To determine whether the oil pool depth of the QJS-D200-100-II gear reducer is appropriate, the core focus is on the three cores of 'lubrication effectiveness, operating status stability, and no abnormal loss'. Combined with practical methods such as oil level observation, working condition matching, and operating parameter monitoring, the following are 8 judgment criteria that can be directly implemented (in order of priority): 1. Observe the oil window / Oil level gauge benchmark: After the equipment is shut down and cooled to room temperature, the oil level should be located at ±5mm from the center line of the oil window (or 2/3 of the oil level gauge scale), and meet the gear oil immersion depth of 1-2 tooth height (the tooth height of this model of large gear is about 25-30mm, corresponding to the oil immersion depth of 25-60mm); if it is lower than the lower limit of the oil window (oil immersion <1 tooth height), it is too shallow, and if it is higher than the upper limit (oil immersion>2 tooth height) is too deep. 2. Monitor whether the operating noise is normal: the noise value during normal operation should be ≤85dB (no load)/≤90dB Read More

QJS - D560 - 3C - 25 belongs to QJ The hard-tooth surface reducer in the series is often used in heavy-load scenarios such as cranes. It is often lubricated by oil pool immersion. The reasonable oil pool depth is generally for large gears to be immersed in oil 1 - 2 The tooth height is appropriate. If the depth of the oil pool is too shallow or too deep, it will shorten its service life by destroying the lubrication effect, exacerbating component losses, and deteriorating the oil. The specific effects are as follows: Oil pool is too shallow: insufficient lubrication causes all-round wear 1. Premature gear failure: Oil pools that are too shallow will cause the gear to be immersed in insufficient depth, making it difficult to form a continuous and stable oil film on the tooth surface, and boundary friction or even dry friction is prone to occur when the gear meshes. This will accelerate tooth surface wear and pitting corrosion. In the long run, it will also cause serious failures such as tooth surface gluing and tooth breakage. Moreover, a shallow oil pool means a small amount of oil, which cannot effectively take away the heat generated by meshing. Local high temperatures will further destroy the stability of the oil film, and at the same time, the performance of the gear material will be reduced, significantly Read More

The core causes of worm gear tooth surface wear of WPWK80-40 reducer (the worm gear is mostly made of copper alloy and the worm is alloy steel) can be summarized into 10 categories, covering key dimensions such as lubrication, load, installation, and material. The details are as follows: 1. Improper lubrication: Not using special extreme pressure oil for worm gears (select ordinary gear oil), oil level is too low/ Too high, the oil has deteriorated (containing impurities and moisture) or the oil has not been changed for a long time, resulting in the failure of the lubricating film on the tooth surface and dry friction/semi-dry friction and wear. 2. Overload operation: Long-term over-rated load (WPWK80-40 rated torque is about 250N·m), frequent starts and stops, and impact loads (such as hard starts with load, emergency stops), make the tooth surface contact stress exceed the design limit, aggravating wear. 3. Installation deviation: The verticality of the worm and worm gear axis is out of tolerance (standard ≤ 0.02mm), and the meshing gap is too large/too small (normally 0.15-0.3mm), resulting in deviation. Read More

WPDS135-30-B As a worm gear reducer, the worm gear is mostly made of tin bronze and the worm is mostly alloy nitride steel. This type of reducer itself has obvious sliding friction and is easy to generate heat. Excessive operating temperature will cause chain damage to the worm gear, and will also cause problems with peripheral components, further aggravating the worm gear. The damage is as follows: lubrication failure causes severe wear of the tooth surface: rising temperature will cause the viscosity of the special lubricating oil for worm gears to drop significantly, and the thickness of the oil film will become thinner or even ruptured, and the metal meshing surfaces of the worm gear and worm cannot be effectively isolated, resulting in boundary friction or even dry friction. At the same time, high temperatures will accelerate the oxidation of lubricating oil and generate sediments such as sludge and colloid. These impurities will cause abrasive wear when mixed into the meshing surface, resulting in a large number of scratches and pitting on the tooth surface. For every 10°C increase in oil temperature, the oxidation rate of lubricating oil will be approximately doubled, and the wear rate will also increase sharply. Tooth surfaces are prone to sticking and seizure: high temperature Read More

Determine whether the KAF77-17.87-3KW reducer is overloaded through noise and vibration, as follows: 1. Noise characteristic analysis‌Overload performance‌: Continuous low-frequency 'buzzing' sound, which increases as the load increases‌. If there is a periodic impact sound (such as gear meshing impact), the tooth surface may be worn or the gap may be expanded due to overload. ‌Comparison standard‌: Noise should be ≤75dB (1 meter distance) when no-load. For every 10% increase in load, the noise rises ≤3dB. ‌2. Vibration monitoring‌‌Key parameters‌: Vibration speed effective value (RMS) should be ≤4.5mm/s (ISO 10816-3 standard). When the acceleration kurtosis value is >3, it indicates abnormal wear of the bearing or gear. ‌Overload signal‌: The vibration amplitude increases linearly with the load. If the vibration amplitude exceeds 20% of the rated load by >50%, the machine needs to be stopped immediately‌. The harmonic amplitude of the meshing frequency (such as 206.15Hz) in the spectrum increases suddenly. Read More

The specific steps to optimize the box structure and heat dissipation area of the KAF97-Y11-4P-24.75-M5 reducer are as follows: 1‌. Box structure optimization‌‌Material selection‌: Use high thermal conductivity Steel (such as Q355ND, thermal conductivity 45W/(m·K)), and graphene modified epoxy coating (thermal conductivity 2.5W/(m·K)) is sprayed on the outside of the box to accelerate heat conduction‌. ‌Heat sink design‌: Change the traditional flat plate heat sink to a spiral wound design. The height of the heat sink is recommended to be 15mm, the spacing is 20mm, and the pitch is 15° to prevent the accumulation of coal dust‌. ‌Internal diversion structure‌: An 8mm-high oil diversion rib is installed on the inner wall of the box to guide the lubricating oil to flow from the high-temperature gear area to the heat dissipation area on the side wall of the box, reducing local oil temperature‌. 2‌. Increased heat dissipation area‌‌ Passive heat dissipation enhancement‌: Through the spiral heat sink design, the heat dissipation area can be increased by 30%-50% (such as DC Read More