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Analysis of common problems of worm gear reducer

发布 时间:2011.05.24 news source:Zibo Boshan Ever-Power Deceleration Machinery Factory

    Worm gear reducer is a kind of transmission machinery with compact structure, large transmission ratio and self-locking function under certain conditions. It is one of the most commonly used reducers. Among them, the hollow shaft worm gear reducer not only has the above Features, easy installation, reasonable structure, and more and more widely used.The hollow shaft worm gear reducer is equipped with a helical gear reducer at the input end of the worm gear reducer. The multi-stage reducer formed can obtain very low output speed. It is a combination of helical gear stage and worm gear stage, which is more pure Single-stage worm gear reducer has higher efficiency.Moreover, the vibration is low, the noise is low, and the energy consumption is low.Common problems and their causes. 1) The reducer heats up and leaks oil, (2) the worm gear is worn, (3) the drive pinion helical gear is worn, and (4) the bearing (at the worm) is damaged. 1 The reducer heats up and leaks oil.In order to improve the efficiency of the worm gear reducer, non-ferrous metals are generally used as the worm gear, and the worm is made of harder steel. Because it is a sliding friction transmission, it will generate higher heat during operation, which makes the parts and seals of the reducer There is a difference in thermal expansion between them, which creates a gap in each mating surface, and the oil becomes thinner due to the increase in temperature, which is easy to cause leakage.There are four main reasons. One is whether the combination of materials is reasonable, the other is the surface quality of the meshing friction surface, the third is the choice of lubricating oil, whether the amount of addition is correct, and the fourth is the assembly quality and use environment. 2 Worm gear wear.The worm wheel is generally made of tin bronze, and the matched worm material is generally hardened with 45 steel to HRC45-55, and 40C: hardened HRC50-55 is commonly used, and it is ground to a roughness of RaO.8fcm by a worm grinder. When the reducer is in normal operation, the worm It is like a hardened "file" that keeps filing the worm gear, causing the worm gear to wear.Generally speaking, this kind of wear is very slow, like some reducers in a certain factory can be used for more than 10 years.If the wear rate is fast, it is necessary to consider whether the selection of the reducer is correct, whether there is overload operation, the material of the worm gear, the assembly quality or the use environment and other reasons. 3 The drive pinion helical gear is worn.It usually occurs on the reducer installed vertically, mainly related to the amount of lubricant added and the choice of lubricant.When installed vertically, it is easy to cause insufficient amount of lubricating oil. When the reducer stops running, the transmission gear oil between the motor and the reducer is lost, and the gears cannot get the proper lubrication protection, and they cannot get effective during start-up or operation. The high lubrication causes mechanical wear and even damage. 4 Worm bearing is damaged.When the reducer fails, even if the reduction box is well sealed, the factory often finds that the gear oil in the reducer has been emulsified, and the bearings have been rusted, corroded, and damaged. This is because the gear oil is It is caused by the condensation of moisture generated after the heat becomes cold; of course, it is also closely related to the quality of the bearing and the assembly process.Solution. (1) Guarantee assembly quality.In order to ensure the quality of assembly, the factory purchased and made some special tools. When disassembling and installing the worm gear, worm, bearing, gear and other parts of the reducer, try to avoid direct hitting with hammers and other tools; when replacing gears, worm gears, and worms, try your best Use original parts and replace in pairs; when assembling the output shaft, pay attention to the tolerances, D≤50mm, use H7/k6, D>50mm, use H7/m6, and use anti-sticking agent or red lead oil to protect the hollow The shaft prevents wear and rust, prevents the mating area from being dirty, and is difficult to disassemble during maintenance. (2) Selection of lubricating oil and additives.Worm gear reducers generally use 220# gear oil. For reducers with heavy loads, frequent starts, and poor use environments, the factory also uses some lubricating oil additives (such as Anji Chemical Company’s good). When the operation is stopped, the gear oil is still attached to the gear surface to form a protective film to prevent heavy load, low speed, high torque, and metal-to-metal contact during startup.The additives also contain seal ring regulator and anti-leakage agent to keep the seal ring soft and elastic and effectively reduce lubricating oil leakage. (3) Selection of the installation location of the reducer.Where the location permits, try not to use vertical installation.In vertical installation, the amount of lubricant added is much larger than that in horizontal installation, which is likely to cause heat generation and oil leakage of the reducer.Some of the 40000 bottles/hour pure draft beer production lines introduced by the factory are installed vertically. After a period of operation, the transmission pinion gears are greatly worn or even damaged. After adjustments, the situation has been greatly improved. . (4) Establish a corresponding lubrication maintenance system.The factory maintains the reducer in accordance with the "five fixed" principle of lubrication work, so that every reducer is regularly inspected by a valuable person. When the oil temperature is found to rise significantly during work, the temperature rise exceeds 40 ℃ or the oil temperature When the temperature exceeds 80°C, the quality of the oil is reduced, or more copper powder is found in the oil, and abnormal noise is generated, immediately stop using it and repair it in time, eliminate the fault, and replace the lubricating oil before use.When refueling, pay attention to the same amount of oil and installation position to ensure that the reducer is properly lubricated.In short, the hollow shaft worm reducer is easy to install, reasonable in structure, reliable and durable.Of course, we must also pay attention to choosing the grade of the reducer. The powerful company will adopt the design points according to the design of the reducer, the layout of the heat dissipation ribs, the calculation of the heat balance, the design of the oil circuit, and the actual use and operating conditions of the reducer. The manufacturing process produces high-quality, reliable and durable reducers.As long as users use and maintain them correctly, they can get satisfactory results

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