The abnormal state of the TPA125-25-1 worm gear reducer will directly lead to a significant decrease in transmission efficiency. Different abnormal types have different effects on efficiency. The specific correlation is as follows:
1. Abnormality in the meshing system: the most significant decrease in efficiency
If the meshing clearance of the worm gear is too large, pitting/gluing/flaking occurs on the tooth surface, or the coaxiality and parallelism are too poor after installation, the tooth surface contact area will be reduced, and additional impact and sliding friction losses will occur during meshing.
Under normal working conditions, the transmission efficiency of this type of reducer is about 75%-85% (the worm gear is made of tin bronze). When the meshing is abnormal, the efficiency will drop to 50%-60%. When the tooth surface is seriously damaged, the efficiency drop can reach more than 40%.
2. Lubrication system failure: friction loss increases sharply
Insufficient amount of lubricating oil, deterioration of oil quality (mixed with wear debris/moisture) or mismatched model (not using special extreme pressure oil for worm gears) will result in the inability to form an effective oil film on the tooth surface and bearings, and direct metal contact causing dry friction.
When lubrication fails, friction loss will increase by 2-3 times, and transmission efficiency will decrease by 15%-25%. At the same time, the temperature rise will increase and abnormal noise will intensify, further deteriorating efficiency.
3. Abnormality of bearings and shafting: increased additional resistance
Bearing wear, cage damage, or worm axial movement will increase additional resistance to the operation of the shaft system; oil seals that are too tight and shaft end fits loosely will also cause additional friction.
Such anomalies will reduce the transmission efficiency by 5%-15%, which is manifested as an increase in motor current but insufficient output torque of the reducer.
4. Abnormal external connections: indirect loss of efficiency
The coaxiality of the coupling is out of tolerance and the loose anchor bolts cause resonance, which will cause the input bearing to be subject to additional bending moments. Part of the motor power is consumed in vibration and impact and cannot be effectively transmitted to the output end.
Abnormal external connections usually reduce efficiency by 3%-8%. If components are subject to collision and friction, the efficiency drop will be further amplified.
Core conclusion: Any abnormal state of the reducer will destroy its normal transmission rules and reduce the transmission efficiency by increasing friction, impact, additional resistance, etc.; the longer the abnormality lasts and the more serious the damage, the greater the efficiency drop. At the same time, it will accelerate the aging of components and shorten the life of the equipment.
