How to adjust the daily inspection and maintenance cycle of ZSY reducer under humid conditions?
1、 Daily inspection adjustment (daily/shift)
Daily inspections should focus on "waterproofing, anti emulsification" and checking the basic operating status:
Oil level and quality monitoring: Check the lubricating oil status daily through the oil level window. If the oil is found to be cloudy, white (emulsified), or the oil level is abnormally high, it indicates that the box may have been mixed with water, and the machine should be stopped immediately to replace the gear oil and check the seal.
Appearance and sealing inspection: Focus on checking whether there are signs of oil or moisture infiltration on the sealing surfaces of the gearbox housing, end cover, junction box, etc., to ensure that the sealing cover of the junction box is tightened and prevent water vapor from entering the motor wiring terminals.
Operation status check: Confirm whether the operating temperature is normal (normal oil temperature should be ≤ 80 ℃) by touching the shell (non high temperature area) or using an infrared thermometer; At the same time, pay attention to the running sound and check for sharp abnormal noises or vibrations caused by poor lubrication.
2、 Regular maintenance cycle adjustment (shortening lubrication and maintenance intervals)
The humid environment will accelerate the deterioration of lubricating oil and the loss of grease, and it is necessary to significantly shorten the original maintenance cycle:
Gear oil replacement: Under normal circumstances, gear oil is usually replaced every 6000-8000 hours; But in humid conditions, the oil change cycle should be shortened to 3000-4000 hours (or about every 3 months). Before each oil change, it is necessary to thoroughly drain the old oil and flush the inside of the box with new oil to remove residual emulsified oil and rust.
Lubricating grease replenishment for bearings: Lubricating grease should be replenished every 2000-3000 hours under normal conditions, and shortened to every 1000-1500 hours under humid conditions. In addition, a thorough replacement should be carried out after every 3 supplements to avoid the mixing of new and old oils affecting the water resistance performance.
Fastener and seal inspection: Key fasteners such as box connection bolts and bearing end cap bolts need to be inspected and tightened in diagonal order every month. It is recommended to replace the skeleton oil seal every 6000 hours. During installation, make sure that the lip faces the inside of the box to enhance the waterproof sealing effect.
3、 Metal rust prevention and electrical protection
External rust prevention treatment: For exposed metal parts such as motor anchor bolts, gearbox observation window bolts, shaft extension key slots, etc., rust proof grease or paint should be applied regularly every 2-3 months. If rust has been found, it needs to be thoroughly removed before protective treatment.
Electrical moisture-proof insulation: The junction box should be opened every quarter, and the moisture on the terminal block should be wiped with a dry cloth, and moisture-proof insulation grease should be reapplied. If the insulation resistance of the winding is detected to be low, the hot air drying method (blowing the shell with hot air at 50-60 ℃ for 2-4 hours) or low-voltage drying method can be used to remove moisture. After drying, the insulation resistance needs to be retested until it is qualified.
