The XLD5-3KW-87 cycloid reducer relies on the meshing transmission of the cycloid wheel and pin teeth. It has a compact overall structure and limited impact resistance. Long-term or instantaneous overload will directly destroy key matching and stressed components, causing irreversible damage. The specific hazards are as follows:
1. The cycloidal wheel is broken or chipped.
The cycloidal wheel is the core stress-bearing component. When overloaded, the contact stress on the tooth surface far exceeds the design value, and it is easy to cause tooth root cracks, tooth surface chipping, or even overall fracture. Broken fragments will jam the whole machine, causing instant transmission failure, and will also scratch the needle teeth and needle tooth shell.
2. The needle teeth are worn and the needle tooth sleeve is broken.
The needle teeth and needle tooth sleeves are subjected to periodic alternating loads. Overloading will aggravate surface fatigue wear, causing pitting and peeling; in severe cases, the needle tooth sleeves will break and lose their supporting function, causing abnormal noise and vibration of the entire machine to intensify, and the meshing accuracy to drop significantly.
3. The input and output shafts are twisted and the keyway is rolled.
The overload torque of the 3KW motor suddenly increases, far exceeding the design allowable torque of the shaft body, which will cause the input shaft and output shaft to twist or break; the key and keyway bear excessive shear force, and the roller key and keyway will be extruded and deformed, causing the shaft and wheel body to slip and power cannot be transmitted normally.
4. Premature bearing failure
Overload causes the bearing to bear huge radial and axial loads. The rolling elements and raceways undergo plastic deformation and pitting corrosion, and the cage is deformed and damaged. This manifests as abnormal temperature rise, louder noise, stuck rotation, and eventually lock-up.
5. Cracking of machine base and flange
The impact and vibration caused by overloading repeatedly act on cast iron components such as boxes, flanges, and end covers, which are prone to stress concentration cracking, especially at the connection between the flange and the machine base. After cracking, oil leakage and axis deviation will occur, further aggravating component damage.
6. Damage to eccentric bearing and cross coupling
The cycloidal machine is driven by an eccentric mechanism. Overload will cause the eccentric bearing to wear and crack, and the eccentric sleeve to deform. The coupling and pin connecting the motor and the reducer will also be sheared and broken, cutting off the power transmission to protect the motor, but the inside of the reducer will most likely be damaged.
7. Severe heating, lubrication failure, and seal damage
Friction loss increases sharply during overload operation, oil temperature rises rapidly, lubricating oil viscosity decreases, lubrication fails, and aggravates tooth surface and bearing wear; high temperature can also cause oil seal aging, hardening, leakage, box joint surface seal failure, and large-area oil leakage.
8. The performance of the whole machine is permanently reduced.
Even if there is no immediate damage, long-term overloading will cause hidden fatigue damage to internal parts, which is manifested as increased noise and vibration, reduced transmission efficiency, increased return clearance, loss of positioning accuracy, and significantly shortened service life.
Note: In daily use, overloading, jamming, frequent forward and reverse rotation, etc. should be avoided. Installing an overload protection device can effectively reduce the risk of such damage.
