With the rapid development of the tech industry, robots have gradually appeared in everyone's vision and constantly updated and iterated, the reducer as one of the core parts of the robot, its material selection, processing technology and technical requirements are very high. The harmonic gearbox has the characteristics of high precision, large speed ratio and small volume, which makes it an ideal choice for robot joint transmission. In addition, the compact structure and high torque density of the strain wave gear enable it to achieve greater output torque and power in a limited space. Therefore, the harmonic drive has a wide range of applications in industrial robots, automation equipment, medical machinery, high-precision motion control, aerospace and precision instruments.
In the process of long-term operation, the speed reducers is under the pressure of high load, high speed and long time operation, so abnormal noise, oil leakage, gear wear, vibration and other faults will occasionally occur. For the failure of harmonic reducer, timely diagnosis and maintenance is the key to ensure the normal operation of equipment.
1.Gear wear
The reducer operation load is too large or long-term impact on the gearbox, installation eccentric or poor size coordination, poor lubrication will cause abnormal wear between the parts, thus affecting the performance accuracy of the harmonic drive.
2.Vibration
Due to the improper selection and installation of the harmonic reducer, excessive load, the superposition of the inherent vibration coefficient and the body resonance, the Angle error will be further amplified, the accuracy of the bearing will be insufficient, resulting in the flexible wheel and the rigid wheel in the engagement operation will lead to the vibration of the harmonic gear drive.
3.The abnormal sound
There are foreign bodies in the harmonic wave reducer, insufficient lubrication, the installation position of the wave generator does not meet the requirements, and the improper installation and interference of the internal parts will produce abnormal sound during operation.
4.Oil leakage
There are foreign bodies in the oil sealing lip, lip lips during installation, eccentric lip sealing and the shaft of the oil sealing lip, no oil film without poor lubrication, resulting in dry friction, poor size coordination and other oil leakage of the harmonic drive gearbox during use.
1.Observation and analysis of sound and vibration
Speed reducers failure usually produces abnormal sound and vibration. Through careful observation and analysis of the characteristics of these sounds and vibrations, the type of failure can be tentatively determined. First of all, judge the source of sound, and eliminate the abnormal noise vibration caused by motor problems. If it is a relatively sharp abnormal sound in operation, it is necessary to check the bearing problems and check whether the bearing rotation is stuck and stagnant.
2.Check the lubrication
The lubrication condition of the strain wave drive is crucial to its normal operation. Check the lubricant for cleanliness, viscosity and grease filling to ensure that the lubrication system works properly. If metal particles are found in the lubricating oil, the bearing or gear may be damaged.
3.Check the gear wear condition
Gear is the core component of harmonic gearbox and also one of the sources of common faults. The most direct method is to first judge whether there is an obvious gap in the reducer, if there is an obvious gap, you can determine the wear inside the wear of the gear, including tooth surface wear, tooth surface peeling, tooth bottom wear, etc., can determine whether there is a gear fault.
4.Perform a diagnostic test
After confirming the possible faulty parts, some special fault diagnosis tests can be conducted, such as vibration analysis, temperature measurement, oil analysis, etc. These tests can provide more detailed and accurate fault diagnosis results and help determine the specific cause of the failure.
1.Check and replace the lubricating oil regularly
The normal operation of the harmonic speed reducer requires adequate lubrication. Regular inspection of the quality and quantity of lubricants and replacement as per the manufacturer's recommendations will help to reduce the probability of wear and failure.
2.Note the load and rotational speed range
The design of the harmonic reducer is based on a certain range of load and rotational speed. Beyond these ranges may lead to overload and vibration that can damage the harmonic gearbox. Therefore, during the use process to ensure that the load and speed within a reasonable range.
3.Avoid shock and vibration
Impact and vibration will increase the load of strain wave gear, which easily lead to failure. In the process of operation, attention should be paid to avoid impact and vibration, such as reasonable layout of the working environment, the use of shock absorber, etc.
Overall, the fault diagnosis of the harmonic gearbox needs to determine the type and cause of the fault through observation, analysis, and testing. Through timely fault diagnosis, effective repair and maintenance measures can be taken to extend the service life of harmonic reducer and avoid the occurrence of emergency faults.
Zhejiang Laifual Drive Co. Lto. Is committed to becoming a supplier of precision motion control solutions. We have developed harmonic gearbox frameless motors, encoders, drives, precision bearings and planetary gearbox etc, forming three major business segments: harmonic gearbox, rotary actuators and precision components. After more than 10 years of dep cultivation in the industry, Laifual has become a comprehensive service-oriented enterprise from single parts to precision motion control solutions.
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