Xieyi Village, Jingjiang Street, Xiaoshan, Hangzhou, Zhejiang
Menu
Xieyi Village, Jingjiang Street, Xiaoshan, Hangzhou, Zhejiang
The worm speed reducer is a crucial component in various industries, playing a significant role in the transmission equipment industry. This article aims to provide a comprehensive understanding of the worm speed reducer, its common issues, and the innovative solutions to address these problems. We will delve into the intricacies of the worm speed reducer, its tooth shape change faults, and the methods to diagnose and rectify these faults.
What is the impact of tooth shape change on the operation of a worm speed reducer?
Tooth shape change in a worm speed reducer is a significant factor that can lead to high failure rates. This change refers to the deviation of the worm gear teeth from their ideal profile during operation, resulting in frequency modulation. This modulation is primarily characterized by the lucid frequency as the carrier frequency and the worm wheel shaft rotation frequency as the modulation frequency, thereby causing the worm speed reducer to fail.
Maintenance personnel can identify that tooth shape change faults generally do not produce a large shock vibration and have low energy. However, when the tooth shape change is severe, it will produce a large shock vibration and generate significant energy. This will affect the intrinsic frequency of the worm wheel and trigger the failure of the worm speed reducer.
Multidimensional EMD is a method used for processing new types of signals and is applied to the signal of a worm speed reducer in a non-stationary period. A non-stationary signal can be transformed into multiple stationary Intrinsic Mode Functions (IMFs) after EMD decomposition. After decomposition, signals with poor and good performance are grouped separately.
Autocorrelation function is a crucial analysis method that describes the degree of correlation between the instantaneous values of random vibration samples at different moments. When using autocorrelation analysis, the autocorrelation function obtains its maximum value at zero. The autocorrelation function of the periodic function is still a periodic function of the same frequency, and its amplitude has some connection with the amplitude of the original periodic signal.
The Hilbert transform is an important signal analysis and processing tool for the extraction of the fault of the worm speed reducer tooth shape variation. It is mainly based on the decomposition of the empirical mode, and the resulting IMF, and the IMF is Hilbert transformed to obtain a Hilbert spectrum. A complete Hilbert spectrum primarily contains three parts: time, tonality, and amplitude. By analyzing the original signal in the demodulated spectrum, the condition of the worm speed reducer tooth change fault can be analyzed.
The packing chamber volume in a worm speed reducer is small, and only one layer of 25mm X 25mm oil-impregnated packing is filled inside. Because the oil-impregnated packing is small, the resilience is poor, and the sealing function will be lost after a short time, resulting in the leakage of lubricating oil. In daily operation, the daily oil leakage is usually about 2~3kg, and in serious cases, it reaches 5kg, and the oil has to be replenished once in 2 days.
In addition, the environment temperature of the reducer is too high, the temperature of the body reaches 80°C in summer, which exceeds the working temperature of the oil-impregnated packing. Therefore, the elastic-plastic deformation capacity of the packing is reduced, and the service life is shortened, basically, it is replaced once every 1-2 months.
Due to more and faster oil leakage, the oil level in the worm gear cavity is always low, and the worm gear lubrication effect is poor. This increases friction, aggravating the degree of wear of the tooth surface, so that the tooth surface pitting is serious.
As the worm wheel and worm gear tooth surface deteriorate, the operation of the reducer will produce a large impact load. Therefore, the shaft tile and bearing are easy to damage. This not only increases the maintenance workload but also affects the overall efficiency of the worm speed reducer.
To mitigate these issues, several improvement methods can be implemented. Firstly, remaking the active end cover with an inner diameter of 115mm and discarding the oil-impregnated packing. Instead, adopting 4 sets of 90mm X 115mm X 12mm skeleton type rubber oil seal can be beneficial. The working temperature of the skeleton type rubber oil seal is 110~130C, and it has good resilience and can withstand large friction torque. Therefore, the skeleton oil seal is better than the oil-impregnated packing in terms of durability and sealability.
Vibration signal analysis is a crucial aspect of diagnosing and maintaining the health of a worm speed reducer. By acquiring the vibration signal, the original vibration signal of the reducer is decomposed into several IMF components of different frequency domain bands. These IMF components in different frequency domains are then analyzed to determine whether they contain fault signals.
Autocorrelation function is a crucial analysis method that describes the degree of correlation between the instantaneous values of random vibration samples at different moments. When using autocorrelation analysis, the autocorrelation function obtains its maximum value at zero. The autocorrelation function of the periodic function is still a periodic function of the same frequency, and its amplitude has some connection with the amplitude of the original periodic signal.
The Hilbert transform is an important signal analysis and processing tool for the extraction of the fault of the worm speed reducer tooth shape variation. It is mainly based on the decomposition of the empirical mode, and the resulting IMF, and the IMF is Hilbert transformed to obtain a Hilbert spectrum. A complete Hilbert spectrum primarily contains three parts: time, tonality, and amplitude. By analyzing the original signal in the demodulated spectrum, the condition of the worm speed reducer tooth change fault can be analyzed.
After the vibration signal analysis of the gearbox, the tooth shape variation parameters of the gearbox should be measured, which can be done by precision measuring instruments, such as JD45+ gear measuring instrument. After the relevant parameters are obtained, the measured parameters can be compared and the data can prove that the combination of EMD and Hilbert transformations can effectively diagnose the fault of tooth shape change of the worm speed reducer.
The tooth shape change fault in a worm speed reducer can lead to accidents, causing a great impact on normal production. In the downtime maintenance, it will also bring a large loss to the enterprise economy. For this reason, enterprises should continue to strengthen and change the tooth shape change fault feature extraction method, and based on this to detect the working condition of the worm speed reducer, in order to achieve the purpose of”timely detection of faults and timely maintenance”.
The packing chamber volume is small, and only one layer of 25mm X 25mm oil-impregnated packing is filled inside. Because the oil-impregnated packing is small, the resilience is poor, and the sealing function will be lost after a short time, resulting in the leakage of lubricating oil. In daily operation, the daily oil leakage is usually about 2~3kg, and in serious cases, it reaches 5kg, and the oil has to be replenished once in 2 days.
In addition, the environment temperature of the reducer is too high, the temperature of the body reaches 80°C in summer, which exceeds the working temperature of the oil-impregnated packing. Therefore, the elastic-plastic deformation capacity of the packing is reduced, and the service life is shortened, basically, it is replaced once every 1-2 months.
Due to more and faster oil leakage, the oil level in the worm gear cavity is always low, and the worm gear lubrication effect is poor. This increases friction, aggravating the degree of wear of the tooth surface, so that the tooth surface pitting is serious. At the same time, also because of serious friction generated too much heat, resulting in high temperature of the reducer body, making the oil film between the tooth surface is too thin, further deteriorating its working conditions.
As the worm wheel and worm gear tooth surface deteriorate, in the operation of the reducer will produce a large impact load, therefore, the shaft tile and bearing easy to damage. This not only increases the maintenance workload but also affects the overall efficiency of the worm speed reducer.
To mitigate these issues, several improvement methods can be implemented. Firstly, remaking the active end cover with an inner diameter of 115mm and discarding the oil-impregnated packing. Instead, adopting 4 sets of 90mm X 115mm X 12mm skeleton type rubber oil seal can be beneficial. The working temperature of the skeleton type rubber oil seal is 110~130C, and it has good resilience and can withstand large friction torque. Therefore, the skeleton oil seal is better than the oil-impregnated packing in terms of durability and sealability. Secondly, replacing the No. 2 thrust bearing at the passive end of the worm, and replacing the original 8324 bearing with 48324 bearing. This can effectively overcome the axial force to prevent the worm from moving, improve the bearing life and reduce the maintenance workload.
These are the first half of the main part of the content of the worm speed reducer analysis. The article continues to delve into the topic, providing more insights and detailed analysis of the worm speed reducer.
A worm speed reducer is a type of gear mechanism that is primarily used to reduce speed and increase torque. It plays a vital role in various industries, including manufacturing, construction, and automotive. The worm speed reducer is composed of a worm wheel and a worm, and its performance can significantly impact the efficiency and productivity of the operations it supports.
One of the main issues with worm speed reducers is the tooth shape change fault. This fault occurs when the worm gear teeth deviate from their ideal profile during operation, resulting in frequency modulation. This can lead to a high failure rate of the worm wheel. Moreover, this fault does not produce a large shock vibration and only generates small energy. However, when the tooth shape change is severe, it can produce a large shock vibration and generate substantial energy, triggering the failure of the worm speed reducer.
One of the solutions to address the issues with worm speed reducers is to remake the active end cover and discard the oil-impregnated packing. Instead, skeleton type rubber oil seals can be used, which have a higher working temperature and better resilience, making them more durable and effective in sealing. Another solution is to replace the No. 2 thrust bearing at the passive end of the worm with a bearing that can effectively overcome the axial force to prevent the worm from moving. This can improve the bearing life and reduce the maintenance workload.
These solutions can significantly improve the performance of worm speed reducers by reducing the occurrence of tooth shape change faults. By using a skeleton type rubber oil seal, the resilience and sealing function of the reducer are enhanced, thus reducing the leakage of lubricating oil. Furthermore, replacing the No. 2 thrust bearing can prevent the worm from moving, thereby improving the bearing life and reducing the maintenance workload. These improvements can lead to a more efficient and reliable operation of the worm speed reducer.
Autocorrelation function is a new analysis method that describes the degree of correlation between the instantaneous values of random vibration samples at different moments. When using autocorrelation analysis, if the correlation function analysis is performed for the same random sample, then the sample after a time shift is the autocorrelation function. This function obtains its maximum value at zero lag time. When the lag time is large enough or when there is no intrinsic connection between the random variables, the autocorrelation function is evenly divorced, i.e., it is symmetric about the y-axis. By studying the autocorrelation function and using its properties, the IMF component containing the periodic shock signal can be accurately selected.
Tooth shape change faults can lead to serious problems in the operation of the worm speed reducer. They can cause a high failure rate of the worm wheel, produce a large shock vibration, generate substantial energy, and trigger the failure of the worm speed reducer. These faults can also affect the worm wheel intrinsic frequency and make it change, thus triggering the failure of the worm speed reducer. Therefore, it is crucial to diagnose and rectify these faults promptly to ensure the efficient operation of the worm speed reducer.
The environment temperature can significantly impact the performance of the worm speed reducer. For instance, during summer, the temperature of the reducer body can reach up to 80°C, exceeding the working temperature of the oil-impregnated packing. This high temperature reduces the elastic-plastic deformation capacity of the packing, shortens its service life, and leads to the leakage of lubricating oil. This leakage can result in poor lubrication of the worm gear, increased friction, and aggravated wear of the tooth surface, leading to serious pitting on the tooth surface.
Read more about Unlock Your Power Potential:Universal Speed Reducers
Oil leakage in the worm speed reducer can lead to several issues. Firstly, it results in a low oil level in the worm gear cavity, which negatively impacts the lubrication effect of the worm gear. This can increase friction and exacerbate the wear of the tooth surface, leading to serious pitting. Secondly, the friction generated due to poor lubrication can produce excessive heat, resulting in a high temperature of the reducer body. This high temperature can thin the oil film between the tooth surfaces, further deteriorating the working conditions of the worm speed reducer.
One effective solution to address the issues caused by oil leakage is to replace the oil-impregnated packing with a skeleton type rubber oil seal. The skeleton type rubber oil seal has a higher working temperature and better resilience, making it more durable and effective in sealing. This can significantly reduce the leakage of lubricating oil, improve the lubrication effect of the worm gear, reduce friction, and lessen the wear of the tooth surface.
Replacing the No. 2 thrust bearing at the passive end of the worm with a bearing that can effectively overcome the axial force can prevent the worm from moving. This can improve the bearing life, reduce the maintenance workload, and enhance the overall performance of the worm speed reducer. It can also prevent the occurrence of a large impact load during the operation of the reducer, thereby reducing the likelihood of damage to the shaft tile and bearing.
The deterioration of the worm wheel and worm gear tooth surface in a worm speed reducer can lead to significant operational issues. As the tooth surface deteriorates, the reducer will produce a large impact load during operation. This can easily damage the shaft tile and bearing, leading to further complications and potential failure of the reducer. Therefore, it’s crucial to monitor the condition of these components and take preventative measures to avoid such deterioration.
The skeleton type rubber oil seal in a worm speed reducer plays a crucial role in preventing the leakage of lubricating oil. It has a higher working temperature and better resilience compared to the oil-impregnated packing. This makes it more durable and effective in sealing, thereby improving the lubrication effect of the worm gear, reducing friction, and lessening the wear of the tooth surface.
The replacement of the No. 2 thrust bearing at the passive end of the worm with a bearing that can effectively overcome the axial force prevents the worm from moving. This improvement enhances the bearing life, reduces the maintenance workload, and enhances the overall performance of the worm speed reducer. It also prevents the worm speed reducer from producing a large impact load during operation, thereby reducing the likelihood of damage to the shaft tile and bearing.
To prevent the deterioration of the worm wheel and worm gear tooth surface in a worm speed reducer, it’s crucial to ensure proper lubrication. This can be achieved by using a skeleton type rubber oil seal, which can significantly reduce the leakage of lubricating oil, improve the lubrication effect of the worm gear, reduce friction, and lessen the wear of the tooth surface. Additionally, replacing the No. 2 thrust bearing can prevent the worm from moving, thereby improving the bearing life and reducing the maintenance workload.
The environment temperature can significantly impact the performance of the worm speed reducer. High temperatures can reduce the elastic-plastic deformation capacity of the packing, shorten its service life, and lead to the leakage of lubricating oil. This leakage can result in poor lubrication of the worm gear, increased friction, and aggravated wear of the tooth surface, leading to serious pitting on the tooth surface.
Understanding the intricacies of the worm speed reducer and the common issues associated with it is crucial in the transmission equipment industry. By employing innovative solutions such as the use of skeleton type rubber oil seals and replacing the No. 2 thrust bearing, we can significantly improve the performance of these reducers and ensure their efficient operation. For more information on similar topics, feel free to explore our other blogs on universal speed reducers, helical gearboxes, and worm gear reducers.