How to improve the accuracy of bearing inspection for CJY160-140-4KW gear reducer
Method for improving the accuracy of bearing inspection for CJY160-140-4KW gear reducer
1. Clarify the bearing configuration and damage characteristics
The CJY160-140-4KW reducer usually adopts a conical cylindrical gear structure, and the noise characteristics of bearing damage are related to the position:
High speed bearings (such as deep groove ball bearings): prone to high-frequency "sizzling noise" (2000-3000Hz), significant noise during no-load operation, and vibration values ≥ 1.2mm/s ².
Low speed bearings (such as cylindrical roller bearings): may be accompanied by periodic "clattering" or whistling sounds (4000-6000Hz), and the damage frequency needs to be located through spectral analysis.
2. Standardize the inspection process
Daily inspection:
Before starting, manually turn the wheel to confirm that there is no jamming or abnormal noise.
Monitor vibration (amplitude ≤ 0.05mm) and temperature (shell surface ≤ 70 ℃) during operation.
Regular inspection (every 3000-5000 hours):
Disassemble and inspect the meshing status of the gears, and check for pitting or wear on the tooth surface (if the tooth thickness is reduced by more than 10%, it needs to be replaced).
Measure the bearing clearance (if the bearing clearance of NU2220 exceeds 0.05mm, it needs to be replaced).
3. Use professional testing tools
Vibration analyzer: Identify high-frequency noise (2000-8000Hz) and abnormal spectral peaks.
Sound level meter: Distinguish between gear noise (500-1500Hz) and bearing damage noise.
Vernier caliper/micrometer: measure the depth of wear grooves on the raceway (if it exceeds the nominal size by 15%, it needs to be replaced).
4. Lubrication and maintenance optimization
Lubrication cycle: Change the oil every 2000-3000 hours under normal working conditions, and shorten it to 1000-1500 hours in harsh environments.
Oil selection: Use ISO VG 150-460 extreme pressure gear oil to avoid mixing different brands.
Sealing inspection: Replace the shaft end oil seal every 10000 hours to prevent bearing wear caused by contamination.
5. Data recording and trend analysis
Establish a bearing life record and compare the trends of vibration and temperature data changes.
When the continuous operation exceeds 180000 hours or the vibration spectrum shows peak values exceeding the limit, the bearing shall be forcibly replaced.
6. Environment and operating standards
During maintenance, the environmental humidity should be below RH85% to avoid bearing moisture.
Tighten the bolts in diagonal order (e.g. M8 bolts with a torque of 20-25N · m) to prevent coaxiality deviation.
The above methods can significantly improve the accuracy of bearing inspection and reduce the risk of unplanned downtime.
