To reduce the load on the worm gearbox of the WPS40-60-B worm gear reducer, it is necessary to follow the idea of 'source load reduction → transmission optimization → operation control → protection pocket'. Combined with the characteristics of this type of reducer (small, large reduction ratio, low rated torque), low-cost and easy-to-implement solutions are given priority. The specific measures are as follows:
1. Source load shedding: reducing the actual resistance at the load end
This is the most direct way to reduce load. It starts with the load itself to reduce the output torque demand of the reducer. It is suitable for scenarios where there is additional resistance at the load end.
1. Clear load stagnation and friction resistance
Check the moving parts of load equipment (such as conveyor belts, valves, small robotic arms), remove dust, debris, and rust on guide rails, gears, and bearings to reduce mechanical jamming;
Add grease (such as lithium-based grease) to the sliding parts at the load end to reduce the sliding friction coefficient and reduce the static friction and dynamic friction that the reducer needs to overcome;
If the load is fluid equipment (such as a small pump body), clear pipeline blockages and valve jams to reduce fluid resistance.
2. Optimize load structure and working conditions
If the load is lifting equipment, check whether the counterweight is reasonable and add counterweights appropriately to offset part of the lifting weight and reduce the output torque of the reducer;
Reduce the additional inertial load on the load end, such as removing unnecessary metal baffles and brackets, reducing the weight of moving parts, and reducing the impact torque during start and stop;
To prevent the load end from being in a 'stuck' state for a long time (such as material stuck), install a material detection sensor to stop the machine immediately when stuck to prevent instant overload.
2. Transmission optimization: reduce reducer load through system transformation
For scenarios where the load cannot be reduced from the source, the actual load of the WPS40-60-B can be reduced by optimizing the transmission link to disperse or transfer the load torque.
1. Install a force-increasing/labor-saving mechanism
For linear motion loads, add a pulley block or screw nut pair, and use the mechanical labor-saving principle to reduce the output torque demand of the reducer to 1/2~1/3 of the original;
For rotating loads, install a first-level small reduction ratio gear pair (such as 1:2~1:3) between the reducer and the load to disperse the torque by increasing the transmission ratio (pay attention to matching the speed to avoid the load end speed being too low);
Note: The additional installation mechanism must ensure coaxiality and installation rigidity to avoid introducing additional vibration loads.
WPS40-60-B is a worm gear structure with a transmission efficiency of about 60% to 70%. If the working conditions permit, it can be replaced with a helical gear reducer (efficiency above 90%). Under the same load, the motor input power can be reduced by 20% to 30%, which indirectly reduces the load pressure of the reducer;
If you need to retain the worm gear structure, you can replace it with a high-precision worm gear pair (tooth surface roughness Ra≤0.8μm) to reduce meshing friction loss and reduce the 'hidden load' caused by increased friction.
