenance, it needs to be modified or replaced.