Elastic block aging, cracking, and excessive gaps can lead to what issues in the ZLYJ250-10-1 reducer

1、 Vibration and impact related faults

Vibration exceeding limit: After the failure of the elastic block, the centering buffer between the motor and the input shaft of the reducer is completely lost, directly triggering the safety threshold of the whole machine vibration speed far exceeding 5mm/s.

Periodic impact load: When the clearance is too large, rigid impact will occur during forward and reverse rotation or start stop moments, and the impact load will be directly transmitted to the high-speed shaft bearing and gear meshing pair.

Additional radial force on the shaft system: After the elastic block breaks, the coupling experiences eccentric swinging, and the input shaft of the reducer continues to bear additional radial loads, exacerbating the risk of shaft system deformation.

2、 Abnormal noise and transmission accuracy faults

Abnormal noise at the coupling: There is a periodic "clanging" impact sound during operation, and the abnormal noise is more pronounced when unloaded. After loading, the abnormal noise will be transmitted to the inside of the gearbox.

Loss of transmission accuracy: After the clearance between the elastic blocks exceeds the allowable value, there is a significant backlash on the input side, and the actual deviation of the reduction ratio exceeds the design allowable range.

Gear meshing noise: Under repeated impact loads, the backlash between the gear pairs is damaged, resulting in irregular gear knocking sounds during operation.

3、 Chain damage to core components

Early failure of high-speed bearings: Continuous impact and radial loads can cause pitting corrosion and deformation of the high-speed shaft bearing raceway, leading to excessive temperature rise and abnormal noise in advance.

Accelerated wear/pitting of tooth surface: Alternating impact causes the contact stress of tooth surface to far exceed the design limit, and normal hard tooth helical gears will quickly experience tooth surface wear and early pitting.

Input shaft keyway rolling key: Repeated impacts caused by excessive clearance can cut off the flat key or grind down the inner wall of the keyway, resulting in power transmission slipping or even complete disconnection.

4、 Temperature rise and operational stability issues

Local abnormal temperature rise: Friction at the coupling connection increases, and the temperature can quickly exceed 60 ℃. Heat is conducted to the high-speed shaft bearing chamber, causing the bearing temperature to exceed the standard.

Chain reaction of bolt loosening: After the vibration of the whole machine is amplified, the foundation bolts of the reducer and the joint surface bolts of the box will gradually loosen, further exacerbating the instability of the whole machine operation.

Motor load fluctuation: Discontinuous power transmission leads to periodic and significant fluctuations in motor current, which can trigger motor overload protection tripping in severe cases.

5、 Malignant faults under extreme working conditions

Complete power interruption: After the elastic block fractures as a whole, the motor coupling idles, the input shaft of the reducer does not move at all, and the entire extrusion production line stops unplanned.

Risk of input shaft fracture: Long term repeated alternating impacts can generate microcracks at the stress concentration of the high-speed shaft, ultimately leading to instantaneous fracture of the input shaft.

Gear tooth breakage: The peak impact load far exceeds the designed bending strength of the gear, causing brittle fracture of the hard tooth helical gear teeth, and the entire reducer is completely scrapped.