The difference in lubrication methods between hard-tooth surface reducers and soft-tooth surface reducers directly affects the maintenance frequency, failure rate and service life of the equipment. Hard-tooth surface reducers have higher performance requirements for lubricants, requiring the use of gear oil with high viscosity, containing extreme pressure and anti-wear additives, and stricter maintenance cycles; while soft-tooth surface reducers have relatively low lubrication requirements and can use mineral oil-based lubricants, which are easier to maintain but have weak impact resistance. This difference determines that the maintenance strategies of the two types of equipment should be different in actual operation.
1. The impact of differences in lubrication methods on maintenance
1. Lubricating oil Selection has different requirements
Hard tooth surface reducer : The tooth surface has high hardness and requires extremely high lubricating film strength. High viscosity industrial gear oil must be selected and contain sulfur-phosphorus extreme pressure additives to prevent tooth surface gluing or pitting under high load.
Soft tooth surface reducer : Generally, medium load gear oil (CKC) can be used. It has low requirements for extreme pressure performance, low maintenance cost, and strong oil versatility.
2. Oil change intervals and maintenance frequencies are different
(1) Hard tooth surface reducer:
The lubricating oil must be replaced 100 to 200 hours after the first operation of a new machine (metal debris contaminates the oil during the running-in period).
Under normal working conditions, replace it every 6 months to 1 year; in dusty and high-temperature environments, it should be shortened to 3 to 6 months.
It is recommended to take samples regularly to check the oil quality. If the concentration of iron filings exceeds 50ppm, it indicates abnormal wear.
(2) Soft tooth surface reducer:
It is recommended that the first oil change be performed after 300 to 500 hours of operation.
It will be replaced every 1 to 2 years, depending on the load.
Pay more attention to oil level inspection to prevent dry friction caused by lack of oil.
3. Typical failures caused by poor lubrication are different
Hard tooth surface : prone to pitting, peeling, gluing, and broken teeth, which is a catastrophic failure
Soft tooth surface: The soft tooth surface is not lubricated in place: mainly due to wear, louder noise, and slower failure.
2. Key operational suggestions in daily maintenance
1. Maintenance points of hard tooth surface reducer
Regularly monitor oil temperature and vibration: Abnormal temperature rise or vibration is often a precursor to internal wear, and the machine should be shut down in time for investigation.
Keep it clean and prevent contaminants from intruding: Use compressed air to clean the casing and heat sink every week to avoid dust entering the box and causing oil contamination.
Standardize the oil change process: Drain the old oil completely, flush the inside with new oil if necessary, and then refill it to the center line of the oil level mirror.
Enhanced lubrication under extreme working conditions: Use high viscosity index oil for high temperature environments; solid lubricants such as molybdenum disulfide can be added for low speed and heavy loads.
2. Maintenance points of soft tooth surface reducer
Strictly prevent overload operation: Strictly control within the rated load range to avoid tooth root breakage caused by impact loads.
Enhance anti-rust treatment: In a high-humidity environment, check whether the seals are aging after cleaning, and replace the oil seal if necessary.
Check the oil level and lubrication status regularly: Ensure that the gear surface is always covered with an oil film to avoid dry operation.
