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1. Heat and oil leakage in reducers are common issues that can significantly affect performance and lifespan. To improve efficiency, worm gear reducers often use non-ferrous metals for the worm gear, while the worm itself is made from harder steel. Since this is a sliding friction system, a lot of heat is generated during operation. This heat causes thermal expansion differences between the various components and the seals, leading to gaps at mating surfaces. Additionally, as the temperature rises, the lubricating oil becomes thinner, increasing the likelihood of oil leakage. There are four main reasons behind this problem: improper material matching, poor surface quality on the friction surfaces, incorrect oil levels, and low-quality assembly or usage.
2. Wear on the worm gear is another critical issue. Typically, worm gears are made of tin bronze, while the worm is made from hardened steel (45 steel with HRC 45–55 or 40Cr with HRC 50–55) and ground to a surface roughness of Ra 0.8μm. Under normal conditions, the wear rate is very slow, and some reducers can last over 10 years. However, if the wear accelerates, it’s important to check whether the materials were properly selected, if the reducer is overloaded, or if there are issues with the assembly quality or operating environment.
3. Wear on small helical gears is commonly seen in vertically mounted reducers. This is largely related to the amount and type of lubricant used. When installed vertically, the reducer may not retain enough oil, especially after shutdown. The lubricant between the motor and the reducer can drain away, leaving the gears unprotected. When the reducer starts again, the lack of proper lubrication can cause mechanical wear or even damage to the gears.
4. Bearing damage in the worm can lead to serious problems, even if the reducer is well sealed. Often, the lubricating oil inside becomes emulsified, and the bearings show signs of rust, corrosion, and damage. This is typically caused by condensation when the oil temperature rises and then cools down over time. In addition, bearing quality and the precision of the assembly process also play a significant role in preventing such issues.
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