What impact does the state of the worm shaft assembly have on the performance of the WPDO135-30-4KW-B reducer?

The state of the worm shaft component directly determines the performance of the WPDO135-30-4KW-B reducer, with the following specific impacts:

1、 Bearing clearance and axial positioning
Bearing clearance: Excessive clearance can cause radial movement of the shaft system, fluctuation of the meshing center distance, and exacerbation of off load; If the clearance is too small, the internal compression and friction of the bearing will cause severe heating, which may lead to bearing jamming and directly interrupt the transmission.

Axial positioning: Insufficient axial positioning accuracy of the worm gear can lead to uneven meshing clearance, affecting transmission stability.

2、 Mesh clearance and contact spot
Mesh clearance: If the clearance is too small, the tooth surface will be squeezed and rubbed, the oil temperature will rise, the oil film will rupture, resulting in adhesive wear and a sudden drop in bearing capacity; Excessive clearance can easily generate impact loads when the gears reverse during loading, causing repeated impacts on the tooth surface and leading to root fatigue cracks.

Contact spot: If the contact spot is not centered or has insufficient area, it can cause uneven stress distribution on the tooth surface and accelerate local wear.

3、 Installation accuracy
Coaxiality: The coaxiality deviation between the worm gear and worm gear should be ≤± 0.02mm. If the deviation exceeds 0.05mm, it will cause unilateral contact during meshing, reduce the contact area by more than 50%, double the stress on the unit tooth surface, and easily cause tooth surface pitting or plastic deformation.

Flange installation: If the coaxiality deviation between the flange and the output shaft exceeds 0.03mm, additional radial force will be generated, exacerbating the wear of the worm gear bearing and further weakening the support capacity of the shaft system.

4、 Lubrication system
Lubricating oil selection: Replace worm gear oil with ordinary gear oil. The oil film is prone to rupture, the tooth surface is in direct contact, the wear rate increases by 3-5 times, and the bearing capacity can be reduced by 50% within 1-2 months.

Oil aging and pollution: Special oil contains extreme pressure anti-wear agents and friction reducers, which can form an oil film with a thickness of 5-10 μ m on the tooth surface; Oil aging and pollution can cause oil film rupture and accelerate wear.

5、 Load characteristics
Load type: Impact load can cause a sudden increase in tooth surface stress, which can easily lead to tooth root fracture and tooth surface peeling; Periodic variable loads can accelerate material fatigue and reduce the contact fatigue life of gears/worm gears.

Load size: Long term exceeding the rated load can cause the tooth surface contact stress to exceed the allowable value, the lubricating oil film to rupture, and lead to adhesion or pitting corrosion; Light load may result in the inability to form a lubricating oil film, leading to slight sliding and abrasion, and reducing efficiency.

6、 Materials and Manufacturing Processes
Material: Insufficient depth of gear carburizing layer can cause surface peeling, especially under impact load.

Manufacturing process: Tooth profile errors can cause impact during meshing, increase noise, and decrease efficiency; Poor surface roughness can increase the friction coefficient, and the friction loss of the worm gear in WP reducers can increase by 20%.

7、 Structural Design
Center distance and modulus: If the center distance is too small, it will limit the tooth width and modulus, and the bearing capacity will be insufficient; If it is too large, the structure will be bulky and the heat dissipation area will increase, but the cost will also rise; A smaller gear module can lead to insufficient tooth root strength and easy breakage.

Box rigidity and heat dissipation design: Insufficient box rigidity can cause the gearbox body to tilt, the gear axis to shift, and result in unbalanced load; Poor heat dissipation design can lead to excessive temperature rise, affecting the performance of lubricating oil.