1. Motor-related faults
The motor is the power source of the transmission system, and common faults include:
1. Motor overheating
Reason: excessive load (such as too much material, cylinder jamming); poor motor heat dissipation (fan damage, vent blockage); abnormal power supply voltage (too high or too low); motor bearing wear or poor lubrication.
Performance: The motor housing temperature exceeds the rated value (usually ≤65℃), which may be accompanied by abnormal noise or tripping.
2. Motor vibration or abnormal noise
Reason: loose motor anchor bolts; rotor imbalance (such as winding failure causing center of gravity offset); bearing damage; excessive deviation from the coupling of the reducer.
2. Reducer failure
The reducer reduces the motor speed to the required speed of the cylinder, and is a high-incidence component:
1. Reducer oil leakage
Reason: aging of seals (such as oil seals and gasket wear); loose bolts on the joint surface of the box; excessive oil level leads to pressure leakage; cracks in the reducer housing (very rare, mostly due to installation stress or material problems).
2. Abnormal noise or vibration of reducer
Reasons: poor gear meshing (such as tooth surface wear, pitting, broken teeth, mostly due to insufficient lubrication or assembly deviation); bearing damage (rolling element or cage wear); input/output shaft alignment error is too large; internal foreign matter (such as metal debris).
3. Reducer oil temperature is too high
Reasons: insufficient lubricating oil, inconsistent model or deterioration; gear/bearing wear leads to increased friction; cooling fan failure or heat sink blockage.
3. Coupling failure
The coupling connects the motor and reducer, and the reducer and the barrel (or pinion shaft), and is responsible for transmitting torque:
1. Coupling offset or looseness
Reasons: inaccurate alignment during installation (excessive radial or axial deviation); loose bolts after long-term operation; aging and failure of elastic elements (such as elastic pins, diaphragms).
Influence: leads to additional torque, aggravated bearing and gear wear, and causes vibration and abnormal noise.
2. Elastic element damage
Reason: elastic pin (nylon material) wear, break (due to impact load or over-tight installation); metal diaphragm of diaphragm coupling fatigue cracking (due to frequent start and stop or overload).
4. Gear transmission failure (edge drive ball mill)
The edge drive ball mill is driven by meshing with the large gear on the cylinder through the small gear (motor side). Common faults:
1. Gear meshing abnormal sound or vibration
Reason: uneven wear of tooth surface (such as unilateral wear, because the two gear axes are not parallel during installation); adhesion and pitting of tooth surface (poor lubrication or poor oil quality); excessive gear clearance (caused by long-term wear).
2. Gear broken teeth
Reason: instantaneous overload (such as cylinder jamming); stress concentration at the root of the tooth (processing defects or fatigue crack extension); unqualified gear material.
3. Poor gear lubrication
Performance: scratches and bonding on the tooth surface, mostly due to insufficient lubricating oil injection (oil pump failure), oil pollution or wrong selection (such as viscosity mismatch).
5. Bearing failure
The bearings in the transmission system (such as motor bearings, reducer bearings, and pinion shaft bearings) bear radial and axial loads, and the consequences of failure are serious:
1. Bearing overheating
Reason: insufficient grease, deterioration or wrong model; too tight installation (too small clearance); poor fit between the bearing seat and the shaft (interference or too large clearance).
2. Bearing abnormal noise or vibration
Reason: wear of rolling element, raceway or cage (metal friction sound); impurities mixed in the bearing (particle impact sound); looseness of the outer ring of the bearing and the bearing seat (radial movement).
3. Bearing stuck
In extreme cases, long-term overheating often causes the roller to stick to the raceway, or foreign matter to get stuck, which may cause the shaft to break or the motor to burn.
6. Coupling alignment deviation
If the axis of the motor, reducer, and barrel (or pinion shaft) is not strictly aligned (parallel or concentric), it will lead to:
Premature damage of the coupling elastic element;
Bearings and gears bear additional radial forces, which aggravates wear;
Increase in overall vibration of the equipment, and even cause the anchor bolts to break.
