What are the specific effects of low oil level in the splash lubrication system of KF47 reducer on the equipment?

When the oil level is 10mm or more below the centerline of the oil level plug, the stirring ability of the gear during rotation is insufficient, and sufficient oil mist coverage and oil flow flushing cannot be formed. The core effects are concentrated in insufficient lubrication and increased component wear, specifically manifested as:

1. Key friction pair lubrication failure, high incidence of wear/bonding faults

Gear meshing surface: When the oil level is too low, the gear teeth cannot be fully immersed in the oil, and the amount of oil mist generated during rotation is greatly reduced, making it difficult to form a continuous and stable oil film on the meshing surface. In the initial stage, there may be slight pitting and scratches on the tooth surface. As the operating time increases, the oil film will completely rupture, and the metal on the tooth surface will come into direct contact, causing adhesion and peeling of the tooth surface. In severe cases, tooth fracture may occur, leading to the failure of the gearbox transmission.

Bearing components: The lubrication of bearing rollers and raceways relies on splashing oil flow erosion. When the oil level is insufficient, there is not enough oil to infiltrate the inner side of the bearing end cover, and the rollers are in a boundary lubrication state. The running resistance increases, and the roller surface will have pitting and peeling. The bearing clearance gradually increases, accompanied by obvious "rustling" abnormal noise, and ultimately the bearing locks up, causing the shaft system to jam.

2. Abnormal increase in operating temperature accelerates the aging of lubricating oil

Insufficient lubrication can lead to a significant increase in mechanical friction resistance of the friction pair, which is converted into a large amount of heat and causes the oil temperature of the gearbox to rise rapidly during operation. The normal operating oil temperature should be ≤ 80 ℃. When the oil level is too low, the oil temperature can rise above 90 ℃, and even exceed 100 ℃.

High temperature will accelerate the oxidation and deterioration of lubricating oil, causing a decrease in viscosity and the failure of additives, further reducing the lubrication effect and forming a vicious cycle of "insufficient lubrication → temperature rise → oil degradation → even less lubrication".

3. Uneven distribution of oil mist, resulting in local lubrication blind spots

The KF87RF57 reducer has multiple gear pairs and bearings inside. When the oil level is too low, the splashing oil mist can only cover the parts near the oil surface, and the high-speed shaft bearings, upper gear meshing surfaces, and other parts far away from the oil surface will become lubrication blind spots. These parts have been in a state of oil shortage for a long time, with a much higher wear rate than other parts, becoming the "weak points" of equipment failure.