Determine whether the KAF77-17.87-3KW reducer is overloaded through noise and vibration, as follows:
1. Noise characteristic analysis
Overload performance:
Continuous low-frequency 'buzzing' sound 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 (distance of 1 meter) when no-load. For every 10% increase in load, the noise rises ≤3dB.
2. Vibration monitoring
Key parameters:
The effective value of vibration speed (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 shut down immediately.
The harmonic amplitude of the meshing frequency (such as 206.15Hz) in the spectrum suddenly increases, indicating that the gear is overloaded.
3. Comprehensive diagnosis
step:
(1) Record baseline noise/vibration values during no-load operation.
(2) Gradually load to the rated load and compare the data changes.
(3) If the noise/vibration exceeds the limit value by 20% when the load increases by 10%, it is determined to be overloaded.
Auxiliary inspection:
If the oil temperature is >60°C or the oil contains metal debris, lubrication failure may occur due to overload.
