Common problems and causes of helical gear reducer

1. Heat and oil leakage in reducers are common issues that can significantly affect performance and longevity. To enhance efficiency, worm gear reducers typically use non-ferrous metals for the worm gear, while the worm itself is made from harder steel. Since this type of transmission relies on sliding friction, it generates more heat during operation. This heat causes thermal expansion differences between various components and the seals, which can lead to gaps forming at mating surfaces. Additionally, the lubricating oil tends to thin out due to rising temperatures, increasing the likelihood of oil leakage. Several factors contribute to this problem: improper material matching, poor surface quality on the friction surfaces, incorrect lubricant levels, and substandard assembly or usage practices. 2. Wear on the worm gear is another frequent concern. Worm gears are usually made from tin bronze, while the paired worm is often hardened to a range of HRC 45–55 (for 45 steel) or HRC 50–55 (for 40Cr steel), and then ground to a surface roughness of Ra 0.8 μm using a worm grinder. Under normal conditions, wear occurs very slowly, and some reducers can last over 10 years without major issues. However, if the wear rate increases, it's important to check whether the design is appropriate, if the reducer is overloaded, or if there are problems with the materials, assembly quality, or operating environment. 3. Wear on small helical gears in vertical-mounted reducers is also a common issue, mainly related to the amount and type of lubricant used. When installed vertically, it’s easy for the lubricant to be insufficient. When the reducer stops running, the oil between the motor and the reducer may drain away, leaving the gears unprotected. Upon restarting, the lack of proper lubrication can cause mechanical wear or even damage to the gears. 4. Damage to the worm bearing can lead to serious problems, even if the reducer is well-sealed. Often, the lubricating oil inside becomes emulsified, and the bearings may show signs of rust, corrosion, or damage. This happens because moisture condenses as the oil heats up and cools down over time. In addition, the quality of the bearings and the precision of the assembly process play a significant role in preventing such failures. Regular maintenance and proper installation are essential to avoid these issues and ensure long-term reliability.

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