1. External load stuck (priority troubleshooting)
(1) Cause of external load stuck failure: The ball press is stuck by the driving equipment itself (such as iron blocks and other extremely hard debris and materials stuck between the rollers, etc.), which in turn causes the output shaft of the reducer to be 'locked'.
(2) Solution to external load jamming: First, disconnect the coupling between the reducer and the ball press host, and manually turn the reducer output shaft. If the manual rotation is smooth and without jamming, it means that the fault is in the external load, and foreign matter between the rollers of the briquetting machine needs to be cleaned or the feeding system needs to be checked.
2. Mechanical connection and installation issues
(1) Mechanical connection and installation problems Causes of failure:
Coupling/key connection failure: The elastic element of the coupling is aged and broken, or the key between the motor shaft and the input shaft of the reducer is severely worn and the keyway is deformed, resulting in the inability to transmit power.
Installation deviation: The installation coaxiality error of the reducer, motor, and load equipment is too large, resulting in uneven force and jamming of the shaft system.
Loose locking ring: The locking ring screw on the planetary reducer flange is loose or pushes against the flange wall, causing the motor shaft to lose connection force or become completely blocked.
(2) Solutions to mechanical connection and installation problems: Check and replace damaged couplings or keys; recalibrate the installation accuracy of the reducer and motor (coaxiality is generally required to be ≤0.1mm); check and retighten the locking ring screws to ensure return.
3. The internal components of the reducer are damaged.
(1) Reasons for damage to internal components of the reducer:
Gear/bearing stuck: Internal gears are severely worn, teeth are broken, or metal debris is stuck between the teeth; bearing balls are broken and cages are broken, resulting in shaft system jamming.
Shaft wear: The mating parts of the reducer input shaft and the hydraulic coupler cause vibration due to long-term high-load operation, clearance fit, or insufficient initial installation accuracy, resulting in serious wear of the keyway and journal.
Poor lubrication: Insufficient, deteriorated or improperly selected lubricating oil leads to dry grinding and jamming of gears and bearings.
(2) Solutions to damage to internal parts of the reducer: disassemble the reducer to inspect the interior, clean foreign matter, and replace broken teeth, severely worn gears, and damaged bearings; if the journal or keyway is worn, professional carbon nanopolymer materials must be used for on-site online repair or shaft replacement. Do not blindly use metal repair agents for emergencies; replenish or replace special lubricating oil that meets the manufacturer's requirements.
4. Abnormality of motor and electrical system
(1) Causes of abnormal faults in motors and electrical systems:
Motor failure: The input motor is overloaded and burned, the winding is short-circuited or the insulation is damaged, resulting in insufficient output torque.
Electrical and control problems: The power supply is missing a phase and the voltage is unstable; the frequency converter acceleration time is set too short or the torque boost is insufficient; the brake is not released normally.
Overload protection: The equipment load exceeds the bearing capacity of the reducer, triggering the overload protection device of the motor or reducer to operate.
(2) Solutions to abnormalities in motors and electrical systems: test the motor without load, measure the insulation resistance and troubleshoot winding faults; check the power supply voltage and inverter parameter settings; confirm that the brake control circuit and mechanical release action are normal; if overloading occurs due to too much material, the load needs to be reduced or the reducer model needs to be replaced with a larger torque.
