Horizontal deviation will accelerate the wear of components of the motor and ZDY200-1.4-2 reducer, significantly shortening the overall service life of the equipment. The greater the deviation, the more obvious the life span will be attenuated.
1. Impact on the service life of the reducer
The gear life is greatly shortened. Horizontal deviation leads to uneven gear meshing, local contact stress is doubled, tooth surface wear, pitting, and gluing are accelerated. The normal service life can be shortened by 30%-60%. In severe cases, broken teeth may occur within a short period of time.
Bearings fail prematurely. The tilt of the axis causes the bearings to bear additional radial forces and bending moments. The wear of the balls and raceways is intensified, and the grease is prone to deterioration and loss. The service life of the bearings is usually reduced to 20%-50% of the design value, and heating and jamming failures often occur.
The aging of the casing and seals accelerates. Long-term uneven stress causes slight deformation of the reducer casing. The seals harden and crack prematurely due to vibration and abnormal stress. Lubricating oil leaks occur frequently, further aggravating the wear of internal components.
2. Impact on the service life of the motor
The motor bearings are damaged more quickly, and the coaxiality caused by horizontal deviation exceeds the standard, causing the motor bearings to bear additional loads, aggravating wear and heat, and shortening the service life by 40%-70%. In severe cases, the bearings lock up and cause the motor to burn out.
The loss of the rotor and stator increases, and the horizontal deviation causes the motor rotor to be eccentric, causing electromagnetic imbalance during operation. The stator winding heats up, the insulation layer ages faster, and the overall life of the motor can be shortened by 20%-40%.
The end cover and base are deformed. Long-term vibration and uneven force will cause plastic deformation of the motor end cover and base, further amplifying the horizontality and coaxiality deviation, forming a vicious cycle, and ultimately causing the motor to fail to operate normally.
3. Chain effects on overall lifespan
The interval between equipment failures is shortened, and component wear caused by horizontality deviation has a cascading nature. Damage to one component will accelerate the failure of other related components, significantly reducing the average trouble-free working time of the equipment.
Maintenance frequency and costs increase. Frequent component replacement and maintenance will reduce equipment utilization, and long-term abnormal operation will cause irreversible damage to the core components of the equipment (such as reducer gearboxes and motor rotors), eventually entering the scrap cycle early.
The life span decreases when the deviation exceeds the standard. When the horizontality deviation is >0.1mm/m, the overall service life of the motor and reducer may be only 30%-50% of the normal level; if it is in this state for a long time, the equipment is prone to sudden failure.
