How to Determine if a Worm Gear is Overloaded?

Determining whether a worm gear is overloaded is crucial for preventing malfunctions. The following methods are commonly used for monitoring and judgment:

Monitoring Motor Current and Power

In worm gear reducer drives, the load on the worm gear is directly reflected in the motor current. When the worm gear load exceeds the design rated torque, the motor current will significantly exceed the rated value. If an abnormally high current is detected, it often means that the worm gear is under overload.

Monitoring Temperature Increase

Overload operation will cause abnormal increases in the temperature of the worm gear bearings, tooth surfaces, and lubricating oil. While worm gears generate some heat during normal operation (due to their inherently low efficiency), exceeding design thresholds (e.g., abnormal bearing temperature) typically indicates excessive load.

Detecting Output Shaft Torque

Directly measuring the output shaft torque using a torque sensor is the most straightforward method. If the measured torque is close to or exceeds the manufacturer's rated torque (e.g., the torque value specified in the technical parameters of Yifeng products), it indicates the worm gear reducer is operating at its limit load, or even overload.

Observing Operating Status and Startup Overload operation is often accompanied by slow operation, difficulty starting, or abnormal noise (e.g., metallic clanging). If the equipment experiences hesitation or jamming during startup or low-speed operation, the load may have exceeded the design range.