The daily maintenance of gears mainly includes the following aspects:
Appearance inspection
Wear situation: Check the tooth surface of the gear regularly to check for wear, scratches, peeling and other phenomena. Slight wear can slow its development by adjusting load, lubrication, etc., while severe wear may require timely replacement of gears to avoid affecting transmission accuracy and efficiency.
Tooth surface damage: observe the tooth surface for damage such as cracks, pitting and other damage. Cracks may cause gear breakage, and pitting will reduce the contact strength of the tooth surface. Once such problems are found, the causes need to be analyzed and corresponding measures must be taken, such as improving lubrication conditions and adjusting installation accuracy.
Deformation: Check whether the gear teeth are deformed, such as bending, twisting, etc. Deformation may cause poor gear meshing, resulting in vibration and noise. If deformation is found, find the cause in time, such as whether it is subjected to excessive impact load or improper installation.
Lubrication maintenance
Oil quality inspection: Check the quality of gear lubricating oil regularly, observe the color, transparency and viscosity of the oil, and determine whether there is deterioration, pollution or emulsification. Deteriorated lubricating oil will lose good lubricating performance and accelerate the wear of the gears and need to be replaced in time.
Oil level check: Make sure the lubricating oil level in the gearbox is within the normal range. If the oil level is too low, it cannot provide sufficient lubrication, which will cause dry grinding of the gears; if the oil level is too high, it may cause problems such as rising oil temperature and splashing of oil, affecting the lubrication effect.
Lubrication system maintenance: Check whether all components of the lubrication system, such as oil pumps, oil filters, oil pipes, etc. are working normally. Ensure that the oil pump can supply oil normally, the oil filter is not blocked, and the oil pipe is not leaked, so as to ensure that the lubricating oil can reach the gear meshing part smoothly.
Operation status monitoring
Noise monitoring: Listen to whether there is abnormal noise during operation of the gear. Under normal circumstances, the gear operation sound is stable and even. If there is a harsh, sharp or periodic noise, it may be caused by poor gear meshing, uneven wear or foreign objects entering the meshing area, and the machine needs to be shut down and checked in time.
Vibration monitoring: Use vibration monitoring equipment or hand feel to judge the vibration status of the gear. Slight vibration is normal, but excessive vibration may indicate that the gear has problems such as imbalance, misalignment of the shaft system or gear failure, and should be analyzed and dealt with in a timely manner.
Temperature monitoring: Pay attention to the temperature changes of the gear box. Generally speaking, the temperature of the gear should not be too high during normal operation. If the temperature rises abnormally, it may be caused by excessive load, insufficient lubrication or poor heat dissipation. Timely measures should be taken to reduce the temperature to avoid damage to the gears due to overheating.
Cleaning and maintenance
External cleaning: Regularly clean dust, oil and debris from the surface of the gear to keep the gear appearance clean. This not only helps dissipate heat, but also prevents impurities from entering the gear meshing area, aggravating wear.
Internal cleaning: When regularly inspecting or replacing lubricant, clean the inside of the gearbox to remove impurities such as sludge and metal chips. These impurities may affect the performance of the lubricant and accelerate gear wear, so make sure the inside of the gear box is clean.
Installation and connection check
Installation accuracy check: Check whether the gear installation meets the requirements, including whether the gear and the shaft are closely cooperating, and whether the axial and radial jumps of the gear are within the allowable range. Failure to meet the installation accuracy will lead to uneven stress on the gear and accelerate wear, so regular inspections and adjustments are required.
Check the connection component: Check the tightening of the gears and shafts, couplings and other connecting components to ensure that the connection bolts are not loose. Loose connections will cause unstable transmission, generate vibration and noise, and may even cause safety accidents such as gear falls off, so tighten the loose bolts in time.
