What are the reasons for the abnormal connection status between the motor and the ZSY560-90-2 gear reducer?

The connection status between the motor and ZSY560-90-2 gear reducer is abnormal, usually manifested as increased vibration, abnormal noise, transmission failure, or loose connection. The root causes mainly focus on poor installation alignment, coupling failure, mechanical component wear, and improper lubrication management, among which installation and alignment problems account for the highest proportion, reaching over 40%. The following is a systematic analysis:

1、 Installation and alignment issues (high incidence reasons, accounting for about 40%)

1. Coaxiality deviation exceeds the limit
The coaxiality between the input shaft (motor side) and the input shaft of the reducer is strictly required, generally ≤ 0.1mm; if the deviation is too large, it will cause additional radial force during the transmission process, leading to periodic vibration and early bearing damage.

2. Unstable basic installation

The anchor bolts are not tightened according to the specifications or the pre tightening force is uneven, resulting in "displacement vibration" during operation;

Poor flatness of the installation surface (deviation>0.1mm/m) causes uneven stress on the box, affecting the meshing state of the internal gears.

3. Poor alignment of the coupling
Even when using an elastic coupling, it is necessary to ensure that the axial, radial, and angular deviations are within the allowable range, otherwise it will accelerate the aging of the elastic body and cause impact loads.

2、 Coupling failure (common external causes)

1. Aging or fracture of elastic components
Cracking of rubber pads and deformation of metal membranes can lead to uneven torque transmission, resulting in a "jumping" power interruption phenomenon.

2. Loose or broken connecting bolts
Under long-term vibration environment, if the fastening is not checked regularly, bolt loosening may occur, directly leading to power transmission interruption.

3. Improper selection or incorrect installation
If a rigid coupling is used in situations where there is a slight deviation, it cannot absorb errors and instead amplifies stress.

3、 Mechanical component wear or internal failure (accounting for approximately 30%)

1. Abnormal gear meshing

Tooth surface wear (tooth thickness reduction>5%), pitting (area>10%) or tooth breakage, resulting in excessive meshing clearance and generating "meshing impact";

Poor meshing can also cause an increase in reverse clearance, affecting transmission accuracy.

2. Bearing damage
Bearing ball breakage, cage fracture, or loose inner and outer rings can cause shaft system jamming or excessive radial runout, and in severe cases, cause input shaft locking.

3. Bending or deformation of the shaft extension
Due to improper installation or external impact, the input shaft bends, damaging the original alignment state and exacerbating vibration and wear.