The transmission efficiency of WS300-23.5-II worm gear reducer is affected by a variety of factors, as follows:
Worm lead angle : The larger the lead angle, the smaller the sliding friction between the worm and the worm gear tooth surface, and the higher the transmission efficiency. Generally speaking, the lead angle is more suitable between 3.5°-33°. If it exceeds 30°, although the theoretical efficiency will be further improved, the processing difficulty will increase significantly. In addition, the lead angle of the multi-head worm is larger than that of the single-head worm, so under the same conditions, the transmission efficiency of the multi-head worm (such as double-head and triple-head) is higher, but the transmission ratio will be reduced accordingly.
Material pairing and friction coefficient : Usually the worm is made of steel, such as medium carbon steel or medium carbon alloy steel, while the worm gear is made of bronze, such as cast tin bronze or cast aluminum bronze. This combination of steel worm and bronze worm gear can effectively reduce the coefficient of friction, reduce wear, and thus improve transmission efficiency. In addition, quench hardening and hardening the worm gear, or surface treatment such as coating the worm gear (such as tin plating), can further reduce friction and increase efficiency by about 5%-10%.
Manufacturing and assembly accuracy :
Tooth surface roughness : The lower the tooth surface roughness, the smoother the tooth surface, the less friction the worm and the worm gear mesh, and the higher the efficiency. For example, every step reduction in tooth surface roughness can increase efficiency by 2%-3%.
Meshing gap : If the meshing gap is too large, it will cause impact during the transmission process and increase energy loss; if the gap is too small, it will increase friction. Therefore, it is necessary to accurately adjust the engagement clearance to ensure transmission efficiency.
Assembly pair neutral : If the axis of the worm and the worm gear are offset or angular deviation, it will aggravate local wear and reduce the transmission efficiency by up to 10%-15%. Therefore, during assembly, the centering accuracy between the worm and the worm gear axis should be ensured.
Lubrication conditions :
Lubricant performance : The viscosity selection of lubricant oil is very critical. Lubricant with higher viscosity can form a thicker oil film, reducing direct contact and friction between the tooth surfaces, but excessive viscosity will increase the loss of oil stirring and reduce efficiency. Generally speaking, for worm gear reducers, lubricating oil of ISO VG 220-460 is often used. In addition, adding grease containing extreme pressure additives such as MoS₂ or graphite can reduce friction under boundary friction conditions, increasing efficiency by about 3%-5%.
Working temperature : If the working temperature is too high, it will cause the lubricant viscosity to decrease, the oil film to rupture, and the friction will intensify. When the temperature rises by 10°C, the transmission efficiency will drop by about 1%-2%. Therefore, the working temperature of the reducer should be controlled to avoid excessive temperature rise.
Load characteristics : When the load rate is low (<30%), friction loss accounts for a large proportion of the total loss, and the transmission efficiency may be less than 50%. When the reducer is overloaded, it will accelerate the wear of components such as worm gear and worm, and long-term overload will reduce the transmission efficiency by up to 20%. Therefore, the reducer should be kept within the appropriate load range as much as possible to avoid long-term light load or overload.
Structural type : WS300-23.5-II is a cylindrical worm reducer, and its transmission efficiency is generally between 60% and 80%. Compared with the toroidal worm reducer, the contact area of the cylindrical worm reducer is relatively small and the transmission efficiency is relatively low. The efficiency of the toroidal worm reducer can reach 85%-94%, but the manufacturing cost is higher.
