What impact will increased equipment wear have on the service life of the ZL115-7.1 reducer?

ZL115-7.1 belongs to cylindrical gear reducers, which are commonly used in heavy-duty transmission scenarios such as metallurgy, building materials, and mining. Its core transmission components include gear pairs, bearings, shafts, and seals. Increased equipment wear can directly damage the accuracy of component coordination, lubrication status, and force balance, gradually triggering a chain reaction from local failures and significantly shortening the service life of the entire machine. The specific impacts are as follows:

1. The wear of the gear pair intensifies, directly causing the failure of the core transmission

After the gear tooth surface wear (such as abrasive wear, fatigue wear, and adhesive wear) intensifies, the tooth surface roughness increases, and the meshing clearance far exceeds the design value, resulting in an increase in impact load during gear transmission, and a sharp increase in tooth surface contact stress and tooth root bending stress. In the initial stage, there is an increase in operating noise and vibration. In the middle stage, there may be pitting, peeling, and thinning of the tooth surface. When the wear of the tooth thickness exceeds 5% to 8% of the original tooth thickness, the stability of the gear meshing is completely lost, which can easily lead to fatal faults such as tooth root fracture. Under normal operating conditions, the design life of the ZL115-7.1 reducer gear pair can reach 10000-15000 hours. However, with increased wear and tear, the life will be reduced to 30% -50% of the original design, and may even be scrapped in a short period of time.

2. Accelerated bearing wear and tear, damaging the overall operational accuracy of the machine

The increased wear of bearing raceways and balls (rollers) can lead to excessive radial and axial clearances of the bearings, resulting in a significant decrease in the rotational accuracy of the bearings during operation and an inability to effectively support the stable operation of the shaft system. On the one hand, bearing wear can cause eccentric swinging at the shaft end, further amplifying the misalignment deviation of gear meshing and forming a vicious cycle of "wear deviation more severe wear"; On the other hand, the increased running resistance and significant increase in friction temperature of the worn bearings will accelerate the aging and deterioration of the lubricating grease, leading to dry friction in the bearings and ultimately causing them to lock up and burn out. As a key supporting component of the gearbox, bearings usually have a normal lifespan that is synchronized with the overall lifespan of the machine. However, with increased wear, the lifespan of bearings can be shortened to 20% to 40% of the original design. If bearings fail and are not replaced in a timely manner, it can also damage related components such as the journal and bearing seat.

3. Wear and tear of shaft components, damaging the assembly relationship of components

The increased wear of the journal of the input shaft and output shaft can lead to excessive clearance between the shaft, oil seal, and bearing, which not only causes oil leakage at the shaft end, but also causes axial displacement and radial jumping of the shaft during operation, damaging the meshing position accuracy of the gear pair. If the wear of the shaft neck is accompanied by rust and pitting, it can also lead to a decrease in the strength of the shaft, and under heavy load conditions, it is easy to cause deformation of the shaft neck or even fracture of the shaft body. Shaft components are the core load-bearing components of reducers, requiring high machining accuracy and difficult to repair after wear. Once severe wear occurs, the entire shaft often needs to be replaced. However, shaft failures can cause a long maintenance cycle and significantly increase maintenance costs, indirectly shortening the effective service life of the entire machine.