1. The function of worm gear reducer:
The application of worm gear reducer in traditional mechanical systems mainly has the following functions:
First of all, the rotary reducer can increase the output torque of the system after deceleration, and the torque output is in a certain proportion to the output deceleration of the motor or hydraulic motor. It should be noted that the torque output cannot exceed the rated torque of the reducer.
Secondly, deceleration can effectively reduce the inertia of the load, and the reduction in inertia is the square of the reduction ratio.
Finally, the reducer can change the output direction of the torque, so that the output torque and the input torque are distributed vertically.
2. Common faults and solutions of worm gear reducer
Reducer heating and oil leakage faults:
Most rotary reducer worm gears use tooth surface quenching or steel with higher hardness as raw materials. This is to improve the operating efficiency and wear resistance of the reducer. However, since the transmission method of the rotary reducer is friction transmission, a large amount of heat will be generated during operation, and the temperature will increase quickly. Over time, The heat will produce a certain amount of thermal expansion between the parts and seals of the reducer, which will cause gaps on the surface of the reducer parts. In addition, the temperature of the grease will increase and the density will decrease. After long-term use, oil leakage and severe tooth surface wear of the reducer will easily occur, resulting in jitter or abnormal noise.
Therefore, through the analysis of the accident, we summarize the main causes of the accident as follows:
First, the application and matching of reducer materials are unreasonable.
Second, the workmanship quality of the meshing tooth surface is unqualified.
Third, the selected grease is unreasonable.
Fourth, factors related to equipment assembly quality and operating environment.
Therefore, the processing and material selection of parts should be strictly controlled; during the assembly or replacement of parts of the rotary reducer, violent knocking with hammers and other tools should be avoided, and original bearings, oil seals and other accessories should be used for replacement; appropriate grease should be used to protect the cavity of the housing of the worm to avoid wear or tooth surface rust.
Worn gear wear phenomenon:
The processing material of the worm gear is generally S48C, and the matching worm material is generally 42CrMo steel hardened to HRC45-55, or 40Cr hardened to HRC50-55, and then processed by a worm grinder. Grinding to make the roughness reach Ra0.8. During the operation of the rotary reducer, the worm will grind the worm gear like a "file". Generally, this wear degree is slow. Under normal circumstances, the life of the reducer can reach more than 3 years.
If it is found that the wear of the worm gear is abnormal and the wear is rapid, you can consider whether the parameters of the rotary reducer are wrong, or it has been overloaded for a long time, as well as factors such as heavy load, high speed and harsh operating environment.
Under normal circumstances, the corresponding lubrication method should be selected based on the actual working conditions of the reducer. If the operating environment of the reducer is complex and harsh, some grease additives should be appropriately added to protect the normal operation and service life of the gear.
Worm bearing damage:
When a mechanical failure occurs in the reducer, although there is no problem with the seal of the reducer, the gear grease in the reducer still emulsifies, and the bearings become rusted and damaged.
The main reason is that during the process from normal operation to shutdown of the reducer, the temperature of the gear grease changes from hot to cold and moisture condenses. In addition, it also has a certain relationship with the quality and assembly process of the bearing itself. Therefore, in order to prevent the occurrence of the above failures, enterprises should establish a sound lubrication maintenance system to effectively ensure the normal operation of the reducer.
Helical gear wear:
The wear of transmission helical gears generally occurs on horizontally installed reducers. The cause of wear is mainly related to the amount and amount of grease added. During the installation process, it is easy to cause insufficient lubrication. In addition, when the reducer works for a long time, the grease is lost from the transmission gear under the action of extrusion. The gear loses the lubrication protection of the grease. When it is started again, the friction will increase and mechanical wear or damage will occur. Therefore, when installing the horizontal reducer, sufficient grease must be added.
