What precautions should be taken when maintaining a double-enveloping worm gearbox?

1. Daily inspection
(I) Appearance inspection
Regularly check the appearance of the double-enveloping worm gearbox to see if there is any obvious deformation, crack or damage. Check whether the paint layer on the surface of the housing is intact and whether there is any rust. If cracks or deformations are found in the housing, it may cause lubricating oil leakage or affect the normal meshing of the gears, and should be repaired or replaced in time. For rusted parts, they should be cleaned and repainted in time to prevent further spread of rust.

(II) Oil level inspection
Ensure that the oil level of the gearbox is within the normal range. If the oil level is too high, the lubricating oil will produce too much foam during operation, increase power loss, and may also overflow from the vent hole and other parts; if the oil level is too low, the gears and bearings will not be fully lubricated, resulting in overheating and wear. Usually there will be an oil level observation window or oil level dipstick on the gearbox. When checking, the gearbox should be placed in a horizontal position and the correct oil level height should be determined according to the requirements of the equipment manual. If the oil level is found to be insufficient, the same type of lubricant should be added in time to avoid mixing lubricants of different brands or models to avoid affecting the lubrication effect.

(III) Sound and vibration inspection
During the operation of the reducer, listen carefully to its operating sound. Under normal circumstances, it should be a smooth and uniform operating sound. If there is abnormal noise, such as sharp metal friction, impact or periodic abnormal noise, it may be caused by gear wear, bearing damage or incorrect installation. At the same time, observe the vibration of the reducer and touch the reducer housing with your hand to feel its vibration intensity. If the vibration is too large, it may be caused by loose anchor bolts, misalignment of input and output shafts or internal component failure. Once abnormal sound or vibration is found, the machine should be stopped immediately for inspection to find out the cause of the fault and eliminate it in time to prevent the fault from further expanding.

2. Regular maintenance
(I) Lubricant replacement
Replace the lubricant regularly according to the operating conditions of the double enveloping worm reducer and the maintenance cycle recommended by the manufacturer. Even if the oil level looks normal, the lubricant will gradually deteriorate and lose its good lubrication performance during long-term use due to oxidation, contamination and other reasons. Generally, the first oil change should be carried out after the gearbox has been running for a period of time (such as 200-300 hours). After that, the lubricating oil should be changed every 3000-5000 hours or every six months to one year according to the frequency of use and environmental conditions. When changing the lubricating oil, the old oil in the gearbox should be completely drained first, and the impurities and sediments in the oil tank should be cleaned, and then new oil should be added. When refueling, pay attention to controlling the oil volume to avoid the oil level being too high or too low.

(II) Gear and bearing inspection
Regularly check the gears and bearings inside the gearbox. For gears, check whether there is wear, pitting, bonding and other damage on the tooth surface. Minor wear can be improved by adjusting the meshing clearance of the gears, but if the wear is severe, such as the tooth thickness wear exceeds a certain proportion or a large tooth surface damage area appears, the gear needs to be replaced. When checking the bearings, observe whether the rolling elements and raceways of the bearings have cracks, peeling or wear marks, turn the bearings by hand, and feel whether they are flexible, stuck or have abnormal sounds. If the bearing is damaged, it should be replaced in time, otherwise it will cause poor gear meshing, increase the vibration and noise of the gearbox, and even cause more serious failures.

(III) Inspection and replacement of seals
The sealing performance of the gearbox is crucial to prevent lubricating oil leakage and the entry of foreign impurities. Regularly check the condition of each seal, including the seal ring of the input shaft and output shaft and the seal gasket of the housing joint surface. If the seal is found to be aging, deformed or damaged, such as cracks in the seal ring, the seal gasket is squeezed and deformed, resulting in poor sealing, etc., the seal should be replaced in time. When replacing the seal, pay attention to selecting the appropriate model and material, ensure that the size and elasticity of the seal meet the requirements, and follow the correct steps and methods during the installation process to avoid affecting the sealing effect due to improper installation.

Cast Iron Reducer Double Enveloping Worm Gearbox 

3. Operating environment and installation and maintenance
(I) Operating environment control
Try to install the double enveloping worm gearbox in a clean, dry and temperature-appropriate environment. Avoid long-term exposure to humid, dusty or corrosive gas environments. These harsh environments will accelerate the deterioration of lubricating oil and corrosion of components. If the harsh environment cannot be avoided, appropriate protective measures should be taken, such as installing a protective cover on the outside of the gearbox to prevent dust and moisture from entering; regularly clean up the debris and dust around the gearbox and maintain good ventilation conditions to reduce the adverse effects of the environment on the gearbox.

(II) Installation and calibration
Ensure that the gearbox is firmly installed and the anchor bolts are reliably tightened to avoid excessive vibration during operation due to unstable installation. During the installation process, the concentricity of the input shaft and output shaft with other connecting parts must be ensured. Non-concentricity will cause additional radial loads and increase the wear of bearings and gears. At the same time, the horizontality or verticality of the gearbox should be adjusted according to the requirements of the equipment manual to ensure its normal operation. If the installation position of the gearbox changes during use due to reasons such as foundation sinking, it should be recalibrated in time to ensure that its installation accuracy meets the requirements.

(III) Load control
Double-enveloping worm gearboxes are designed with a certain rated load range and should avoid long-term overload operation. Overloading will cause excessive stress on gears and bearings, accelerate their wear and damage, and reduce the service life of the gearbox. In actual use, the model and specifications of the reducer should be reasonably selected according to the working conditions of the equipment to ensure that it works within the normal load range. If a short-term overload occurs, the operating status of the reducer should be closely observed, such as temperature changes, sound and vibration, etc. Once an abnormality is found, take immediate measures, such as reducing the load or stopping the machine for inspection.