Failures in the connection between the motor and the ZSY630-22.4-2 hard tooth surface gear reducer will generally manifest in four aspects: abnormal operating noise, excessive vibration, abnormal temperature rise, and transmission failure. The detailed phenomena are described as follows:
1. Abnormal noise during operation
Periodic "click" impact sound in the coupling position: usually the coaxiality deviation exceeds the standard, the elastic parts of the coupling are aged and damaged, or the pins and fastening bolts are loose, resulting in a large gap between the joint surfaces, and rigid impact during rotation.
Continuous sharp whistling sound: the shaft and the coupling are loose (keyway wear, interference fit failure), the angular alignment deviation of the motor shaft and the reducer input shaft is too large, the friction is intensified during high-speed operation, and high-frequency noise is generated.
Irregular "clunking" and abnormal noise: the elastic body of the coupling is broken, the pin is sheared and deformed, the key and keyway are severely worn, and intermittent jamming occurs during transmission.
2. Vibration exceeding the standard fault
Vibration in the coupling area increases significantly: According to the ISO 10816 standard, the vibration speed is greater than 2.8mm/s, and the equipment shell feels strongly shaken. Common causes are radial and angular misalignment, or loose anchor bolts.
Vibration changes synchronously with the rotational speed: the vibration frequency is a multiple of the motor rotational speed. Spectrum detection shows a significant double frequency peak, which is mostly caused by coupling imbalance and shaft end eccentricity.
Resonance phenomenon of the whole machine: The connection deviation causes the operating frequency of the equipment to be close to the natural frequency. The whole machine shakes violently and is transmitted to the equipment foundation. Long-term operation may easily cause anchor bolts to break and the base to crack.
3. Abnormal temperature failure
Part of the coupling heats up rapidly: within 1 hour of startup and operation, the temperature of this part rises 50°C above the ambient temperature; infrared temperature measurement shows that the temperature of the coupling and the shaft end bearing is obviously high. This is mostly due to additional frictional heat caused by poor alignment, or vibration and frictional heat caused by loose bolts.
The temperature of the motor and reducer bearings increased: the temperature of the reducer input shaft bearing exceeded 80°C, accompanied by oil leakage. Connection deviation will cause the bearing to bear additional radial force, worsen the lubrication conditions, and accelerate wear and heat.
4. Transmission failure
Output speed fluctuation: The motor operates normally, but the output speed of the reducer fluctuates high and low, causing slippage. The main reason is that the elastic part of the coupling is damaged, the pin falls off, or the feather key fails between the key and the keyway.
Decreased load-carrying capacity: When running with load, the machine becomes dull and shuts down, and the motor"s operating current soars. Misalignment of the connection will cause the input bearing of the reducer to be subject to additional bending moments and increase the gear meshing resistance.
Damage to connecting components: coupling bolts are broken, elastomers are broken, flat keys are sheared and damaged, and in severe cases, the motor shaft or reducer input shaft is bent. This type of severe failure is generally caused by long-term misalignment and accumulation of continuous impact loads.
