How to determine the wear condition of the cycloidal gear and needle gear housing of BWED2715-187-2.2KW reducer

To determine the wear condition of the cycloidal gear and needle gear housing of this model reducer, the core is to comprehensively judge the three-dimensional degree through appearance inspection, clearance measurement, and operation status observation, and accurately identify the degree of wear:
1. Visual inspection of appearance

If the tooth tip becomes dull, or if grooves or bumps appear on the tooth surface. Check if there are any chipped corners, peeling, or cracks on the gear teeth. If the tooth thickness has significantly decreased (compared to new parts or technical drawings), it indicates severe wear.

Needle tooth shell: Check whether the internal needle tooth surface is smooth, whether there is rust, pitting or uneven wear, and whether the needle tooth sleeve is loose, cracked or detached. Observe whether there are scratches, elliptical deformation, or stepped wear on the mating surface of the needle tooth housing.

Auxiliary judgment: If there is a large amount of metal debris and wear powder on the assembly surface, combined with the running time, it can be preliminarily judged that there is moderate or above wear.

2. Gap measurement comparison

Measure the radial clearance with a feeler gauge, record the values of four uniform points on the circumference, and compare them with the manufacturer's standard value (usually 0.05-0.15mm).

If the measured gap is greater than 0.2mm or the deviation of the gap at each point exceeds 0.05mm, after excluding assembly problems, it is considered that the gap exceeds the standard due to wear.

After multiple adjustments to the gap, the rapid rebound still exceeds the standard, indicating that the part has reached the wear limit and cannot be compensated through adjustment.

3. Auxiliary judgment of operating status

Is there any abnormal friction sound or metal impact sound during operation, and the noise intensifies with the increase of load? When there are no other sources of faults, it is highly likely that wear causes excessive clearance in the fit.

The vibration value of the output shaft increases, the transmission efficiency decreases (such as abnormal increase in motor current, insufficient output torque), or there is a noticeable looseness or jamming sensation when rotating the output shaft after shutdown.

If there is periodic abnormal noise or vibration, it may be due to uneven wear of the cycloidal gear teeth, causing fluctuations in the meshing clearance.

4. Classification and determination of wear degree

Mild wear: There is no obvious damage to the appearance, the clearance is within the standard range, there is no abnormal operation, no need for replacement, only regular monitoring is required.

Moderate wear: There are slight wear marks on the tooth surface, the clearance is close to the standard upper limit, and the operating noise has slightly increased. The monitoring cycle needs to be shortened.

Severe wear: If there is tooth surface peeling, excessive clearance, abnormal operation, or part deformation or cracking, it must be replaced immediately to avoid transmission failure.