Xieyi Village, Jingjiang Street, Xiaoshan, Hangzhou, Zhejiang
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Xieyi Village, Jingjiang Street, Xiaoshan, Hangzhou, Zhejiang
Hangzhou Yiding Transmission Machinery Co., Ltd. stands at the forefront of the industry as an exceptional worm gear gearbox and worm gear reduction manufacturer. For over 12 years, we have dedicated ourselves to engineering excellence, delivering high-quality, efficient, and reliable gearboxes that meet a variety of needs.
Our flagship product, the YNMRV Series Involute Spur Gear 1400rpm Worm Gearbox, is a testament to our commitment to quality and innovation. This worm gear reducer is designed for superior performance, featuring a rated power of 0.06-15KW, making it versatile for a wide range of applications.
At Hangzhou Yiding, we understand the value of uniqueness in every project. That’s why we offer customization options for our worm gear gearboxes. With orders of 1000 sets or more, clients can avail personalized logos, custom packaging, and graphic designs, enabling our product to align seamlessly with your brand identity.
Reliability is at the core of our services. Boasting an on-time delivery rate of 100%, we ensure that our products reach our clients as scheduled. Our quick response time of less than 3 hours is a demonstration of our commitment to excellent customer service.
Quality control is a paramount aspect of our operations. We employ a team of 15 dedicated QA/QC inspectors, and our finished product inspection services ensure that every worm gear gearbox leaving our factory meets our stringent quality standards.
In choosing Hangzhou Yiding, you are opting for a partnership with a leading worm gear gearbox manufacturer that is devoted to quality, customer satisfaction, and innovation.
(1) The worm gear reducer is more crude, not as precise as the worm gear reducer, and the torque of the worm gear reducer of the same specification is larger than that of the worm gear reducer.
(2) worm gear gearbox is mainly aluminum alloy more, but the worm gear reduction is only cast iron.
(3) The price of worm gear reduction is much cheaper than the price of worm gear gearbox.
The worm gear reducer, when used, must be replaced with new spare parts after running-in and load test before official use. It is a power transmission element that can be used with common motors, stepless transmissions and other transmission products.
The worm gear gearbox is a power transmission mechanism that uses the speed converter of gears to decelerate the number of revolutions of the motor (motor) to the desired number of revolutions and to obtain a larger torque. Among the mechanisms currently used to transmit power and motion, worm gear reduction has a wide range of applications.
Worm gear reduction is a power transmission mechanism that uses a gear speed converter to decelerate the number of revolutions of a motor (motor) to the desired number of revolutions and to obtain a larger torque. Among the mechanisms currently used to transmit power and motion, the range of applications for worm gear reduction is quite wide. It can be found in almost all kinds of machinery transmission systems, from ships, automobiles, locomotives for transportation, heavy machinery for construction, processing machines and automated production equipment used in the machinery industry, to common household appliances and clocks in daily life, etc.. The applications of worm gear reduction range from large power transmission to small loads and precise angular transmission, and in industrial applications, worm gear reduction has the function of deceleration and torque increase. Therefore, it is widely used in speed and torque conversion equipment.
(A) Reduce the speed and increase the output torque at the same time, the torque output ratio is multiplied by the motor output by the reduction ratio, but be careful not to exceed the rated torque of the worm gear reduction.
(B) deceleration while reducing the inertia of the load, the reduction of inertia is the square of the reduction ratio. You can look at the general motor has an inertia value.
In addition, the table machine manufacturers introduce the following worm gear common failures:
(1) worm gear reduction heat and oil leakage.
(2) worm gear wear.
(3) drive pinion wear.
(4) bearing (worm gear) damage.
1, worm gear reduction heat and oil leakage. worm gear reducer in order to improve efficiency, generally use non-ferrous metal worm wheel, worm gear is made of harder steel, because it is sliding friction transmission, in the process of operation, it will generate high heat, so that worm gear reduction between the thermal expansion of the parts and seals to produce Differences, thus creating a gap between the mating surfaces, and the oil due to the rise in temperature becomes thin, easy to cause leakage. There are four main reasons, one is whether the material with reasonable, two is the surface quality of the mesh friction surface, three is the choice of lubricant, add the correct amount, four is the quality of assembly and use of the environment.
2、Worm wheel wear. The worm wheel generally uses tin bronze, paired with the worm material is generally 45 steel hardened to HRC45 a 55, also commonly used 40C: hardened HRC50 a 55, by worm grinding machine grinding to roughness RaO. 8 fcm, worm gear reduction in normal operation, the worm is like a hardened “file “, constantly filing the worm wheel, so that the worm wheel wear. Generally speaking, this wear is very slow, such as Taiwan machine worm gear reduction can be used for more than 10 years. If the wear rate is faster, we should consider whether the selection of worm gear reduction is correct, whether there is overload operation, worm gear material, assembly quality or use environment and other reasons.
3, drive pinion gear wear. Generally occur in the vertical installation of the worm gear reduction, mainly with the amount of lubricant added and the choice of lubricant. Vertical installation, it is easy to cause insufficient lubricating oil, when the worm gear reduction stop running, the motor and worm gear reduction between the transmission gear oil loss, gears do not get the proper lubrication protection, start or operation process can not be effectively lubricated resulting in mechanical wear and even damage.
4, worm bearing damage. worm gear reduction failure, even if the gearbox is well sealed, or often found in the worm gear reduction gear oil has been emulsified, the bearing has been rusted, corrosion, damage, this is because the worm gear reduction in the process of operation and stopping, gear oil from hot to cold after the generation of water Coalescence caused by hot to cold gear oil in the process of operation and stopping; of course, also and bearing quality, assembly process method is closely related.
The first thing that comes to your mind is the cylindrical worm drive and the ring envelope worm drive. Next I introduce another kind of worm gear transmission: worm gear transmission.
The worm gear drive has been standardized in many countries, but it has not been popularized in China because the designers are less exposed to it. The worm gear drive is suitable for staggered shaft drive with transmission ratio greater than 10 (can not be 90°). The worm gear is offset on one side of the conical worm wheel, and the worm gear tooth surface is Archimedean spiral, with equal lead along the indexing cone bus, which can be processed by turning, milling, rolling, etc. The hard-tooth worm gear with high accuracy and surface finish requirements also needs to be ground. The conical worm wheel is cut by the conical hobbing tool in line with the worm gear on a common hobbing machine, the appearance like a spiral bevel gear, precision and surface finish requirements are high, fine rolling after rolling or honing; large output and precision to be not high, but also can choose die-casting, sintering, die forging and other processing methods.
Archimedes worm gears and Archimedes cylindrical worm gears have the same principle of tooth surface transformation, both belong to the cylindrical spiral surface.
The difference only lies in the fact that the worm gear intercepts the part between the top conical surface and the root conical surface on this spiral surface as the tooth surface, therefore, the conical.
The worm drive retains all the advantages of Archimedes cylindrical worm drive, such as easy to build and assemble, worm gear axial position without destroying the tooth conjugation, etc.
The conical worm drive therefore retains all the advantages of the Archimedean cylindrical worm drive, such as ease of construction and assembly, axial displacement of the worm without destroying the tooth conjugation, etc. The key difference between worm gearing and cylindrical worm gearing is that the worm gear is biased, so the number of teeth in contact increases significantly at the same time.
If the geometric parameters are selected normally, the instantaneous contact line can be obtained, which is favorable to the liquid power lubrication of the tooth surface.
If the geometric parameters are selected normally, the instantaneous contact line can be obtained, which is favorable to the liquid power lubrication of the tooth surface. This makes the meshing function of worm gear transmission significantly better than Archimedes cylindrical worm transmission.
(1) the degree of overlap is large, while the number of contact teeth is intended to be 10% of the number of teeth of the conical worm gear.
(2) The angle between the combined speed and the instantaneous contact line normal is small, even close to zero degrees, which is conducive to liquid power lubrication between the teeth.
(3) By moving the worm gear axially, the tooth side clearance can be adjusted without destroying the conjugate of the tooth surface.
(4) It can be used as a clutch, and it is very flexible in combining and disconnecting, and the central distance remains unchanged when disconnecting.
Compared with the cylindrical worm, the worm gear transmission is smooth, the load capacity is large, the efficiency is high, and the structure is hinged when the transmission contrast is large.
The structure is also tight when the transmission is large. When the tooth surface finish is high, the tooth surface contact is good, and the extreme pressure lubricant is selected, carburizing and quenching steel or nitriding steel can also be used instead of bronze.
When the tooth surface finish is high and the tooth contact is good, and extreme pressure lubricant is used, carburized hardened steel or nitride steel can be used instead of bronze as worm gear material. This is also in line with the contemporary gear industry’s recommendation to use hardened gears.
Because the worm gear has
The worm gear has a taper and is slightly more mixed than the Archimedes cylindrical worm.
Compared with the annular worm, the worm gear is simpler to build and assemble, and is not sensitive to axial position deviation.
The worm gear can maintain a good contact area when the worm gear moves slightly under axial force.
A worm gear reduction is a power transmission mechanism that is used in applications where high torque and low speed are required, such as conveyor belt mixers, automation machines…
With the development of industry and factory automation, the demand for worm gear reduction is growing.
There are many ways to reduce speed, but the most common method is to use gears to reduce speed. The gear box itself is not powered, so it needs a drive component to drive it, where the drive component can be a motor or steam engine.
1. Power transmission
2. to obtain a certain speed, usually a lower speed
3. to obtain a larger torque, can use less energy to drive more bulky machinery and equipment.
4. Deceleration reduces the inertia of the load at the same time, and the reduction of inertia is the square of the reduction ratio.
cycloid worm gear reduction (electric de-dusting, alkaline ash tank, digester ) hardened cylindrical gear reduction (disc evaporator, pre-hanging, de-slagging machine)
Planetary gear worm gear reduction (into the black liquid tank)
crane worm gear reduction(electric hoist)
Worm gear reduction ( solid-liquid separator, causticizer, pre-hanging scraper, soot blower )
Soft tooth surface worm gear reduction
Three ring worm gear reduction
Shaft-mounted hard gear worm gear reduction
Stepless transmission
1, worm gear gearbox of the two axes are crossed perpendicular to each other; worm can be seen as a cylinder along the spiral line around a tooth (single head) or several teeth (multi-head) of the spiral, worm gear is like a helical gear, but its teeth wrapped worm in the mesh, worm turn a turn, drive the worm wheel to turn a tooth (single head worm) or several teeth (multi-head worm), so worm gear transmission Therefore, the speed ratio of the worm gear transmission i = the number of heads of the worm Z1 / the number of teeth of the worm wheel Z22.
2. The worm gear can also be regarded as the most basic spiral principle. The worm gear is equivalent to a nut and the worm to a screw.
1. It has a reverse self-locking function. Therefore, the steering wheel of a vehicle generally uses this function, which has the characteristics of labor-saving and flexible rotation.
2, can have a large reduction ratio ( single-stage speed ratio is generally 10 ~ 80) 3, the input axis and output axis is not in the same axis, nor in the same plane 4, worm gear can get a precise small rotation, so worm gear transmission is often used for indexing.
1.Low efficiency, generally 0.7–0.9; when the speed reduction ratio is large, the efficiency is even below 0.5
2.The relative sliding speed between the teeth is large, so the heat generation is large, and good cooling and lubrication conditions are required when working.
3.When transmitting power at higher speed, the worm gear is often made of more expensive non-ferrous metal (bronze), which is more costly.
4.The worm wheel is more difficult to manufacture than the gear.
5.The axial force of worm gear is large, and the bearing wear is large.
1, bronze has a lubricating effect, which is conducive to reducing friction
2, bronze texture is soft, generally worm gear materials are harder than the worm wheel, worm wheel is the passive wheel, worm is the active wheel is generally connected to the motor, in case of equipment failure can not rotate, the motor can be damaged by the worm gear soft texture to protect the motor is not burned, the motor continues to rotate.
1、Check that there is no jam and abnormal sound
2、Lubricant meets the requirements, according to the company’s equipment department requires all worm gear gearbox use 460# gear oil
3、Tightening of couplings such as couplings and foot bolts should be free of looseness.
1、Check the seal for leakage, oil leakage and other phenomena.
2、Check the bearing temperature, rolling bearing temperature is not more than 70°C.
3、Run smoothly, no shock, vibration and abnormal sound, the current does not exceed the rated value.
worm gear reducer in order to improve efficiency are generally used non-ferrous metal worm gear worm is made of harder steel, because it is sliding friction transmission, in the process of operation, it will generate high heat, so that worm gear reduction parts and the difference in thermal expansion between the seal, thus creating a gap in the mating surface, and the oil due to the rise in temperature becomes thin This will easily cause leakage.
Worm gear is generally used tin bronze, paired worm material is generally used 45 steel hardened to HRC45 a 55 also commonly used 40C: hardened HRC50 a 55, by rod grinder grinding to roughness Ra08 fcm, worm gear reduction in normal operation, worm like a hardened “clang knife” When the worm gear reduction is in normal operation, the worm gear is like a hardened “clamping knife”, which keeps clamping the worm gear and makes the worm gear wear.
Because the worm gear reduction in the process of operation and stopping, gear oil from hot to cold after the water coalescence caused; of course, also closely related to the quality of the bearing, assembly process method.
1, according to the company’s lubrication work in the “five” principle, the maintenance of worm gear reduction. (Five fixed: fixed point: according to the requirements of lubrication parts refueling, not missing. Fixed: the daily refueling parts of the equipment, regular refueling parts are responsible by a person. Quality: according to the requirements of the equipment to choose the quality of qualified lubricating grease. Timing: the lubrication parts of the equipment, according to the specified time interval for refueling, cleaning or replacement of new oil. Monthly or according to the oil level to determine the refueling time; quantitative: according to the number of equipment calibrated, plus the selected lubricating grease, oil window between 1/2-2/3).
2、worm gear reduction by a person to regularly check
3、When the oil temperature is found to rise significantly during the inspection, the temperature rise exceeds 40°C or the oil temperature exceeds 80°C, the quality of the oil decreases or more copper powder is found in the oil as well as generating abnormal noise and other phenomena, the use should be stopped immediately for timely maintenance and troubleshooting.
The input form of worm gear reduction is divided into: hole input, shaft input, and extended worm shaft type; the output form of worm gear reduction is divided into: hole output, one-way shaft output, and two-way shaft output.
1、Worm gear speed is less than or equal to 1400rpm.
2、The center distance has 25, 30, 40, 50, 63, 75, 90, 110, 130 total 9 kinds; 3、Single speed ratio has, 7.5, 10, 15, 20, 25, 30, 40, 50, 60, 80, 100 total 11 kinds of speed ratio.
4, worm gear reduction can be forward and reverse direction operation.
1、A variety of installation forms can be used according to the actual requirements, and all six sides can be installed.
2、Installation must be solid and reliable.
3, the prime mover, worm gear reduction of the working mechanism must be carefully aligned between the error shall not be greater than the permissible compensation of the coupling used; 4, after installation by hand rotation, must be flexible, no stalling phenomenon.
1、Replace the lubricant after 150-400 hours of operation when using or replacing the worm gear gearbox for the first time, and after that the oil change interval is less than or equal to 4000 hours.
2、Check the quantity and quality of oil regularly, keep enough oil, and replace the oil mixed with impurities or deteriorated oil in time.
3、The oil injection quantity shall be according to the table requirements, different grades of oil are prohibited to be mixed, the same grade but different viscosity of oil is allowed to be mixed.
4、The amount of oil injection Schedule I, oil products according to Schedule II.
5、worm gear reduction working environment temperature is a 40 ° C ~ +40 ° C, when the ambient temperature is lower than 0 ° C, lubrication must be heated to more than 0 ° C before starting or use low freezing point of the lubricant.
1、No gravity hammering worm gear reduction shell to avoid damage.
2, regular maintenance of the installation base, seals, drive shaft, etc. is normal.
3, such as normal use, the maximum temperature of the lubricating oil should be less than 85 ° C. Oil temperature changes abnormally, resulting in abnormal noise and other phenomena, should be immediately shut down to check, after the exclusion of other faults, the main can continue to use.
4, the replacement of new spare parts must be run together and load test before official use.
Each type of worm gear reduction has its own specific performance and characteristics, to understand the advantages and disadvantages of worm gear gearbox, you can make better use of worm gear reduction. first you have to know what is worm gear gearbox. worm gear gearbox is a traditional transmission device inside It is a worm gear with involute teeth. Its advantages are: long service life, low speed of the promised input scale, and large scale of deceleration. With self-locking function suitable for lifting operations, such as elevators, hoists, etc. are indispensable worm gear reducer.
The disadvantage of worm gear reducer is: the working efficiency is too low, it can only reach 60~70 percent and the wheel rod is generally output by the shaft. It is difficult to control the empty return, especially when the worm gear and worm gear are worn out for a long time, the empty return is larger.
The worm gear gearbox has significant advantages. The first point is that, at the design level, its design structure is relatively compact, so the volume is relatively small and the weight is relatively light, which makes it a very efficient machine to use, and the efficiency is relatively high.
The second point is that it has good heat exchange performance, after a long time using the machine, it is generally more difficult to dissipate heat, resulting in the onset of heat of the machine, because the performance of this aspect of the worm gear reducer is better, the distribution is also faster, so you can use the length of time is also relatively long.
And the purpose will not be too much heat and other issues to form harm to the staff.
The third point, worm gear reduction device is particularly convenient, its six sides can be installed at will, will not be easy to appear stuck phenomenon, the operation is also more flexible, is a superior performance of the machine. Because the disassembly and assembly is more convenient, so the repair is also more convenient. The fourth point, in the use of noise does not easily appear when the operation is stable, the use of a long time. Finally, it is adaptable, and the safety factor is also relatively large.
worm gear gearbox disassembly and overhaul has always been a headache for the protection staff, many times due to untimely protection led to worm gear reducer damage or problems, resulting in the project can not be carried out properly, so it is still advocated that repair staff to protect in a timely manner, and to protect in place. Many people do not know where to start when overhauling the worm gear reducer, today to solve this problem for you, so that you become a good technician to protect the worm gear reducer.
1. Ensure the quality of the device. Can buy or gram some special tools, disassembly and installation of worm gear reduction parts, try to avoid knocking with other tools such as hammers; replacement gear, worm gear, try to use the original parts and replacement pairs, the device output shaft, to pay attention to the public service cooperation; to use anti-adhesive or red Dan oil to protect the hollow shaft, to avoid wear and rust or cooperation area scale, repair difficult to disassemble .
2 establish lubrication protection guidelines. Can be based on lubrication work “five” principle of worm gear reduction for protection, so that each worm gear reduction are responsible for the regular check, found that the temperature rise significantly, beyond 40C or oil temperature beyond 80C oil quality decline or oil found in more copper powder and Generate abnormal noise and other phenomena, to immediately suspend the use of timely maintenance, troubleshooting, replacement of lubricants. When refueling, pay attention to the amount of oil, to ensure that the worm gear reduction get the correct lubrication.
3. The choice of lubricants and additives. Worm gear reduction generally choose 220 # gear oil, heavy load, start frequent use of poor environment worm gear reduction, can choose some lubricant additive, so that worm gear reduction in suspended operation gear oil still attached to the gear surface, the formation of protective film, to avoid heavy load, low speed, high It can avoid the direct contact between metal when heavy load, low speed, high torque and start. The additive contains seal adjuster and anti-leakage agent, which makes the seal stick to be soft and elastic, and effectively reduces the leakage of lubricant.
4. worm gear reduction device location selection. worm gear reduction factory thought that the location allows the situation, try not to use the vertical device vertical device, the amount of lubricant increase than the horizontal device much more, easy to form worm gear reduction heat and oil leakage.
5. Sort out the external oil of the worm gear reducer, check the oil level of the lubricant, and make a record of releasing the lubricant
6. Remove the cover screw, open the cover, check the wheel and record (position and direction)
7、Take out the worm gear reducer and shaft, and then disassemble the worm shaft in the same way to check the worm and shaft.
8, check the oil quality condition (there is no oil, iron quiet and impurities, deterioration, etc. in order to standby fault inquiry with)
9, disassemble the worm gear shaft end cover screws, remove the end cover, to make a record or symbol (the number of gaskets, etc.)
10、Before the collapse, check the axial clearance of the worm gear and make a record
11、Collapse (before cone, make a symbol to take out the box locating pin deep hole locating pin with a pin remover to take out, through-hole locating pin its hit from the small head.
12, clean the box, worm gear and all parts.
Modulus m, pressure angle, worm diameter coefficient q, lead angle, worm head number, worm gear tooth number, tooth top height coefficient (take 1) and top coefficient (take 02.) Among them, modulus m and pressure angle refer to the modulus and pressure angle of the shaft surface, that is, the modulus and pressure angle of the wheel shaft surface, and they are standard values; worm diameter coefficient q is the ratio of worm index diameter and its modulus m.
Worm guide angle 0 is the angle between the tangent line of the worm indexing cylinder on the helix and the end face of the worm, and the relationship between the screw helix angle, the helix angle of the worm wheel, large transmission efficiency is high, when smaller than the equivalent friction angle between the meshing teeth, the mechanism self-locking.
The worm diameter coefficient q is introduced to limit the number of worm wheel hobs, so that the rod indexing circle diameter is standardized m-timing,9 large is large, the worm shaft stiffness and strength increases accordingly, when certain, small is the lead angle increases, the transmission efficiency increases accordingly.
The recommended values of worm head are 1, 2, 4, 6, when taking small values, the transmission ratio is large and self-locking; when taking large values, the transmission efficiency is high
Different from cylindrical gear transmission, the transmission ratio of worm gear mechanism is not equal to, but, the center distance of worm gear mechanism is not equal to, but.
The method of determining the worm wheel steering in worm gear transmission can be determined according to the direction at the meshing point K, the direction (parallel to the tangent of the helix) and the speed vector triangle that should be drawn perpendicular to the axis of the worm wheel, or the right-hand grip of the right-hand worm and the right-hand grip of the left-hand worm with four thumbs].
1. The modulus and pressure angle of the worm and worm gear in the middle plane are equal respectively, that is, the end surface modulus of the worm gear is equal to the axial surface modulus of the worm gear and is the standard value; the end surface pressure angle of the worm gear should be equal to the axial surface pressure angle of the worm gear and is the standard value, that is, ==m, =
2 When the intersection angle of the worm wheel and worm gear is, it is also necessary to ensure that the worm wheel and worm gear helix rotation must be the same.
Line contact between the meshing tooth surfaces of the two wheels, and its load-bearing capacity is much higher than the staggered shaft helical gear mechanism
The worm drive is equivalent to the helical drive, and is a multi-tooth mesh drive, so the drive is smooth and very quiet.
It has self-locking property. When the lead angle of the worm is smaller than the equivalent friction angle between the teeth of the meshing wheel, the mechanism has self-locking, which can realize reverse self-locking, that is, only the worm can drive the worm wheel, but not the worm wheel can drive the worm. For example, the self-locking worm gear mechanism used in heavy machinery, its reverse self-locking can play a safety protection role
The transmission efficiency is lower and the wear is more serious. When the worm gear mesh transmission, the relative sliding speed between the teeth of the mesh wheel is large, so the friction loss is large and the efficiency is low. On the other hand, the relative sliding speed of the teeth of the ambassador wear serious, serious heat, in order to dissipate heat and reduce wear, often using more expensive friction and anti-wear materials and good lubrication device, and therefore higher cost worm shaft axial force is larger
The worm gear mechanism is often used to transmit the motion and power between two staggered shafts. The worm gear and worm gear are similar to the gear and rack in its middle plane, and the worm gear is similar to the shape of the screw.
The worm gear gearbox is a kind of transmission machinery with compact structure, large transmission ratio and self-locking function under certain conditions, which is one of the commonly used worm gear reductions. Among them, the hollow shaft type worm gear reduction not only has the above characteristics, but also has an easy installation and reasonable structure, which is becoming more and more widely used. Hollow shaft worm gear reduction is a multi-stage reducer with a helical gear reducer at the input end of the worm gear reducer, which can obtain very low output speed and is a combination of helical gear stage and worm gear stage.
The worm gear reducer has the characteristics of compact structure and good transmission effect, and also has its own self-locking ability, so the safety is more stable. The worm gear reduction not only has the above characteristics, but also has the characteristics of low installation difficulty and excellent convenience, so it is loved by most industries. In the process of application, by installing the reducer gear at the input end, two different combinations can be formed to achieve multi-stage combined reduction, thus ensuring the transmission ratio while improving the mechanical efficiency and stability of the system.
The worm gearbox is used in the traditional machinery field, mainly because of its advantages in the following aspects.
First, worm gear gearboxes can greatly increase the output torque of the system after deceleration. The higher torque not only helps to accomplish more intense work, but also prevents the wear and tear caused by insufficient torque. In this way, the electric motor hydraulic booster can be more widely involved in the production and practice of human society.
Second, the reducer can reduce the inertia load of the load, by reducing the inertia load, it can effectively improve the conversion rate of the system energy, so that the motor output power energy is not wasted.
Thirdly, the worm gear reduction can change the direction of the torque, so the output torque can be more flexibly distributed in the system, which effectively extends the flexibility of the application.
(1) Reduce the speed and increase the output torque at the same time Torque output ratio according to the motor output multiplied by the reduction ratio, but be careful not to exceed the rated torque of the worm gear reduction.
(2) Deceleration reduces the inertia of the load at the same time, and the reduction of inertia is the square of the reduction ratio.
(1) worm gear reduction heat and oil leakage.
worm gear reducer in order to improve efficiency, the general use of non-ferrous metal worm wheel, using harder steel, because it is sliding friction transmission, in the process of operation, it will generate higher heat, so that the worm gear reduction between the parts and sealing thermal expansion differences, thus creating a gap in the mating surface, and the oil due to the rise in temperature becomes thin. easily cause leakage.
There are four main reasons:
(a) whether the material match is reasonable.
(b) the surface quality of the mating friction surface.
(c) the choice of lubricant, add the correct amount.
(d) assembly quality and use of the environment. Ensure the quality of assembly. Can buy or make some special tools, disassembly and installation of worm gear reduction parts, try to avoid using hammers and other tools to knock; replacement of gears, worm gear, try to use the original spare parts and pairs of replacement: assembly output shaft to pay attention to the tolerance fit; to use anti-adhesive or red Dan oil to protect the hollow shaft, to prevent wear and rust or with the area of dirt, difficult to disassemble during maintenance.
The tooth surface of worm gearbox is mostly treated by quenching, so that the overall stability and wear resistance of the reducer will be improved. However, since the motion itself is frictional transmission, it is inevitable that a large amount of heat will be generated, which will lead to thermal expansion, and long-term thermal expansion will lead to gaps in the surface of the worm gear reduction parts, and at this time, if the lubrication level is not sufficient, it will lead to oil leakage in the worm gear reduction, and the heat generation will also increase dramatically. The heat generation will also increase rapidly. In view of this type of failure, the following protection strategies are needed.
First, change the material and choose a material with better heat resistance.
Second, choose the appropriate grease for lubrication treatment to improve the lubrication performance; again. The assembly quality of the equipment should be controlled. And improve the management level of the operating environment.
Lastly. In the process of equipment operation, use the original bearings and oil seals.
(2) Worm wheel wear.
Worm gear generally uses tin green paired worm material generally used 45 hardened to HRC5 – 55 also commonly used 40C; hardened HRC50 a 55 by worm grinding machine to roughness Ra08 fcmworm gear reduction normal operation of the worm is like – a hardened “clang knife”, constantly cutting the worm wheel The worm gear wears out. Generally speaking, this wear is very slow, such as a factory some worm gear reduction can be used for more than 10 years.
If the wear rate is faster, we should consider whether the selection of the worm gear reduction is correct, whether there is overload operation, the material of the worm gear, the quality of assembly or the use of the environment and other reasons.
Selection of lubricant and additives. Tooth worm gear reduction generally choose 220 gear oil, heavy load, start frequently, the use of poor environment worm gear reduction, can choose some lubricant additives, so that worm gear reduction in stop running gear oil is still attached to the gear surface, forming a protective film to prevent heavy load, low speed and high torque and Direct contact between metals during start-up. The additives contain seal conditioners and anti-leakage agents to keep the seals soft and flexible, effectively reducing lubricant leakage.
The problem of turbine wear occurs mainly during use, as it is a frictional contact, so in the case of poor lubrication, friction will increase and wear and aging will occur. In most cases, the normal working life of a worm gear reduction is at least 3 years, which means that the increased wear within 3 years is a failure. When there is abnormal wear, the first thing to consider is whether it is the wrong type, or overload operation during the work process, and the operating environment and other factors. In most cases, the actual work of the worm gear reduction requires the selection of a suitable lubrication system, and then the consideration of the environment and other factors in the system, and finally, the need to consider the manual operation of the problem.
(3) Drive pinion gear wear.
Generally, it occurs in the vertical installation of the worm gear reduction, mainly related to the amount of lubricant added and the choice of lubricant. Vertical installation, it is easy to cause insufficient lubricating oil, when the worm gear reduction stop running, the motor and worm gear reduction between the transmission gear oil loss, gears do not have due lubrication protection, start or operation process can not be effectively lubricated leading to mechanical wear and even damage. worm gear reduction The choice of installation position. If the location allows, try not to use vertical installation. Vertical installation. The amount of lubricant added is much more than the horizontal installation, easy to cause worm gear reduction heat and oil leakage.
The bearing failure of worm gear box is usually rust or direct breakage limit, the problem is generally due to the sudden change of system temperature, of course, in the actual work, due to the assembly process did not do a good job of quality control or the assembly process itself has problems can also lead to abnormal bearing damage, seriously affect the normal work of worm gear gear box! work
(4) worm gear bearing damage. worm gear reduction failure, even if the gearbox is well sealed, still often appear worm gear reduction gear oil has been emulsified, the bearing has been rusted, corrosion, damage, this is because the worm gear reduction in the process of operation and stopping, gear oil from hot to cold after the generation of water Coalescence, of course, and bearing quality assembly process is closely related to the method. Lubrication maintenance system should be established to ensure that the worm gear reduction is properly lubricated.
The bearing failure of worm gear gearbox is generally rust or direct breakage, the problem is generally due to the sudden change in system temperature, of course, in the actual work, due to the assembly process did not do a good job of quality control or assembly process itself has problems can also lead to abnormal bearing damage, seriously affect the normal work of worm gear gearbox (5) The worm gear gearbox can be damaged due to the lack of quality control during assembly or the assembly process itself.
(5) worm gear reduction transmission gear friction
Most of the problems of gear friction in worm gear reduction transmission are caused by insufficient lubrication. If there is a large amount of friction under adequate lubrication, then mechanical wear should be considered and a system check should be performed to see if it is the result of overload operation or assembly problems.
Improving the daily maintenance and repair is the basic condition to ensure the normal operation of the worm gear reducer. In the maintenance process, on the one hand, we need to judge the sound and state of its operation, to see if there is a strange noise or abnormal shaking. The temperature should also be monitored to see if there is a problem with the combination surface of the gearbox or other problems: on the other hand, the location of the upper and lower combination surface of the gearbox needs to be monitored to see if there is oil seepage and oil leakage, and the location of the oil surface should be checked and replenished regularly. In the maintenance can be some safety protection treatment or local cleaning, if the failure is large then need to repair management of the wear area, by replacing the driven gear and shaft to avoid the failure day.
The development of a comprehensive maintenance plan needs to be selected in relation to the actual type of operation of the equipment and the working environment. Generally speaking, a minor repair should be carried out once in 3-5 months, and a major repair should be carried out once in 6-12 months, and regular re-inspection should be carried out to examine the effect of repair and maintenance after processing.
In order to ensure the quality of assembly, should purchase and homemade some special tools, disassembly and installation of worm gear reduction worm, worm gear, bearings, gears and other components, try to avoid using other tools such as hammers to directly hit; replacement of gears, worm gear, try to use the original parts and replacement in pairs; assembly output shaft, pay attention to the tolerance fit De0 mm using H7/k6, D When assembling the output shaft, we should pay attention to the tolerance fit of H7/k6 for De0 mm and H7/m6 for D >50mm, and use anti-adhesive or red-tan oil to protect the hollow shaft and prevent wear and rusting to prevent the fit area from scaling and difficult disassembly during maintenance.
Worm gear reduction generally choose 220 “gear oil, for some heavy load, start frequently, the use of poor environment worm gear reduction, should also be selected some lubricant additives, worm gear reduction in stop running, gear oil is still attached to the gear surface, forming a protective film to prevent heavy load. Low speed, high torque and start metal and metal contact additives also contain seal regulator and anti-leakage agent, so that the seal remains soft and flexible, effectively reducing the phenomenon of lubricant leakage.
Location allows the case, try not to use vertical installation vertical installation, the amount of lubricant added than the horizontal installation is much more, easy to cause worm gear reduction heating and oil leakage. A plant acid rolling production line, some are installed vertically, after a period of operation drive pinion have greater wear, and even damage, after adjustment, the situation has been greatly improved.
Should be based on the lubrication work “five” principle, the maintenance of worm gear reduction, so that each worm gear reduction are responsible for regular inspection when the work found that the oil temperature rises significantly, the temperature rise of more than 40C or oil temperature more than 80C oil quality decline or in the oil When more copper powder and abnormal noise are found in the oil, it should be stopped immediately and overhauled in time. After the trouble is solved and the oil is replaced, it is necessary to pay attention to the oil quantity and installation position to ensure the correct lubrication of the worm gear reduction.
In view of the advantages of the worm gear gearbox and easy maintenance and repair, worm gear gearbox will continue to play an irreplaceable role in the mechanical transmission system.
The worm gear gearbox has many advantages in the application process, including a large ratio of self-locking and structural stability, which is also makes it in China’s mechanical design and manufacturing links have a wide range of applications.
Although the structure is simple, but it may still face various failure problems, so it needs to do a good job of daily maintenance and maintenance, by doing a good job of worm gear reduction maintenance, can effectively extend the service life, but also can better complete the daily work to improve the comprehensive application of equipment performance.