In addition to gears, bearings, lubrication, motors, installation and foundation problems, SEW reducer abnormal noise may also have other causes of failure. For different faults, corresponding solutions need to be taken, as follows:
Gear problem
Cause of failure: wear, damage or poor meshing of the gear. Long-term use, excessive load, poor lubrication, etc. will cause wear of the gear tooth surface, resulting in decreased meshing accuracy and abnormal noise; poor gear material quality, impact load or fatigue stress, cracks, broken teeth may occur, destroying normal meshing and causing abnormal noise; insufficient installation accuracy and deformation of the gear shaft will cause uneven gear meshing clearance or incorrect position, resulting in abnormal noise caused by abnormal friction and collision.
Solution: For worn gears, if the wear is light, you can slow down the wear by adjusting the load and improving lubrication; if the wear is serious, a new gear needs to be replaced. For damaged gears, if cracks or broken teeth appear, they must be replaced in time. It is necessary to ensure that the materials and specifications of the new gear are consistent with the original gear. In case of poor meshing, the installation accuracy needs to be readjusted and the gear shaft must be corrected so that the gear meshing clearance and position meet the requirements.
Bearing problems
Cause of failure: Bearing worn or damaged. Long-term operation will cause the balls, raceways and other parts of the bearing to wear, increase the play, causing vibration and abnormal noise, which will be more obvious when running at high speed; bearing quality problems, insufficient lubrication, overload or improper installation may lead to the bearing balls breaking, cage damage, etc., causing the bearing to lose its normal function and produce severe abnormal noise.
Solution: Check the wear of the bearing regularly and replace it in time for bearings with severe wear. When replacing, choose bearings with reliable quality and appropriate specifications, and ensure correct installation and good lubrication.
Lubrication issues
Cause of failure: insufficient lubricating oil or deterioration. Insufficient amount of lubricating oil will cause dry or semi-dry friction between gears and bearings, causing abnormal noise and aggravation of wear; after long-term use, the lubricating oil will deteriorate due to oxidation, pollution, etc., and the lubricating performance will be degraded, and a good oil film will not be formed, resulting in increased friction and abnormal noise, and impurities in the oil will also aggravate the wear of the component.
Solution: Check the amount of lubricating oil regularly and replenish it in time when it is insufficient. Change the lubricant regularly according to the equipment usage requirements, and thoroughly clean the inside of the reducer when changing the oil to prevent impurities from remaining.
Motor problems
Cause of fault: The reducer and the motor are not connected firmly. If the connection bolts are loose or the coupling is installed improperly, the transmission will be out of synchronization, resulting in vibration and abnormal noise, and the abnormal noise will change with the motor running state; failures such as motor imbalance and winding short circuit will lead to unstable output torque, causing abnormal vibration and abnormal noise of the reducer.
Solution: Check and tighten the connection bolts between the motor and reducer, and readjust the installation of the coupling to ensure that the two are connected firmly and the transmission is synchronized. A comprehensive inspection of the motor is carried out. If the motor is found to be unbalanced, dynamic balance debugging is required; if there are electrical faults such as winding short circuits, the motor should be repaired or replaced in time.
Installation and basic issues
Cause of the fault: The installation position of the reducer is inaccurate, such as the level does not meet the requirements, and the connection of different shafts from other equipment, which will cause the reducer to bear additional force during operation and produce abnormal noise; the installation foundation is not solid, such as uneven settlement of the foundation and loose anchor bolts, which will cause vibration during operation and cause abnormal noise.
Solution: Re-adjust the installation position of the reducer, use tools such as level to ensure its level, and ensure that it is connected to other equipment by means of coupling alignment. Check and reinforce the installation foundation of the reducer, repair the uneven settlement foundation, and tighten the anchor bolts.
