This problem is very accurate. The core reasons for the abnormal meshing of the worm gear of the WPWA60-40-A reducer are concentrated in four categories: assembly deviation, wear and aging, lubrication failure, and improper working conditions. The details are as follows:
1. Assembly and installation deviations
Center distance deviation, the actual installation center distance deviates from the design value (60mm), resulting in tooth top or tooth root contact during meshing instead of contact in the middle of the tooth surface.
Axis position deviation, the axis of the worm and the worm gear is not perpendicular (tolerance ≤ 0.02mm/m) or not parallel, causing unbalanced meshing.
Bearing installation problems, the bearing clearance is too large/too small or the assembly is tilted, causing the worm/worm gear shaft to move and skew, destroying the meshing accuracy.
The deformation of the box, uneven pretightening force of the base bolts or insufficient foundation rigidity lead to slight deformation of the box, which indirectly affects the meshing position.
2. Component wear and quality issues
Tooth surface wear. After long-term operation, the worm gear (copper) tooth surface wears unevenly and the tooth thickness becomes thinner, or the worm tooth surface is rusted or scratched, resulting in a reduction in the contact area.
Tooth shape accuracy defects, tooth shape errors (such as tooth direction and tooth profile deviation) exceeding the standard during manufacturing, or improper polishing and grinding after repair to damage the tooth shape.
Fatigue damage to components, pitting corrosion and spalling on the worm gear tooth surface, or increased worm lead error, affecting the continuity and uniformity of meshing.
Foreign matter invades, and impurities such as metal chips and dust enter the gear box and get stuck on the meshing surface, causing local bumps and wear.
3. Lubrication system failure
The lubricating oil is improper, special worm gear oil (such as ISO VG 220) is not used, or the oil viscosity does not match the working conditions.
Abnormal oil level, too low oil level leads to insufficient lubrication of the meshing surface, and too high oil level increases stirring resistance, all of which may cause dry friction or poor lubrication.
If the oil deteriorates and the lubricating oil has not been replaced for a long time, it will become black, emulsified, contain metal debris, etc., and the strength of the lubricating film will decrease.
The oil line is clogged, the fuel injection nozzle or the oil line is not smooth, and the lubricating oil cannot be accurately delivered to the meshing area.
4. Working conditions and improper use
Overload operation, exceeding the rated load for a long time will lead to excessive tooth surface contact stress, accelerated wear and damage to the meshing state.
The speed is abnormal, the input speed exceeds the design range, resulting in increased meshing impact, or the speed is close to the resonance speed, causing vibration meshing.
Frequent starts and stops, frequent forward and reverse rotations or start-stop impacts will cause the meshing surface to bear instantaneous impact force, causing local damage.
Environmental impact: The working environment is dusty and humid, causing parts to rust or impurities to invade, worsening the meshing conditions.
