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Analysis of common problems of worm gear reducer
Aug 18, 2018

      Worm gear reducer is a kind of transmission machine with compact structure, high transmission ratio and self-locking function under certain conditions. It is one of the commonly used reducers. Hollow shaft worm gear reducer not only has the above characteristics, but also is easy to install and has a reasonable structure. It is more and more widely used. A helical gear reducer is added to the input end of the worm gear reducer of the hollow shaft type worm gear reducer. The multi-stage reducer can obtain very low output speed. It is a combination of helical gear stage and worm gear stage and has higher efficiency than the single-stage worm gear reducer. Moreover, the vibration is small, the noise is low, and the energy consumption is low.


       Common problems and their causes: 

      1.Reducer heating and oil leakage. In order to improve efficiency, non-ferrous metals are generally used as worm gears, and harder steel is used for worm gears. Because it is sliding friction transmission, higher heat will be produced during operation, so that the thermal expansion of the parts and seals of the reducer will be different, resulting in clearances in various mating surfaces, and oil Thinning due to rising temperature is easy to cause leakage. There are four main reasons. One is whether the material matching is reasonable, the other is the surface quality of meshing friction surface, the third is the choice of lubricating oil, whether the addition is correct, the fourth is the assembly quality and the use environment.

        2.Worm wheel wear. The worm gear is generally made of tin bronze. The matching worm material is usually hardened with 45 steel to HRC45-55. The hardened HRC50-55 is also commonly used 40C: hardened. The roughness RaO.8 FCM is grinded by worm grinder. When the reducer is in normal operation, the worm is like a hardened "file", which is constantly filed to make the worm gear wear. Generally speaking, this kind of wear is very slow, like some reducer in a certain factory can be used for more than 10 years. If the wear rate is fast, it is necessary to consider the correct selection of the reducer, whether there is overload operation, worm gear and worm material, assembly quality or the use of the environment and other reasons.

        3.Transmission small helical gear wear. Generally occurs in vertical installation of the reducer, mainly with the amount of lubricant added and the choice of lubricant. Vertical installation, it is easy to cause insufficient lubricating oil, when the reducer stops running, the motor and reducer transmission gear oil loss, gear can not get the proper lubrication protection, start or operation process can not be effective lubrication resulting in mechanical wear and even damage.

        4.Worm bearings are damaged. When the reducer fails, even if the gearbox is well sealed, the factory often finds that the gear oil in the reducer has been emulsified, and the bearing has been rusted, corroded and damaged. This is because the gear oil is condensed by the moisture produced after the heat becomes cold during the operation and shutdown of the reducer; of course, it is also related to the bearing quality and the assembly process. Law is closely related.


        Resolvent:

        (1) Ensure assembly quality. In order to ensure the quality of assembly, the factory purchased and made some tools, disassembled and installed reducer worm gear, worm, bearing, gear and other parts, as far as possible to avoid hammer and other tools directly knocking; replacement of gear, worm gear and worm, as far as possible to choose the original parts and pairs of replacement; assembly output shaft, pay attention to tolerance matching Close, D < 50mm, using H7 / k6, D > 50mm, using H7 / m6, at the same time to use anti-adhesive or red Dan oil, to protect the hollow shaft, prevent wear and rust, prevent with the area of dirt, difficult to dismantle maintenance.

       (2) Selection of lubricants and additives. The worm gear reducer is usually made of 220# gear oil. For some gears with heavy load, frequent start-up and worse environment, the factory also uses some lubricating oil additives (such as those from the safety and chemical company). When the gear reducer stops running, the gear oil is still attached to the gear surface, forming a protective film to prevent heavy load. Low speed, high torque and contact between metal and metal during startup. Additives also contain a seal regulator and anti-leakage agent, so that the seal ring remains soft and elastic, effectively reducing the leakage of lubricating oil.

        (3) The location of reducer installation. In case of location, try not to use vertical installation as far as possible. Vertical installation, the amount of lubricating oil is much more than horizontal installation, easy to cause the reducer heating and oil leakage. Some of the 40000 bottles /'draft beer production lines imported from the factory are installed vertically. After a period of operation, the transmission pinion gears are worn and even damaged. After adjustment, the situation has been greatly improved.

     (4) Establish a corresponding lubrication maintenance system. According to the principle of "Five Directions" in lubrication work, the factory maintains the reducer so that every reducer is regularly inspected by an expensive person. When the oil temperature rises significantly, the temperature rises above 40 C or the oil temperature exceeds 80 C, the quality of the oil drops, or more copper powder is found in the oil and abnormal noise is produced, etc. It is necessary to immediately stop using timely maintenance, troubleshooting, and replace lubricating oil after use. When refueling, pay attention to the consistency of the oil quantity and installation position, and ensure that the reducer is properly lubricated.

*For more product parameters, size and price, please contact Hangzhou Starred-River Machinery Co., Ltd.

Tel:+86-571-89988766

E-mail:802@china-sr.com

Website:http://www.srgearboxes.com

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