Practical skills and methods for solving the problem of low efficiency of gearbox motors

The motor in the reducer, as the core power source of industrial production, often experiences frequent failures or efficiency decreases due to "overload" operation, that is, the motor in the reducer is overloaded. This will weaken the motor efficiency in the gearbox, shorten its service life, and even cause production interruptions.

Regular maintenance: The constant tooth reducer made of high-quality materials has high gear accuracy and wear resistance. By regularly checking the wear of gears and replacing them in a timely manner, while ensuring sufficient lubricating oil, the reducer can operate smoothly, reduce the burden on the motor, and effectively prevent overload.

Optimizing the environment: The constant gear reducer is equipped with an efficient heat dissipation system and good ventilation device, which can significantly reduce the working temperature and create a suitable operating environment for the motor. This not only extends the lifespan of the motor, but also improves work efficiency.

Gear reducer processing box factory building

Accurate matching: Based on customer needs and actual load conditions, Zhejiang Hengchi provides professional selection services to ensure perfect matching of motor and reducer models. Reasonable selection fundamentally avoids overload and ensures stable system operation.

1、 Optimize mechanical coordination and reduce mechanical losses
Mechanical losses (such as friction and meshing losses) are one of the core reasons for low efficiency, and need to be optimized from two aspects: structural fit and component status:

1. Calibrate the "centering" accuracy of the transmission system
The installation alignment deviation of reducers, motors, and load equipment (including radial deviation, axial deviation, and angular deviation) is a common cause of additional mechanical losses. Excessive deviation can cause additional stress on gears and bearings, increase frictional resistance, and reduce efficiency by 5% -15%.

Optimize lubrication system to reduce friction losses
Poor lubrication is a hidden killer of mechanical wear and tear, which needs to be controlled from three aspects: lubricant selection, filling amount, and replacement cycle:

1. Accurately select lubricants
Different types of lubricants need to be matched for different operating conditions (load, speed, temperature):

Low speed heavy load (speed<1000r/min, load>70% of rated value): choose high viscosity gear oil (such as 220 #, 320 #) or extreme pressure lithium grease (EP2 grade) to enhance oil film strength;

High speed light load (speed>3000r/min, load<50% of rated value): choose low viscosity gear oil (such as 68 #, 100 #) to reduce viscous resistance;

High temperature environment (ambient temperature>40 ℃): Choose synthetic lubricants (such as poly alpha olefin oil), which have better high temperature resistance than mineral oils, to avoid friction intensification caused by lubricant failure.

Match load and equipment selection to avoid "big horse pulling small car"
If the rated parameters of the motor and reducer do not match the actual load, the efficiency will significantly decrease (such as when the load is less than 30% of the rated value, the motor efficiency can be as low as 50% or less).

1. Re calculate the load and optimize the selection
Measure the actual load (including peak load and average load) with a torque sensor to ensure that the rated power of the equipment is 1.1-1.3 times the actual average load (avoiding overload and reducing redundancy);

If the load fluctuates greatly (such as intermittent operation), priority should be given to selecting a gearbox motor combination that is adapted to "variable torque" (such as a cycloidal pinwheel gearbox+variable frequency motor), rather than traditional fixed speed equipment.

2. Adopting variable speed drive technology to adapt to dynamic loads
For scenarios where the load varies with working conditions (such as conveyor belts and mixing equipment), install a frequency converter or servo system to match the load requirements by adjusting the motor speed:

For example, when the load drops to 50% of the rated value, by using frequency conversion to reduce the speed to 70% of the rated speed, the motor efficiency can be increased from 60% to over 85% (in line with the characteristic of the motor that "speed is proportional to the square of the load");

Attention: The reducer needs to be adapted to a variable frequency motor (such as adding a cooling fan) to avoid insufficient heat dissipation during low-speed operation.