Analysis of common problems of worm gear reducer

Worm gear reducer is a kind of transmission machinery with compact structure, transmission ratio and self-locking function, under certain conditions.It is one of the most commonly used reducers.Among them, the hollow shaft worm gear reducer not only has the above characteristics, but also has the advantages of convenient installation and structural integration, and is more and more widely used.The hollow shaft worm gear reducer is equipped with a helical gear reducer at the end of the worm gear reducer, and the multi-stage reducer can obtain very low output speed.It is a combination of helical gear level and worm gear level, which is more effective than pure single 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, (2) worm gear wear, (3) transmission small helical tooth wear, (4) bearing (worm) damage.

1. Heating and oil leakage of the reducer.In order to improve efficiency, worm gear reducers usually use non-ferrous metals as worm gears, and worms use hard steel.Because it is a sliding friction drive, it will generate high heat during operation, and create a thermal expansion difference between the parts of the reducer and the seal, and create a gap from each mating surface and oil.Thinning due to temperature rise tends to cause leakage.The main reasons are four points, one is that the material matching is reasonable, the other is the surface quality of the meshing friction surface, the third is the choice of lubricating oil, the addition amount is correct, and the fourth is the assembly quality and the use environment.

2. The worm wheel is worn.Worm wheels are usually tin bronze.The pair of worm materials are usually 55 hardened with 45 HRC45 steel.It is also used to grind the HRC50 55~40°C: Worm Grinder to Rao's roughness.8 fcm.The worm gear acts like a hardened 'file' and files, making the worm wheel wear down the worm wheel.Generally speaking, this kind of wear is very slow, just like some reducers in a certain factory can be used for more than 10 years.If the wear rate is faster, you need to consider whether the reducer is the correct type, whether there is overload operation, the material of worms and worms, the quality of assembly or the use of the environment in which it is used.

3. The transmission small helical gear is worn.Usually occurs on the vertical installation of the reducer, mainly related to the amount of lubricating oil and lubricant selection.Vertical installation is easy to cause insufficient grease. When the reducer stops running, the motor and reducer transmission gear oil will be lost, and the gears will not be properly lubricated. The lack of effective lubrication during startup or operation will lead to mechanical wear and even damage.

4. The worm bearing is damaged.When the reducer is broken, even if the gearbox is well sealed, it is usually found that the gear oil in the reducer has been emulsified.Bearings are rusted, corroded and damaged.This is due to the condensation of heat from the gear oil to the cooling of the reducer during transportation; of course, the quality of the bearing and the assembly process.The law is closely related.

parse.(1) Ensure assembly quality.In order to ensure the quality of assembly, the factory purchased and made some special tools to disassemble and install components such as gear reducers, worms, worms, bearings, gears, etc., and avoided direct percussion with other tools such as other tools.When replacing gears and worms and worms, we should try to choose original parts and pairs to replace them.When the output shaft is assembled, the public should pay attention to the public.Poor coordination, D<50mm, use H7/K6, D>50mm, use H7/M6, also use anti-sticking agent or red oil, protect hollow shaft, prevent wear and rust, prevent area scale, difficult to disassemble during maintenance Disassemble.

(2) Select lubricating oil and additives.Worm gear reducers usually use 220 gear oil, which is a heavy-duty, frequent start-up and less environmental reducer.The plant also selects some lubricant additives (for example the interests of chemical companies).When the reducer stops running, the gear oil still adheres to the surface of the gear to form a protective film to prevent heavy load.Low speed, high torque and contact between metal and metal during start-up.The additive also contains seal ring regulator and anti-leakage agent to keep the seal ring soft and elastic, effectively reducing the leakage of lubricating oil.

(3) Select the installation location of the reducer.In position, try not to use vertical installation.When installed vertically, the amount of lubricating oil is far more than that installed horizontally, which may cause heating and leakage of the reducer.The 40,000 bottles/time pure beer production line introduced by the factory, some of which are installed vertically, after a period of time, the transmission gears have greater wear and even damage.After the adjustment, the situation improved greatly.

(4) Establish corresponding lubrication and maintenance systems.According to the lubrication principle of 'five fixes', the factory maintains the reducer so that each reducer is checked regularly.When the oil temperature rises significantly, the temperature rises by 40 degrees Celsius or the oil temperature exceeds 80, the quality of the oily matter decreases or more copper powder is found in the oil, and abnormal noise is found.It is necessary to stop using it immediately for maintenance, troubleshooting, and replace the lubricating oil after use.When refueling, please pay attention to the consistency of the oil quantity and installation position, and ensure that the reducer is properly lubricated.