Fault diagnosis and maintenance of WPKA120-40-B worm gear reducer can refer to the following experience:
Troubleshooting
Listen to the sound to identify the position : The sound of metal friction may be due to lack of oil or oil deterioration. You need to check the oil level of the oil window immediately and touch the box to see if it is hot; regular impact sounds may be broken teeth or damaged bearing cages. You can stop the machine and turn the machine manually to feel if there is any jamming; high-frequency whistling sounds may be poor alignment of the coupling. You can use a screwdriver to hold the bearing end and listen for changes in the sound.
Touch diagnosis : touch the bearing seat, and if it is hot (>70°C), the bearing may be lacking grease or damaged; touch the box joint surface, and if oil leakage or scaling occurs, the seal may be failed; touch the output shaft, if there is obvious swing, the bearing may be worn.
Visual inspection : Check the lubricating oil. If the oil window is turbid, it may be oil emulsification. If the oil is black, it may be metal wear. Check the coupling. If the elastic gasket is cracked, replace it immediately. If the alignment is offset, use a ruler to roughly measure. The gap should be ≤0.1mm. Check the bolts, focusing on the anchor bolts and bearing gland bolts to see if they are loose.
Simple test : no-load test, disconnect the load, and run the reducer alone. If the abnormal noise disappears, the problem may be at the load end. If the abnormal noise is still there, the reducer itself is faulty; for grease replenishment test, use an oil gun to add grease to the bearing. If the noise decreases, it means the bearing is lacking grease. If there is no improvement, the bearing may be damaged.
Maintenance experience
Overheating failure : It may be caused by improper connection of the motor, reducer, and working machine, overload operation, excessive friction of the oil seal, too little or too much lubricating oil, excessive impurities in the lubricating oil, or poor lubricity. It can be solved by adjusting the connection position so that the three connecting axes are coaxial, adjusting the load appropriately, dripping lubricating oil on the lip of the oil seal, adjusting the oil volume according to the oil mark indication point, and replacing the appropriate new oil.
Vibration failure : It may be caused by poor fixation of the motor, reducer, and working machine, wear or damage of the worm gear pair teeth, wear of the bearings, loose bolts, etc. The problem can be solved by detecting the position of poor fixation, tightening it correctly, replacing the worm gear teeth, replacing the bearings, and tightening the bolts.
Noise failure : It may be caused by bearing damage or excessive clearance, poor meshing of the worm gear pair, insufficient lubricating oil, foreign matter in the body, etc. It can be dealt with by replacing the bearing, correcting the tooth surface or replacing the worm gear pair, adding lubricating oil according to the oil mark indication point, pouring out the lubricating oil to bring out foreign matter, and refilling with clean lubricating oil.
Oil leakage failure : It may be caused by the wear of the oil seal lip, the wear of the oil seal gear journal, excessive oil volume, the oil drain plug is not tightened, the oil mark is damaged, etc. The oil seal can be replaced, the output shaft or input shaft can be replaced, the oil volume can be adjusted according to the oil mark indication point, sealant can be added to the threads, the screw plug can be tightened, and the oil mark can be replaced.
Worm gear tooth surface wears too quickly : it may be caused by overload operation, lubricating oil that does not meet the requirements, insufficient lubricating oil, failure to change the oil in a timely manner as required, poor quality lubricating oil, or too high operating temperature. It can be solved by adjusting to the appropriate load, replacing the appropriate lubricating oil, adding enough lubricating oil according to the oil mark indication point, changing the oil in a timely manner according to the regulations, and taking appropriate measures to reduce the ambient temperature.
