[Case Sharing] Detailed Analysis of 6 Reducer Repair Cases

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I. Wear of the reducer bearing chamber: When wear occurs in the reducer’s bearing chamber, traditional methods are inadequate for resolving the issue on-site; external repair services are required, which entails a long period of downtime and results in the waste of the company’s valuable production time. Moreover, metal is used to repair metal, and it is not possible to change the \"hard-on-hard\" fitting; under the combined action of various forces, wear will still occur. The following case demonstrates the use of polymer composite materials for repair. These materials possess exceptional adhesion strength as well as excellent compressive strength and other advantageous properties. By using polymer composite materials, it is possible to repair wear in bearing housings quickly and effectively, without the need for disassembly or machining. There is no effect from the thermal stress associated with patch welding, and there are no limits on the repair thickness. Additionally, the product possesses a ductility that metal materials lack, allowing it to absorb impacts and vibrations from equipment and thus preventing further wear. 1. Wear of the bearing housing in the 40 reducer casing. 2. Repair of wear in the bearing chamber of the inner hole of the coal miner’s reducer casing. 3. Wear of the bearing chamber of the first shaft in the gearbox of the SGD630/220 (264) single-chain scraper conveyor. II. Wear of the shaft diameter of the reducer gear shafts (damage to keyways). During long-term operation, the shaft ends of reducers often suffer from wear and damage to keyways; once such problems occur, traditional methods are insufficient for on-site resolution, and external repair services are necessary ； Moreover, metal is used to repair metal, and it is not possible to change the \"hard-on-hard\" fitting; under the combined action of various forces, wear will still occur. III. On-site repair of wear at the bearing positions of the reducer’s drive shaft: When wear occurs at the bearing positions of the reducer’s gear shaft, traditional methods involve welding or brush plating followed by machining to carry out repairs. However, the thermal stress generated by the welding at high temperatures cannot be completely eliminated, resulting in fractures during operation ； Brush plating is limited by coating thickness and tends to peel off easily ； Moreover, all the above methods involve using metal to repair metal, and they cannot change the \"hard-on-hard\" fitting relationship; under the combined action of various forces, wear will still occur. IV. Leakage at the joints of the reducer: During long-term operation, due to factors such as vibration, wear, pressure, temperature, and repeated disassembly and assembly, oil leakage from the static sealing parts at various joints is a very common phenomenon. This not only leads to significant waste of oil but also affects the on-site management of the enterprise. Traditional maintenance methods require disassembling and opening the reducer in order to replace the sealing gaskets or apply sealant; this is not only time-consuming and labor-intensive, but it also makes it difficult to ensure a proper seal, leading to leaks again during operation.