1. Root causes of water seepage failures and corrective measures
In heavy-load, high-humidity or dusty environments such as roller presses, cooling water, production steam and metal impurities can easily invade the interior of the reduction gearbox.
1. Analysis of the root causes of water seepage:
External water vapor intrusion: The equipment has been in a high temperature and high humidity environment for a long time, and cooling water or steam intrudes from weak locations such as the box joint surface and sealing gap.
Cooling system water quality problems: The quality control of circulating cooling water is not strict. The calcium and magnesium carbonates in the water decompose when heated to form scale. In severe cases, the pipelines will be blocked, affecting the cooling efficiency and increasing the system resistance.
2. Complete rectification measures for water seepage:
Strengthen external sealing and protection: Implement the "plugging loopholes and strong sealing" transformation plan to strengthen the joint surfaces of the box, sealing gaps and other parts that are prone to water intrusion, and block external water vapor intrusion channels.
Add hydrophobic and diversion structures: Optimize the box structure to "drain water", for example, add diversion grooves in areas prone to water accumulation to prevent water from accumulating near the sealing surface.
Strict water quality and cooling system management: Regularly clean plate heat exchangers and cooling pipelines to prevent scale thickening and deterioration of heat transfer. Ensure that the circulating cooling water inlet temperature reaches the standard (such as ≤30°C) to ensure efficient operation of the cooling system.
2. Root causes of oil leakage and corrective measures
Reducer oil leakage is a high-frequency failure, and its root cause is often not the aging of a single seal, but a systemic problem.
1. Analysis of the root causes of oil leakage:
(1) Imbalance of internal and external pressure difference (the most common cause): When the reducer is running, friction and heat cause the temperature and pressure inside the box to rise. If the breather cap (ventilation hole) is blocked by sludge or is designed too small, the internal high pressure will squeeze the lubricating oil out of the weak sealing points (such as the joint surface and shaft seal).
(2) Structural and assembly process defects:
The inspection hole cover is too thin and is easily deformed after tightening, resulting in an uneven joint surface; the casting is deformed because the internal stress is not eliminated.
The box lacks an oil return groove or the oil retaining ring is unreasonably designed (such as using a cup-cover shape that is prone to oil accumulation), resulting in the splashed lubricating oil being unable to flow back smoothly.
During maintenance, the joint surface is not cleaned thoroughly, the sealant is wrong, or the assembly is unevenly stressed.
