Common faults of the TPU315-25-1 worm gear reducer (center distance 315mm, transmission ratio 25) are mostly related to 'lubrication failure, load overload, installation deviation'. The treatment must follow the principle of 'first locate the fault point, and then solve it in a targeted manner' to avoid blind disassembly.
Combined with its structural characteristics of large center distance and medium speed ratio, common faults can be divided into 4 categories. The specific manifestations, causes and treatment methods are as follows.
This is the most easily detectable fault, and it is mostly related to component wear or misalignment. If not handled in time, the damage will be aggravated.
Common reasons :
The worm gear is severely worn (tooth surface peeling, uneven tooth thickness), resulting in excessive meshing clearance or abnormal bite.
The bearing is damaged (the rolling elements are worn, the cage is broken), and irregular vibration and noise are produced during operation.
The concentricity deviation between the motor and the reducer, and the reducer and the load is too large (more than 0.1mm), resulting in additional radial force and abnormal noise.
Treatment method :
After stopping the machine, manually turn the input shaft. If there is obvious stuck or gap, the worm gear needs to be disassembled and inspected. If the wear is serious, replace it with a new one (the worm gear and worm must be replaced in pairs, not separately).
Use a stethoscope close to the bearing seat. If the noise is concentrated here, check the bearing after disassembly. If it is damaged, replace the bearing of the same model (note that the bearing clearance must meet the manufacturer's requirements, usually group C3).
Recalibrate concentricity: Use a dial indicator to measure the radial runout and end face runout of the coupling, adjust the motor or load position to ensure the deviation is ≤0.05mm, and then tighten the connecting bolts.
2. Fault 2: The box temperature is too high (exceeds the ambient temperature + 40°C)
High temperature will accelerate the aging of lubricating oil and reduce the strength of components. Long-term operation may easily lead to ablation of the worm gear.
Common reasons :
Insufficient lubricating oil (the oil level is lower than the minimum mark) or the oil has deteriorated (the oil is black and contains impurities), and lubrication failure leads to increased friction and heating.
Poor heat dissipation: there is too much dust on the surface of the box, the heat sink is blocked, or the ambient temperature is too high (such as being close to high-temperature equipment), and the heat cannot be discharged.
Overload operation: The actual load exceeds the rated torque of the reducer (TPU315 usually has a rated torque of 3000-5000N·m), causing the friction of the worm gear to increase and the heat to increase.
Treatment method :
Check the oil level. If it is insufficient, add the corresponding type of special worm gear oil (such as 320# extreme pressure gear oil); if the oil deteriorates, drain the old oil completely, flush the box with new oil, and then refill it to the standard oil level.
Clean the dust and oil on the surface of the box and the heat sink. If necessary, install a cooling fan (air volume ≥50m³/h) or cooling coil to reduce the impact of ambient temperature on the reducer.
Calculate the actual load: measure the operating torque through a torque sensor. If it exceeds the rated value, the load needs to be reduced or the reducer must be replaced with a larger size to avoid long-term overloading.
3. Fault 3: Lubricating oil leakage (oil leakage from the shaft end and the joint surface of the box)
Leakage not only wastes lubricating oil, but may also pollute the environment (especially in the food and pharmaceutical industries) and lead to insufficient internal lubrication.
Common reasons :
The shaft end seal is aging (the lip of the skeleton oil seal is worn and the spring is falling off), and the sealing performance is reduced.
The bolts on the joint surface of the box are loose, or the sealing pads (such as asbestos pads and rubber pads) are aged and damaged, causing oil leakage from the gaps.
The oil level is too high (exceeds the maximum mark), and the oil is squeezed out of the seal due to centrifugal force during operation.
