Motor failure
Motor overheating
Cause: Motor overload is one of the common causes of motor overheating.
When the weight of the billet transported by the hot delivery roller exceeds the motor’s designed load capacity, or the roller encounters greater resistance during operation, such as billet jamming, roller bearing damage, etc., the motor will be forced to work overload, thereby generating excessive heat.
In addition, poor heat dissipation of the motor can also cause overheating. If the motor’s vents are blocked by dust or debris, or the ambient temperature around the motor is too high, the heat cannot be dissipated in time, and the motor temperature will continue to rise.
Impact: Overheating of the motor will reduce the insulation performance of the motor winding. Long-term overheating may cause the winding to short-circuit, and in severe cases, the motor may even burn out.
At the same time, overheating of the motor will also cause the output power of the motor to decrease, slow down the speed of the roller, and affect the conveying efficiency of the ingot.
Abnormal motor vibration and noise
Cause: Damage to the motor bearing is one of the main causes of vibration and abnormal noise.
During the long-term operation of the bearing, due to factors such as wear and poor lubrication, the matching accuracy between the ball and the inner and outer rings is reduced, resulting in excessive clearance and rough surface.
In addition, the imbalance of the motor rotor can also cause vibration and noise. For example, during the installation of the motor, if the rotor is not installed properly, or the motor is impacted by external force during operation, causing the rotor to deform, imbalance will occur.
Impact: Abnormal vibration and noise will not only affect the working environment, but also accelerate the damage of other parts of the motor. Long-term vibration may loosen the motor wiring, causing electrical failures; at the same time, it will also increase the wear between the motor and other connected parts, reducing the service life of the equipment.
Motor electrical fault
Cause: The motor winding may have electrical faults such as short circuit, open circuit or grounding.
Short circuit may be caused by insulation damage due to overheating of the motor, dampness of the winding or overvoltage shock during operation. Open circuit is usually caused by loose connection points of the winding, poor welding or damage to the winding by external force. Grounding fault is caused by insulation damage of the motor, which makes the winding conductive to the motor housing.
Impact: These electrical faults can cause the motor to not work properly. A short circuit fault may cause the motor to have an excessively large instantaneous current, burning out the fuse or even the motor itself; an open circuit fault may cause the motor to fail to start or suddenly stop during operation; a ground fault may cause an electric shock accident and also affect the normal operation of the motor.
Reducer failure
Reducer oil leakage
Cause: Aging or damage of the reducer’s oil seal is a common cause of oil leakage.
During long-term use, the oil seal will be affected by factors such as lubricating oil immersion, temperature changes, and mechanical vibration. The rubber oil seal will gradually lose its elasticity, crack or break, resulting in lubricating oil leakage.
In addition, the loose sealing of the reducer’s housing joint surface can also cause oil leakage. If the connecting bolts of the housing are loose or the sealing gasket on the joint surface is damaged, the lubricating oil will seep out from the gap.
Impact: Oil leakage in the reducer will reduce the amount of lubricating oil, affecting the lubrication effect of gears and bearings. If not handled in time, it will accelerate the wear of gears and bearings and even cause reducer failure. At the same time, oil leakage will pollute the working environment and increase safety hazards, such as slip accidents.
Gear wear and tooth scuffing
Cause: Gears will gradually wear out during long-term operation due to factors such as friction between tooth surfaces and impact loads.
If lubrication is poor, the oil film between tooth surfaces cannot be effectively formed, and wear will increase. In addition, when the pressure between tooth surfaces is too large, the speed is too high, and the lubrication conditions are poor, the local temperature between tooth surfaces will rise sharply, resulting in direct contact between tooth surface metals and bonding.
Impact: Gear wear will increase the tooth side clearance, affecting transmission accuracy and efficiency.
Severe wear will cause gear failure and make the reducer unable to work properly. Tooth surface bonding will cause adhesion, tearing and other damage to the tooth surface, which will also affect the normal operation of the reducer and is difficult to repair.
Abnormal noise and vibration of reducer
Cause: In addition to gear wear and bonding that can cause abnormal noise and vibration, bearing damage in the reducer is also an important reason.
When the bearing is damaged, abnormal friction and collision will occur between the rolling element and the inner and outer rings, resulting in vibration and noise. In addition, factors such as the loose installation foundation of the reducer, loose anchor bolts, or poor coaxiality between the input and output shafts and external equipment can also cause vibration and abnormal noise.
Impact: Abnormal noise and vibration will accelerate the damage of the internal components of the reducer, and will also be transmitted to other components of the hot delivery roller, affecting the stability and service life of the entire system.
Coupling failure
Coupling wear and damage
Reason: The coupling will be affected by torque, vibration, impact and other factors in the process of connecting the motor, reducer and roller.
If the coupling is not selected properly, its load capacity is lower than the actual working torque, which will cause excessive wear of the coupling. In addition, the elastic elements of the coupling (such as rubber pads, elastic sleeves, etc.) will be damaged due to fatigue, aging and other reasons during long-term use.
Impact: Wear or damage to the coupling will lead to decreased transmission efficiency and unstable power transmission.
For example, when the elastic element of the coupling is damaged, the connection between the motor and the reducer will become loose and slip, making the roller speed unstable and affecting the delivery of the ingot. Severe damage to the coupling will also cause power interruption and stop the hot delivery roller from working.
