I. Common problems and their causes:
Worm gear reducer heating and oil leakage. In order to improve the rate, worm gear reducer generally use non-ferrous metal to do worm wheel, worm is used in harder steel. Due to the sliding friction transmission, operation will produce more heat, so that the reducer parts and seal the difference in thermal expansion between the formation of gaps in the various mating surfaces, the lubricant fluid due to the rise in temperature thinning, easy to cause leakage. There are four main reasons for this situation, one is the unreasonable matching of materials; second is the poor quality of the surface of the meshing friction surface; third is the incorrect selection of the amount of lubricant added; fourth is the poor quality of assembly and use of the environment.
2. Worm gear wear. Worm wheel generally use tin bronze, paired with the worm material with 45 steel hardened to HRC4555, or 40Cr hardened HRC5055 by worm grinding machine grinding to roughness Ra0.8μm. reducer normal operation wear is very slow, some reducer can be used for more than 10 years. If the wear rate is fast, we have to consider whether the selection is correct, whether overload operation, and worm gear worm material, assembly quality or use of the environment and other reasons.
3, drive small helical gear wear. Generally occurs in the vertical installation of the reducer, mainly with the addition of lubricant and oil varieties. Vertical installation, it is easy to cause the amount of lubricant is not enough, the reducer stops running, the motor and reducer transmission gear oil loss, gears do not get due lubrication protection. When the reducer starts, the gears are not effectively lubricated resulting in mechanical wear and even damage.
4. Damage to the worm gear bearing. When the failure occurs, even if the gearbox is well sealed, it is still often found that the gear oil in the reducer is emulsified and the bearings are rusted, corroded and damaged. This is because the worm gear reducer after running for a period of time, the gear oil temperature rises and cools the condensate produced by the water mixed with water. Of course, it is also closely related to the bearing quality and assembly process.
Second, worm gear reducer solution:
1. Ensure the quality of assembly. You can buy or make some special tools, when disassembling and installing reducer parts, try to avoid hammering and other tools; when changing gears, worm gears, try to use original parts and pairs of replacement; when assembling the output shaft, pay attention to the tolerance of the fit; use anti-sticking agent or red Dan oil to protect the hollow shaft, to prevent abrasion and rust or with the area of scale, difficult to dismantle during maintenance.
2, the selection of lubricants and additives. Worm gear reducer generally use 220# gear oil, for heavy load, frequent startup, use of poor environment reducer, you can choose some lubricant additives, so that the worm gear reducer in the stopping of the gear oil is still attached to the gear surface, the formation of a protective film, to prevent heavy loads, low-speed, high-torque and start the direct metal-to-metal contact. The additives contain sealing ring conditioner and anti-leakage agent to keep the sealing ring soft and elastic and effectively reduce the lubricant leakage.
3. Selection of the installation position of the speed reducer. If the position allows, try not to use vertical installation. When installed vertically, the amount of lubricant added is much more than that of horizontal installation, which is easy to cause heat and oil leakage of the reducer.
4, the establishment of lubrication and maintenance system. According to the lubrication work "five" principle of maintenance of the reducer, so that each reducer has a responsible person to check regularly, found that the temperature rise is obvious, more than 40 ℃ or the oil temperature exceeds 80 ℃, the quality of the oil or the oil is found in the decline in the number of copper powder as well as abnormal noise and other phenomena, to immediately stop using, timely maintenance, troubleshooting, change the lubricant. Troubleshooting, change the lubricant. When refueling, pay attention to the oil volume to ensure that the reducer is properly lubricated.