Worm gearbox

NMRV worm reduction gearbox has high quality aluminum alloy die cast housing with plastic spray appearance.The internal worm wheel and worm shaft are with durable material machined by advanced CNC equipment.Each worm reduction gearbox are assembled with famous brand parts,like NAK oil seal,C&U bearing,Boda synthetic oil and so on. The strict inspection standard is performed from material to finished worm gear motor,every one worm gearbox are requested to have 2 hours running test before delivery to clients.
Worm gearbox can be equipped with various input and output type, and conveniently combined with other transmission machinery，so it has been used widely, such as chemical, plating, ceramic, leather, pharmaceutical, foods industry, etc.

installation

Worm gear reducer installed in principle is based on the worm gear reducer output to determine the size of the diameter of axle reducer stent models, as long as the interface forms and sizes, reducer output shaft size within a certain range can make more hits on reducer stent models. If the mounting dimension of the reducer is not in conformity with the speed reducer bracket, we can connect the speed adjusting plate and the reducer in a certain range to meet the user's requirements.

Structure

The basic structure of the RV series aluminum worm gear reducer is mainly composed of worm gear, shaft, bearing, box and accessories of transmission parts. Can be divided into three basic structure parts: box, worm gear, bearing and shaft combination. The box is the base of all accessories in worm gear reducer, it is the important accessory that supports fixed shaft parts, guarantees the correct relative position of transmission parts and supports the load on the reducer. The worm gear is mainly used to transfer the motion and power between the two staggered shafts. The main function of the bearing and shaft is to transfer, operate and improve the efficiency.
The parts of worm gear reducer are explained as follows:
Shell: aluminum alloy (engine seat: 025-090) cast iron (stand: 110-150);
Worm: 20Cr steel. Carburizing of carbon and nitrogen (after fine grinding, the hardness of HRC60, hardness thickness is greater than 0.5mm);
Worm gear: special configuration of wear-resisting nickel bronze;
The oil cover/aerator is mainly used to discharge the gas in the box of the turbine worm reducer.
The end cover is divided into the big end cover and the small end cover. The end cover is the axial position of the fixed shafting part and the axial load is borne. The bearing cover is closed on both ends of the bearing hole.
Oil seal. The main use is to prevent the internal oil leakage of the chassis, improve the use time of lubricating oil;
Drain screw, mainly used for oil removal and cleaning.
Oil standard cover/oil label, mainly used to observe whether the oil quantity in the engine box of the turbine worm reducer is up to standard;

The material selection

The worm gear reducer is not well prepared in processing technology and material, it can cause the transmission failure. Worm gear speed reducer is also the problem that the gear reducer may encounter when making parts, such as the hardness of the hard surface speed reducer, and the unreasonable design of the screw lift bearing design.
Due to large worm drive meshing friction, worm gear hob is difficult to accurately backoff size and shape error. As a result of that the worm gear tooth surface is very difficult to work out and the worm tooth surface match completely to meet the requirements of the theory of conjugate condition. Therefore, the worm and worm gear tooth should have both wear resistance and good running performance.
Worm materials generally made of alloy steel or high quality carbon steel, and worm gear tooth surface by carburizing, quenching and nitriding heat treatment and high hardness, its hardness is between 35-55 HRC in general, but also has more than 60 HRC.
The materials used in worm gear ring are the most ideal for tin bronze, and the mechanical properties of centrifugal casting are the best in the process, followed by casting of metal mould, the most of which is not cast in sand mold.

Considerations

The worm gear reducer shall not be damaged by gravity hammer and reducer. Worm gear speed reducer is normal to overhaul the installation foundation, sealing parts and transmission gearbox. If normal use, the highest temperature of the lubricating oil should be less than 85 ℃. If the oil temperature rise and change abnormal, produce abnormal noise and so on, must stop immediately check, after troubleshooting, can continue to use.

Reducing machine noise processing method

Gear transmission schematic The noise generation of the Cycloidal reducers is mainly due to the friction, vibration and collision of the transmission gear, how to effectively reduce and reduce the noise, make it more environmentally friendly requirements is also a key research topic at home and abroad.
Reducing the gear transmission noise of the parallel shaft helical gearbox has become an important research topic in the industry. Many scholars at home and abroad regard the change of the meshing stiffness of the gear in the gear transmission as the main factor of the dynamic load, vibration and noise of the gear. With the modified method, so that the dynamic load and speed fluctuations to a minimum, in order to achieve the purpose of reducing noise. This method proved to be a more effective method in practice. But with this method, the process needs to have modified equipment, the majority of small factories are often unable to implement.
After years of research, it is proposed that by optimizing the gear parameters such as the displacement coefficient, the tooth height coefficient, the pressure angle and the center distance, the meshing impact velocity is reduced to a minimum, and the ratio of the outburst impact velocity to the hitting impact velocity is at a certain value Range, to reduce or avoid the impact of the pitch circle gear design method, but also significantly reduce the gear unit gear noise.

Reducer type

The high torque gearbox is a relatively sophisticated machine that uses its purpose to reduce the speed and increase the torque. It has a wide variety of models, different types, different types have different uses.
There are many kinds of reducer, according to the type of transmission can be divided into worm reducer gearbox, worm reduction and planetary gear reducer; according to the different transmission stages can be divided into single and multi-stage reducer; according to the shape of the gear can be divided into cylindrical gear Reducer, Cycloidal Speed Reducer Gearbox and conical - cylindrical gear reducer; in accordance with the transmission layout can be divided into expansion, split and coaxial reducer.

Special reducer, is dedicated to specific areas and industry reducer.

variable speed electric motor types are mill reducer, oilfield double word arc gear special reducer, wind turbine with speed changer, planetary differential gear reducer, planer with planetary gear reducer, hardened gear reducer, Deepening reducer, combination worm gearbox for oil extraction machine, special reducer for irrigation machine, reducer for screw conveyor, reducer for asphalt mixer, reducer for reducer, Flying shear machine and so on.
Application areas: advantages of variable speed drives is widely used in metallurgy, mining, lifting transport, electricity, energy, building materials, light industry, transportation and other fields.

Brief introduction of combined reducer

WAH hypoid gearbox, that is, to meet the needs of different operations, according to a certain principle to combine two or more components used in the reducer.
Common combination series with CVT series stepless, WJ series reducer combination; Universal modular reducer, UDL and NMRV combination reducer, PC and NMRV reducer combination, NMRV and NMRV combination reducer, worm reducer and no JWB-X series CVT, JWB-X continuously variable transmission + WWJ rod reducer, multi-functional polyhedron hardened surface combination, DMB series CVT and WJ series of screw Reducer PC Helical Gearbox, ring cone differential planetary transmission and cycloid reducer combination.
Applications: worm gear speed reducer is widely used in metallurgy, mining, lifting, transportation, cement, construction, chemical, textile, printing and dyeing, pharmaceutical and other fields.

What is the transmission reducer

The helical worm gearmotor is a power transmission mechanism which uses a gear speed converter to decelerate the number of revolutions of the motor to the desired number of revolutions and obtain a larger torque. The transmission reducer is a relatively sophisticated machine that uses its purpose to reduce the speed and increase the torque.
Transmission reducer type Hypoid Reducer, with transmission reducer, unilateral double drive reducer, harmonic transmission reducer, the central transmission reducer, edge drive Bevel helical gearbox and so on.
The mechanical variable speed gearbox has the characteristics of large transmission ratio, wide range, high precision, small back load, large carrying capacity, high efficiency, small volume, light weight, smooth transmission, low noise, transmission to the sealed space, etc. It is widely used In the space technology, energy, electronics industry, petrochemical, military industry, robots, instrumentation, textile machinery, printing machinery, packaging machinery, lifting transport machinery, medical equipment, food processing machinery and other industries.

The typical structure of the cycloidal planetary reducer, which consists mainly of four parts:

(1) The planetary frame consists of an input shaft and a double eccentric sleeve, and the eccentric sets of eccentric sets are 180 degrees.
(2) planetary wheel, also known as cycloid, the tooth profile is usually short outside the Cycloidal reducers of the inside of the equidistant curve. According to the requirements of the movement, a planetary wheel can be driven, but in order to make the input shaft to achieve static balance and improve the carrying capacity, for a tooth difference pin pendulum drive, often with two identical odd teeth of the planetary wheel Transmission is not subject to this limit), installed in the double eccentric sets, two rounds of position just 180 degrees difference. A roller bearing (called a boom bearing) is fitted between the planetary wheel (cycloidal wheel) and the eccentric sleeve to reduce friction. In order to save radial space, rolling bearings usually use roller bearings that do not have outer race The pinhole surface of the variable gear motor is directly used as a raceway. In recent years, the structure of the optimized design of the double eccentric sleeve and the bearing made of a whole, said the overall double eccentric bearing.
(3) Central wheel, also known as hypoid gearbox wheel, needle shell with a set of needle pin, usually pin pin is also equipped with needle sets.
(4) Output mechanism This is often used pin-type output mechanism.

What is the ideal gear motor protection?

The ideal vertical gear reducer protection is not the most functional, nor the so-called the most advanced, but should be the most practical. So what is it practical? Practical should meet the reliable, economical, convenient and other factors, with a high cost performance. So what is it? Reliable first should meet the function of reliable, such as the use of motor when the motor over-current, phase failure function must be on a variety of occasions, a variety of processes, various ways of over-current, phase can be reliable action. Followed by its own reliable (since the protector is to protect others, in particular, should have a high reliability) must have a variety of harsh environment of adaptive stability, durability.
Economy: the use of advanced design, reasonable structure, specialization, large-scale production, PC gearboxes product costs, to the user to bring high economic benefits.
Convenience: must be installed, used, adjusted, wiring, etc., at least should be similar to thermal relays, as much as possible easier and convenient.
It is also because of this, the experts have long predicted that in order to simplify the variable ratio gearbox protection device should be designed and used without power transformer (passive) design, and the use of semiconductors (such as SCR) instead of contact electromagnetic operating units. In this way, it is possible to manufacture a gearbox protection device consisting of a minimum number of components.

Gear reducer motor novice common use of the failure

1. Operation errors: Due to the structure and performance of the gear reduction motor, it is not enough (especially the new operator) to cause malfunctions or even cause mechanical accidents and safety accidents due to operational errors.
2. Poor lubrication: Due to the smaller clearance of the newly assembled parts of the single stage gearbox and the fact that the lubricating oil (grease) is not easy to form a uniform oil film on the friction surface due to assembly or the like to prevent wear. Thereby reducing the lubrication performance caused by the early wear of the machine. Severe frictional surface friction or bite caused by the phenomenon of precision caused by the occurrence of failure.
3. Wear speed: due to the new gear reducer motor parts processing, assembly and commissioning and other factors with a small contact area with a small contact with the larger torque. Cycloidal Speed Reducer Gearbox in the process of running the parts of the surface of the concave and convex parts of the friction with each other friction and grinding down the metal debris and as abrasive continue to participate in friction more speed parts with the surface wear. So the run-in period is likely to cause the wear and tear of the parts (especially with the surface) wear too fast. At this time if the overload operation may lead to combined gearbox parts damage caused by early failure.
4. Loose: gears The new parts of the newly machined assembly are geometrically shaped and the variation of the fit size is affected by factors such as impact, vibration and other alternating loads and heat, deformation and other factors in the early stages of use. Easy to make the original tightening parts of the loose.
 5. Leakage phenomenon: due to loose parts, vibration and operation of the heat affected gear reducer motor sealing surface and pipe joints and other parts of the leakage phenomenon; part of the casting and other defects in the assembly and debugging difficult to find but because of the operation process Of the vibration, the impact of this defect was exposed to the performance of leakage (infiltration) oil. So the occasional run-in leakage phenomenon.

How to remove noise problems in geared motors?

Electromechanical industry people know that the noise when the motor is a lot of work so that a headache is a problem, especially the high efficiency gearbox noise is particularly large. Reducing noise and ensuring stability at runtime is the primary condition for the quality of the motor.
For how to achieve this goal, many domestic and foreign manufacturers have cycloidal reducers meshing stiffness changes as the gear dynamic load, vibration and noise of the main factors. With the modified method, so that the dynamic load and speed fluctuations to a minimum, in order to achieve the purpose of reducing noise. This method proved to be a more effective method in practice.
 The caliper of the geared motor shall be mounted on a non-vibrating, very strong level, and the inclination of the axis of the geared motor shall not be greater than 15 degrees when it is necessary to be tilted. If you need to use in addition to foot horizontal installation and flange mounted outside the installation of other special forms, must take the appropriate lubrication and sealing measures to ensure that the Hypoid Gear Reducer can be fully lubricated to prevent oil spills.
In the use of shock, vibration or frequent use of the occasion, the base and the base in addition to the foot bolt with the connection, but also need to use the positioning pin (self) to fix. But with this method, the process needs to have modified equipment, the majority of small factories are often unable to implement. After years of research, it is proposed that by optimizing the gear parameters such as the displacement coefficient, the tooth height coefficient, the pressure angle and the center distance, the penetration impact velocity is minimized and the ratio of the outburst impact velocity to the penetration impact velocity is at a certain value Range, to reduce or avoid the impact of meshing rounds of the gear design method, but also significantly reduce the gear motor gear noise.

How to select the gear reduction motor model by parameter.

 Gear PC gear boxes are widely used in electronic equipment, painting equipment, printing industry, packaging equipment, woodworking machinery, medical equipment, ceramic equipment, breeding equipment. We according to the actual needs of different industries, gear gear motor selection is essential. If the selection error and parameter error will lead to lack of power or excess situation. Pc Helical Gear Box products, functions, parameters, the principle of gear gear motor is several major indicators. So the customer should be based on the following gears to adjust the AC Motor Worm Gearbox parameters:
1, product model
Different types of equipment used in the industry are not the same, so when you do not understand their own equipment used gear reducer motor specific models should be to the manufacturer or dealer consultation.
2, the motor power (including the motor series)
Here is a simple and practical way to calculate the motor power.
Motor power = torque ÷ 9550 × motor power input speed ÷ speed ratio ÷ use coefficient
3, the motor rated voltage
Under normal circumstances, are used three-phase 380V voltage, if the customer special needs should be explained. (Under normal circumstances, more than 5 horsepower motor can only use 3-phase 380V, 5 horsepower motor can use the following three-phase 220V or three-phase 380V)
4, installation
General light gear motor installation is divided into horizontal or vertical installation.
5, reduction ratio
According to the actual needs and refer to the gear reduction motor parameter table
6, the output shaft size.

The future competition of the gear motor industry should be technology as the core

With the rapid development of China's industry, to promote the continuous expansion of the demand for helical bevel worm gearmotor. However, the development of industry is not only a greater demand for the purchase of gear motors, but also a new standard for technological innovation of geared motors.
At present, the domestic gear motor industry competition is still very intense, this competition prompted a lot of motor manufacturers to increase the gear motor technology investment, but also to promote their innovative technology, improve production, sales and after-sales management. However, there are also mainly price-based competition. The competition in the Hypoid speed gearbox industry is more competitive than the price competition, which not only hinders the development of the domestic motor industry, but also is not conducive to the development of the whole national industry. To price as the core of the competition is not the long-term business, only to increase the input of the gear motor technology and attention to technological innovation in order to enable enterprises in the increasingly fierce competition in an invincible position, and only to enhance the combined worm reducer Technical content, in order to make our country gear in the international competition has a place! Technology as the core innovation gear motor technology in order to compete in the industry in the future, invincible.

How can we extend the life of the gear reducer?

vertical gear reducer is an important part of the transmission equipment, to improve the gear reducer load capacity and service life plays a vital role in the reducer selection after adding good lubricants (gear oil or oil line), and install On the workbench, use the height gauge to adjust the center height of each test instrument and reducer. So that they are at the same center height, with bolts, gasket fixed, add a small load, run test run. After running for some time, pour the oil out and check whether the oil contains metal powder and re-clean it, then add the lubricant to fall again until the metal powder is not found. Finally, add the lubricant seal and start to increase the load to test.
Gear reducer for the first time, the first test run is essential. Many users tend to ignore this early work, eventually leading to poor operation of the reducer, or lead to damage to the PC gear reducer, thereby increasing the cost of investment. So the gear reducer test run is to help users reduce the cost of investment, which can greatly improve the gear life and quality.

Instructions: reducer inspection and maintenance

Under normal circumstances, for long-term continuous operation of the combined gearbox, according to run 5000 hours or once a year to replace the new oil, long-term reducer should be replaced before the re-operation of the new oil reducer should be added with the original brand of the same oil, Do not mix with different grades of oil, the same grades and different viscosity of the oil allows mixed use.
Oil change to wait for the WAH hypoid gearbox to cool down without burning danger so far, but should remain warm, because the complete cooling, the oil viscosity increases, oiling difficulties. Note: To cut off the drive power, to prevent inadvertently power!
Work, when the oil temperature rise above 80 ℃ or oil tank temperature exceeds 100 ℃ and produce abnormal noise and other phenomena should stop using, check the reasons, must be troubleshooting, the replacement of lubricants before they can continue to run.
Users should have a reasonable use of maintenance rules and regulations, the operation of the reducer and inspection found in the problems should be carefully recorded, the above provisions should be strictly enforced.

Gear reducer once the oil spill, not only the formation of capital spoil, and pollution of the environment, severe gear will cause less gear, oil, so that gear meshing
Surface wear aggravated, and then attack biting or stripping, resulting in equipment incidents.
The following general and we talk about gear reducer leakage is caused by what factors. The same time as the above-
1, Hypoid speed gearbox surface pressure difference
Gear reducer during the operation, movement, conflict heating and by the impact of ambient temperature, so that the gear reducer temperature to add, if there is no ventilation holes or
Ventilation holes blocked, then the machine gradually add the pressure, the higher the temperature inside the machine, the greater the pressure difference with the outside world, lubricating oil in the pressure effect, from the gap at the leak
Out.
2, combined worm reducer structure design unreasonable
(1) hole cover plate is too thin, tighten the bolt after the deformation, so that the contact surface is uneven, from the touch gap oil. The same time as the above-
(2) in the production of gear reducer process, the casting is not annealing or aging treatment, without eliminating the internal stress, must occur deformation, the formation of gaps, resulting in
Leaked. The same time as the above-
(3) there is no oil tank on the tank, the accumulation of lubricating oil in the shaft seal, cover, contact surface, etc., in the pressure effect, from the gap to the outside leakage. The same time as the above-
(4) shaft seal structure design is unreasonable. Early reducer more use of oil ditch, felt ring seal structure, assembled when the blankets by the compression deformation, and the
Contact surface gap sealed up. If the journal and seal touch is not very desirable, because the blanks of the compensation function is very poor, sealed in a short time that failure
The Although the oil groove on the oil return hole, but easy to block, oil effect is difficult to show.
3, gear reducer fuel too much
 Gear reducer in the course of operation, the oil pool was stirred very ferocious, lubricants in the machine everywhere splash, if the fuel is too much, so that a lot of oil product
Gathered in the shaft seal, contact surface, etc., resulting in leakage.
4, gear reducer repair technology is wrong
In the equipment maintenance, because the contact surface dirt removal is not complete, or sealant selection is wrong, the direction of the seal installed, not timely replacement of seals, etc.

variable ratio gearbox for the gear reducer, according to the current situation, China's gear reducer from the beginning of the development of China to the present, the original effect is not very obvious, there is no change in the form of production, compared with this form, Many foreign gear reducer companies will rely on skills, management, capital and other aspects of the advantages of the unique shopping malls share, and gradually enter the Chinese reducer mall. Facing foreign goods in the Chinese reducer market strong to seize, China's reducer industry is facing a severe shopping malls crisis, and this crisis is also a major impact on the domestic reducer company, to promote its time to form a contend Competition form, and gradually in the skills, processing has increased investment, and strive to compete in foreign goods, to defend the domestic reducer shopping malls.
The world mall needs for heavy machinery and spare parts will also be added. With the gradual recovery of economic recovery in Europe and the United States, the establishment of the real economy in the national economy from the location, as well as the construction of the country's basic construction needs, heavy machinery in the world of shopping malls will have more room for development.
The reducer is a power transmission mechanism that uses its intention to drop the speed and add torque. Its variety is complex, different types, not the same species have different uses. Heavy-duty mechanical reducer planning of the goods include a variety of large industrial gearbox, planetary gear reducer, worm gear reducer and cycloid reducer, also contains a variety of special drive.
According to the industry summary, reducer with relatively large amount of occupation are: power machinery, metallurgical machinery, environmental protection machinery, electrical appliances, road machinery, chemical machinery, food machinery, light industry machinery, mining machinery, transport machinery, construction machinery, Building materials machinery, cement machinery, rubber machinery, water machinery, oil machinery