In fact, more than 90% of the core root causes of this kind of failure that is normal when no load is normal but makes abnormal noise when fully loaded are not parts damage, but excessive load. Today, we will use easy-to-understand words to thoroughly explain the fault principles, performance characteristics, and efficient troubleshooting and solutions. After reading this, you will no longer have to blindly repair.
1. First understand: Why is it okay when empty, but problems occur when it is fully loaded?
First of all, we must understand the difference between no-load and full-load operation of the equipment: in the no-load state, the equipment motor, transmission structure, and body frame are all in a low-load operating state, with almost no additional pressure and resistance, and the internal accessories only need to overcome their own friction to operate.
At this time, even if there are hidden problems in the equipment, insufficient load margin, or transmission coordination deviation, they will not be revealed, so the operating status is completely normal without any abnormal noise or failure.
However, after the equipment enters full load condition, the overall load soars instantly, and the motor torque, transmission tension, fuselage bearing capacity, and bearing pressure will all reach peak values. When the actual load exceeds the rated load standard of the equipment, that is, when the load exceeds the standard, each component of the equipment exceeds the tolerance limit, and the originally hidden problems will explode instantly, and abnormal noise, vibration, and jamming will also appear.
This is why this type of failure is so confusing, causing many people to mistakenly think that it is a sudden damage to a part. It is essentially a chain mechanical reaction caused by overload operation.
2. Four typical manifestations of abnormal noise at full load caused by excessive load
Different equipment and different degrees of exceeding the standard will have obvious differences in the status of abnormal noise. You can make accurate judgments based on your own equipment and quickly locate the root cause of the fault.
1. Low-frequency buzzing vibration and abnormal sound
This type of abnormal noise is the most common and occurs mostly in motors, fans, water pumps, conveyors and other equipment. When no-load, the motor runs smoothly without any noise; after full-load operation, the fuselage emits a dull "buzzing" sound, accompanied by slight fuselage shaking.
The core reason is that the excessive load causes the motor to overload, the current surges, and the electromagnetic vibration intensifies. At the same time, the equipment transmission structure is overloaded and slightly deformed, causing resonance and abnormal noise. Many people mistakenly believe that the motor bearings are damaged, and blind replacement of the bearings is completely ineffective.
2. Metal friction, stuck and abnormal noise
Commonly found in mechanical equipment, transmission gears, chains, and screw rod structures. The no-load operation is smooth and there is no friction sound. After full load, there will be "sizzling" and "clicking" metal friction and jamming sounds. In severe cases, the speed will slow down and the operation will be weak.
After the load exceeds the standard, the transmission components are overstressed, and the gear meshing clearance, chain tightness, and screw rod matching accuracy deviate. The originally fitting parts experience hard friction and jamming, which in turn produces abnormal noise. Long-term overload operation will directly wear and scrap the transmission parts.
3. Intermittent rattling and abnormal noises
The equipment operates stably under no load. When fully loaded, jittering and abnormal noises occur from time to time. The greater the load, the higher the frequency of abnormal noises. Mainly due to excessive load, the equipment body, brackets, and fixing screws were overloaded, causing slight loosening and deflection. Vibrations and collisions occurred during operation, resulting in regular abnormal noises.
