Smoking in gear reducers' generators is often attributed to high temperatures, leading to overheating and subsequent smoking. However, sometimes smoking in gear reducers is not caused by high temperatures and includes other reasons. What could be the cause of smoking in gear reducers that is not due to high temperatures?
Low motor voltage or overload; voltage can be measured with a multimeter. Overload may be caused by a jammed machine structure or poor lubrication of the reducer. Overload can be checked with a clamp meter. Excessive motor temperature is likely due to poor ventilation or excessive exposure to sunlight. Check if the motor fan is damaged or loosely mounted, and be mindful of any objects affecting ventilation; they should be removed promptly to avoid temperature increase. The measurement method is through daily experience.
Excessive motor voltage or incorrect wiring can occur. If the voltage is too high, efforts should be made to appropriately lower it before checking for wiring issues.
Once a broken wire is confirmed, the motor's rotor should be replaced to prevent other issues. If smoking has occurred, it's necessary to inspect other components for potential problems. If there are frequent reversals or excessive startups, it's advisable to reduce the motor's reversal or startup frequency, or switch to a different type of motor to minimize generator damage. If the starting current is too high, increase star-delta startup or install a soft-start protector, even a variable frequency controller.
The motor stator winding of the gear reducer has minor short circuits or localized grounding. Locate the grounding points using a test lamp or megohmmeter, insulate them properly, and then apply and dry the insulating paint.
When the motor is powered on, the starting winding and starting capacitor are connected in parallel in the circuit to enable the motor to start at a low speed. Once the motor's speed reaches three-quarters of its normal speed, the centrifugal switch is activated and released, the starting winding is disconnected, the running winding takes over, and the motor starts up fully. The smoking of the gear reducer may be caused by the above reasons.