Analysis of 4 types of failure phenomena of worm gear reducer

Author: Ever Power Date: 2019-01-26 Source: Attention:

Analysis of 4 types of failure phenomena of worm gear reducer

Worm gear reducer is a common mechanical transmission mechanism, which is widely used in mechanical transmission systems in various industries.Our company (EVER-POWER GROUP CO., LTD) is a technology company specializing in the research and development, manufacturing, sales and service of barrier motors, telescopic door opening motors, motors, reducers, and screw lifts. If you want to consult us, please contact us directly,Contact number: +39 05221606388( ） manager, Now I share with you the common faults and maintenance precautions of the worm gear reducer.

XNUMX. The role of worm gear reducer:

The application of worm gear reducer in the traditional mechanical system mainly has the following functions:
First of all, the rotary reducer can increase the output torque of the system after deceleration, and the torque output is proportional to the deceleration of the motor or hydraulic motor. It should be noted that the torque output cannot exceed the rated torque of the reducer.
Secondly, it can effectively reduce the inertia of the load while decelerating, and the reduction of inertia is the square of the reduction ratio.
Finally, the reducer can change the output direction of the torque, so that the output torque and the input torque are distributed vertically.

XNUMX. Common faults and solutions of worm gear reducer
Reducer heat and oil leakage failure:
Most of the rotary reducer worm wheels use tooth surface quenching or high-hardness steel as raw materials, which is to improve the operating efficiency and wear resistance of the reducer. However, because the transmission mode of the rotary reducer is friction transmission, A lot of heat will be generated during operation, and the temperature will increase quickly. Over time, the heat will generate a certain amount of heat expansion between the parts of the reducer and the seal, which will cause gaps on the surface of the reducer parts and increase the temperature of the grease. Dense reduction, after long-term use, it is easy to cause oil leakage and serious tooth surface wear of the reducer, which will cause jitter or abnormal noise.

Therefore, by analyzing the accident, we conclude that the main causes of the accident are as follows:
First, the application and collocation of reducer materials are unreasonable.
Second, the process quality of the meshing tooth surface is unqualified.
Third, the selected grease is unreasonable.
Fourth, factors related to equipment assembly quality and operating environment.

Therefore, the processing and material selection of parts should be strictly controlled; during the assembly of the rotary reducer or the replacement of parts, avoid violently knocking with tools such as hammers, and use original bearings, oil seals and other accessories to replace; Use suitable grease to protect the worm in the housing cavity to avoid wear or rust on the tooth surface.

Worm gear wear phenomenon:
The processing material of the worm gear is generally S48C, and the worm material matched with it is generally selected from 42CrMo steel hardened to HRC45-55, or 40Cr hardened HRC50-55, and then ground by a worm grinder to make Its roughness reaches Ra0.8. During the operation of the rotary reducer, the worm will grind the worm wheel like a "file". Generally, this degree of wear is slow. Under normal circumstances, the life of the reducer can reach over 3 years.

If it is found that the worm gear wears abnormally and wears quickly, you can consider whether the selection of the rotary reducer is wrong, or whether it is overloaded for a long time, there are factors such as heavy load, high speed and harsh operating environment.

Under normal circumstances, the corresponding lubrication method should be selected according to the actual working conditions of the reducer. If the operating environment of the reducer is complex and harsh, some grease additives should be appropriately added to protect the normal operation and service life of the gear.

Worm bearing damage:
When the reducer has a mechanical failure, although the seal of the reducer does not have a problem, the gear grease in the reducer is still emulsified, and the bearing is rusted and damaged.
The main reason is that during the process of the reducer from normal operation to shutdown, the temperature of the gear grease is caused by the condensation of moisture after the heat becomes cold.In addition, it has a certain relationship with the quality of the bearing itself and the assembly process.Therefore, in order to prevent the occurrence of the above failures, enterprises should establish a sound lubrication maintenance system to effectively ensure the normal operation of the reducer.

Helical gear wear:
The wear of the drive helical gear generally occurs on the horizontally installed reducer. The cause of wear is mainly related to the selection and amount of grease added.In the process of installation, it is easy to cause insufficient lubrication. In addition, when the reducer has been working for a long time, the grease is lost from the transmission gear under the action of squeezing, and the gear loses the lubrication protection function of the grease. It will increase friction and cause mechanical wear or damage.Therefore, when installing the horizontal reducer, adequate grease should be installed.

Maintenance of worm gear reducer
1. Do daily maintenance work.
Keep the equipment and surrounding areas clean and free of water and grease; always pay attention to whether the reducer has abnormal noise during operation; check for abnormal jitter and whether the temperature meets the requirements; pay attention to the upper and lower joint surfaces of the reducer and Whether there is oil leakage at the shaft end, if there is leakage, eliminate it in time; check the oil level at the specified position through an oil dipstick or oil face mirror.

2 Make a periodic maintenance plan.
Set up a reasonable periodic maintenance plan according to the operating conditions of the equipment. Generally, minor repairs are performed every 3-5 months, and large and medium repairs are performed every 6-12 months.
Minor repairs: tighten the loose bolts; check and replace the vulnerable parts on the coupling; eliminate oil leakage or less grease, adjust the tooth surface clearance of the drive shaft; repair the safety protection device.

Intermediate repair: check, repair or replace worn driving gears or worms; check and replace rolling bearings and repair oil baffle plates; clean shells, replace or fill grease; measure tooth surface meshing clearance, repair gear tooth surfaces and shafts.

Overhaul: check, repair or replace the driven gear or shaft; repair the worn bearing seat; repair and scrape the joint surface of the upper and lower housing or replace the housing.