What are the possible consequences of abnormal noise of the TPU250-31.5 worm gear reducer?

Abnormal noise in the PU250-31.5 worm gear reducer is a direct signal of abnormality in the internal transmission system, lubrication system or assembly structure. If not handled in time, it will lead to chain consequences such as increased component damage, failure of transmission performance, and scrapping of the entire machine , as follows:

1. Serious wear and failure of the worm gear pair

If the abnormal sound is a continuous 'gnawing' sound, it is mostly due to excessive meshing clearance of the worm gear, uneven tooth surface wear, or poor tooth profile accuracy. Continuous operation will lead to gluing, pitting, and peeling of the tooth surface. In severe cases, the teeth will break, and the worm gear pair will completely lose its transmission capability.

If the abnormal sound is accompanied by periodic metal impact sounds, it may be due to axial movement of the worm or loose positioning of the worm gear. Long-term impact will cause the fit between the worm gear hub and the shaft to loosen, the keyway to deform and shear, and eventually the transmission to become stuck.

2. Bearing component damage and shafting failure

When the abnormal sound is a sharp 'buzzing' sound or a 'rustling' sound, it is usually due to insufficient lubrication of the bearing, wear of the raceway, and deformation of the cage. Continuous operation will cause the bearing temperature to rise suddenly, fatigue cracks in the raceway, and the bearing to lock up.

After the bearing is damaged, the radial runout and axial movement of the worm shaft exceed the standard, further aggravating the unbalanced load meshing of the worm gear, causing bending and deformation of the worm shaft, and even causing the bearing hole of the reducer box to wear and expand, making it irreparable.

3. Lubrication system failure and secondary damage

If the abnormal sound is caused by insufficient lubricating oil, reduced viscosity or deterioration of oil quality, it will cause direct friction between the metal contact surfaces of the worm gear and bearing, producing a large amount of metal wear debris. The wear debris is mixed into the lubricating oil to form 'abrasives', which accelerates the wear of all transmission components and forms a vicious cycle.

Severe lubrication failure will cause the worm gear pair to glue at high temperature, the lubricating oil will carbonize and deteriorate, block the lubrication channel, and eventually cause the entire machine to lock up and shut down.

4. Seal failure and intrusion of external contamination

The vibration caused by abnormal noise will aggravate the wear of the reducer end cover and oil seal, causing the oil seal lip to deform and age, and cause lubricating oil leakage. At the same time, external dust and water vapor will invade the body through the sealing gap, contaminating the lubricating oil, and further accelerating the corrosion and wear of internal components.

5. Production interruption and safety hazards

If the abnormal noise is not dealt with in the early stage, the fault will deteriorate rapidly, causing the reducer to shut down suddenly and interrupt the production line. Repair requires disassembly and replacement of core components such as worm gears and bearings, which requires a long maintenance cycle and high costs.