FAQs | Xijian Technology Group Co., Ltd.

How to use the gearbox

1. After running for 200-300 hours, the first oil change should be carried out. In future use, the quality of the oil should be regularly checked, and any mixed impurities or deteriorated oil must be replaced in a timely manner. In general, for reducers that operate continuously for a long time, the oil should be replaced once a year or after 5000 hours of operation. For reducers that have been out of service for a long time, the oil should also be replaced before restarting. The reducer should be filled with oil of the same brand as the original, and should not be mixed with oil of different brands. Oil with the same brand but different viscosity is allowed to be mixed for use;

2. When changing the oil, it is necessary to wait for the gearbox to cool down without burning danger, but it should still be kept warm because after complete cooling, the viscosity of the oil increases, making it difficult to drain the oil. Attention: Cut off the power supply of the transmission device to prevent unintentional electrification;

3. During work, when it is found that the temperature rise of the oil exceeds 80 ℃ or the temperature of the oil pool exceeds 100 ℃, and abnormal noise occurs, the use should be stopped. The cause should be checked, and the fault must be eliminated. Only after replacing the lubricating oil can the operation continue;

4. Users should have reasonable usage and maintenance rules and regulations, and carefully record the operation of the reducer and any problems found during inspection. The above regulations should be strictly implemented.

Precautions for using worm gear reducers

If you want to better utilize the performance of the worm gear reducer and avoid unexpected failures, it is recommended that you understand the specific instructions and requirements before installation and use, in order to avoid some incorrect operations that may affect the performance and may even occur in industrial environments

If you want to better utilize the performance of the worm gear reducer and avoid unexpected failures, it is recommended that you understand the specific instructions and requirements before installation and use, in order to avoid some incorrect operations that may affect the performance and even potentially cause various unexpected problems and safety hazards in industrial environments.

Installation and debugging of the reducer

The reducer (motor) can only be installed on a flat, shock-absorbing, and torsion resistant support structure according to the specified installation position; The bottom foot of the box and the installation flange cannot be tightened simultaneously during the installation process to avoid mutual competition; When using bolts or foundation blocks to fix the reducer (motor) on its concrete foundation, there should be suitable grooves to accommodate the reducer (motor); During installation, please check whether the oil injection amount matches the installation position. If the installation position changes, please adjust the oil amount accordingly; Install a straight through breather or open the breather to transport the rubber ring; Do not hit or strike the shaft end; The vertical installation method of the motor should have shielding measures to prevent foreign objects or liquids from entering (rain cover C); When installing the junction box, make sure that the cable inlet points downwards. Installation of solid shaft reducer (motor) Install and fix input and output drive components (such as coupling components) on the shaft of the gearbox; If these components need to be pre heated before installation, please refer to the dimension diagram in the coupling file for the correct fitting temperature; The misalignment of the shaft may be caused by assembly or actual operation (such as thermal expansion, shaft deflection, insufficient stiffness of the frame, etc.); Please refer to the instruction manual of the corresponding brand of coupling for the allowable alignment error of the coupling; The alignment should be carried out in two mutually perpendicular axial planes. You can use a ruler (radial misalignment) and a feeler gauge (angular misalignment) for alignment; Unless otherwise specified, these components can be preheated by induction heating, or by using a burner or in a heating furnace. Installation of hollow shaft reducer (motor) with flat key The solid shaft end of the working machine should be equipped with a flat key that complies with DIN6885 standard Part 1, Type A, and should have a center hole on its end face that complies with DIN standard 322 DS type (threaded); Inspect the hollow shaft of the reducer and the solid shaft of the working machine for damage to the shaft seat and edge parts; If necessary, use suitable tools for repair and cleaning; Install the reducer with nuts and screws, and the reaction force is provided by the hollow shaft of the reducer; In addition to nuts and screws, other types of devices can also be used, such as a hydraulic lifting device. Installation of Hollow Shaft Reducer with Expansion Plate The solid shaft end face of the working machine should be equipped with a central hole that complies with DIN standard 322 DS type (threaded); Install with an integral bushing; Install the reducer with nuts and screws; The reaction force is provided by the hollow shaft of the reducer; Install with loose bushings; Push the loose bushing onto the solid shaft of the working machine, firmly fix it in place with a positioning device, and then pull it into the hollow shaft of the reducer along the solid shaft of the working machine; The outer surface of the hollow shaft of the reducer can be lubricated at the position of the shrink disc seat; Tighten all fastening bolts one by one in sequence, and tighten all bolts through several cycles; Tighten the fastening bolts until the front side of the inner and outer rings are aligned.

Common causes and problems of worm gear reducers

The worm gear reducer is a compact structure, large transmission ratio, and self-locking transmission mechanism under certain conditions. It is also easy to install and has a reasonable structure, and has been increasingly widely used. It is a multi-stage reducer equipped with an oblique reducer at the input end of the worm gear reducer, which can achieve very low output speed, higher efficiency than a single stage worm gear reducer, and has low vibration, noise, and energy.

1. Gearbox heating and oil leakage. In order to improve efficiency, worm gear reducers generally use non-ferrous metal as the worm gear, while the worm gear is made of harder steel. Due to the use of sliding friction transmission, more heat is generated during operation, resulting in differences in thermal expansion between various parts and seals of the reducer, resulting in gaps between various mating surfaces. As the temperature increases, the lubricating oil becomes thinner, which can easily lead to leakage. There are four main reasons for this situation: firstly, the material combination is unreasonable; Secondly, the quality of the meshing friction surface is poor; The third reason is that the selection of lubricating oil addition amount is incorrect; Fourthly, the assembly quality and usage environment are poor.

2. Worn worm gear. The worm gear is generally made of tin bronze, and the matched worm material is quenched with 45 steel to HRC4555, or quenched with 40Cr to HRC5055, and then ground with a worm grinder to a roughness of Ra0.8 μ M. The wear and tear of the gearbox is very slow during normal operation, and some gearboxes can be used for more than 10 years. If the wear rate is fast, it is necessary to consider whether the selection is correct, whether it operates under overload, as well as the material, assembly quality, or usage environment of the worm gear.

3. Worm bearing is damaged. When a malfunction occurs, even if the gearbox is well sealed, it is often found that the oil inside the gearbox is emulsified, and the bearings are rusted, corroded, and damaged. This is because after the gearbox has been running for a period of time, the condensate generated by the oil temperature rising and cooling is mixed with water. Of course, it is also closely related to bearing quality and assembly process.

How to troubleshoot noise in gear reducers?

1、 Listen to the bearing noise of the gear reducer motor

1. Normal sound: There is no continuous metal sound fluctuation.

2. Guard ring sound: A light "chirp" sound generated by the rotation of rollers or balls with the guard ring, containing irregular metal passing through sound unrelated to speed control. If this sound decreases or disappears after adding some lubricating oil to the information, it has no direct impact on the operation process.

3. Cracking sound: The sound emitted when there are no cracks on the raceway surface, ball, or roller surface of the bearing, and its period is proportional to the rotational speed. When cracks occur in bearings, they must be quickly replaced before overheating or sintering occurs.

4. Squeaking noise ": mainly the sound emitted by rolling bearings. When adding lubricant, the 'squeaking sound' will disappear. When there is a "squeaking" sound, the machine can still be used as usual without any abnormal vibration or temperature.

2、 Listen to the noise of the control motor rotor system of the gear reducer

The noise of the rotor is usually the noise of the fan, the friction of the brush, and occasionally as loud as the sound of a drum. This is when suddenly starting and stopping, especially during frequent reverse braking and regenerative braking, as it reduces the torque of the production speed during loading, causing looseness between the iron core and the shaft, and severe critical friction.

The fit between the bearing shells of the coupling or pulley and the shaft is too loose; Wear and deformation of coupling bolts; Insufficient lubricating oil for gear coupling and worn teeth; The belt is loose and worn. All of these factors may cause noise from the reduction motor.

Installation precautions for the cycloidal gear on the cycloidal reducer

1. To rotate one of the cycloidal gears of the cycloidal reducer by 180 degrees. When the middle bearing hole completely coincides with the ten holes, the outer tooth profile is just misaligned, and the root position of the upper plate tooth is exactly the top position of the lower plate tooth. Pay attention to the relative position of the two wheels and remember to mark them yourself. Alternatively, remember the original marked position on the wheel, which is a single tooth difference cycloid wheel, and a double tooth difference does not need to be rotated 180 degrees.

2. Place a piece of cycloidal gear into the needle wheel housing and rotate it by hand to see if it swings smoothly.

3. Install the eccentric bearing. Because the bearing hole of the cycloid is equivalent to the outer shell of an eccentric bearing. Therefore, the correct position of the eccentric bearing is that the bearing hole of the hypocycloid gear completely contains the cylindrical estimated ball of the eccentric bearing.

4. Place the spacer. Then place another cycloidal reducer cycloidal wheel, which is the key when placing this wheel. The position should be placed completely according to the markings drawn on one's own face.

5. Put on the shaft sleeve and rotate it by hand to see if it can rotate. Check if the cycloid reducer is installed correctly.

What issues should be paid attention to when installing a cycloidal reducer?

When installing the cycloidal reducer, attention should be paid to the alignment of the transmission center shaft, and the error should not exceed the compensation amount of the coupling used. Good alignment can extend service life and achieve ideal transmission efficiency.

When installing transmission components on the output shaft of the cycloidal reducer, it is not allowed to strike with a hammer. Usually, assembly fixtures and internal threads at the shaft end are used to press the transmission components in with bolts, otherwise it may cause damage to the internal parts of the reducer. Do not use rigid fixed couplings. Improper installation of such couplings can result in unnecessary external loads, premature bearing damage, and even output shaft fracture in severe cases.