To determine whether the abnormal meshing of the worm gear of the reducer is serious, a three-dimensional comprehensive assessment of 'operating phenomena + component status + detection data' is required, focusing on whether irreversible damage, safety hazards, or normal operation are affected.
1. Look at the intuitive performance during operation
Slight abnormality: only slight abnormal noise at startup or low speed, which is relieved after no-load operation. The box temperature is ≤80°C and there is no obvious vibration.
Moderate abnormality: Continuous abnormal noise (such as 'gnawing teeth' or 'buzzing'), the noise intensifies under load, the temperature rises between 80-100°C, and the vibration amplitude slightly exceeds the equipment standard.
Serious abnormalities: sharp metal friction or impact sounds, temperature rise exceeding 100°C and continuing to rise, violent vibrations causing the fuselage to shake, and even oil leakage.
2. Check the degree of wear and damage of components
Minor damage: slight pitting corrosion and slight wear on the worm gear tooth surface, no obvious scratches on the worm tooth surface, and the meshing clearance is within the range specified by the manufacturer (usually 0.1-0.3mm).
Moderate damage: The worm gear tooth surface is partially glued, the pitting area is expanded, the worm tooth surface is unevenly worn, the meshing gap exceeds the standard by 1.5 times, and there are no chipped teeth or cracks.
Serious damage: The worm gear tooth surface is glued, peeled off or chipped in a large area, the worm spiral is deformed, the tooth surface is corroded, the meshing gap exceeds the standard by more than 1.5 times, or cracks appear on the components.
3. Measure key operating data
Slight abnormalities: The effective value of vibration speed is ≤2.8mm/s, the oil temperature is stable and has no tendency to rise rapidly, and the output torque fluctuation is ≤5%.
Moderate abnormality: The effective value of vibration speed is between 2.8-7.1mm/s, the oil temperature increases by 5-10°C per hour, and the output torque fluctuates by 5%-10%.
Serious abnormalities: The effective value of the vibration speed is >7.1mm/s, the oil temperature rises sharply (over 10°C per hour), the output torque fluctuates >10%, and even the speed drops suddenly.
4. Determine the impact based on usage scenarios
Minor exception: used for non-critical equipment (such as ordinary conveyor lines), short-term operation does not affect production, and shutdown maintenance can be planned.
Moderate abnormality: critical equipment has a backup unit, or the abnormality is stable and does not worsen, and needs to be shut down within 24-48 hours.
Serious abnormality: Key equipment has no backup, operates under heavy load conditions, or the abnormality continues to worsen, and needs to be shut down immediately to avoid the expansion of the fault.
