How to determine if the output shaft of the cycloid reducer is caused by overload after the breaking of the output shaft

To determine whether the output shaft of the BWE74-731 Cycloid reducer is caused by overload, you can start from the following aspects:

• Check the fracture pattern :

• Plastic deformation characteristics : If the output shaft material is a plastic material, there will generally be obvious plastic deformation when overloaded and broken. For example, the diameter of the shaft may become partially thinner and there will be necking near the fracture.

• Fracture texture : brittle fracture caused by overload, the fracture roughness is relatively consistent, there are obvious marks on the surface, and the marks point to the origin of the damage; if the plastic material is under very rapid and severe overload, it may also show a failure mode similar to the brittle material, the crack may show a 45° inclination, and the keyways may be significantly deformed.

• Analyze the operation records and working conditions :

• Load changes : Check the equipment operation records to see if the load on the reducer suddenly increases and exceeds the rated load before the output shaft breaks, such as whether additional heavy objects are suddenly added to the transmission system, or whether the working resistance suddenly increases.

• Running time and frequency : Confirm whether the reducer is running continuously for a long time and has a heavy load, or whether it starts, stops and reverses frequently. These may cause the output bearing to bear a large impact torque. If the impact torque often exceeds twice the rated output torque, it will increase the risk of shaft breaking due to overload.

• Check the status of relevant parts :

• Gear condition : Open the reducer and check the internal gear. If the gear has severe wear, broken teeth, etc., it may be caused by overload, which will cause uneven force of the gear, which will be transmitted to the output shaft and cause breakage.

• Bearing situation : Check the support bearing of the output shaft. If the bearing is damaged, such as pits, fragmentation on the surface of the rolling body, the cage is broken or deformed, it may be that the overload causes the radial or axial load to be too large, which affects the output shaft.

• Coupling status : Check the coupling connected to the output shaft. If it is an elastic coupling, check whether the elastomer is tear; if it is a rigid coupling, check whether the bolt is sheared. These may be signs of overload.

• Comparing rated parameters with actual working conditions :

• Torque calculation : Comparison is made based on the rated output torque of the reducer and the load torque in actual operation. If the actual load torque exceeds about 2 times the rated torque and other possible reasons are eliminated, it is likely that the shaft is broken due to overload.

• Power matching : calculating whether the matching between the motor power and the reducer is reasonable. If the motor power is too large and it is often running at full or overload, it will cause the reducer output bearing to bear too much force.