Will the ZQ series soft tooth surface gear reducer be immediately damaged if overloaded

1. Common overload scenarios that will not be immediately damaged

Minor sustained overload: The overload amplitude is within the range of 110% to 130% of the rated load, which belongs to the conventional short-term tolerance range of soft tooth surface reducers. It will not immediately cause structural fracture, but will only accelerate component fatigue wear.

Low frequency minor impact: Occasional instantaneous impact loads do not exceed 1.5 times the rated torque. The core toughness of the soft tooth surface quenched and tempered gear can absorb some of the impact energy and will not directly cause tooth breakage.

This type of overload will not directly cause shutdown faults, but it will leave hidden fatigue damage inside the gears and bearings, greatly reducing the remaining life of the equipment.

2. Overloading scenarios that may cause immediate damage

Instantaneous severe impact overload: When the instantaneous impact torque exceeds 2-3 times the rated torque, directly exceeding the bending strength limit of the gear tooth material, the tooth root will undergo brittle fracture, resulting in immediate failure phenomena such as gear tooth fracture and complete tooth breakage.

Extreme sustained overload: If the long-term overload amplitude exceeds 150% of the rated load, the contact stress on the tooth surface in a short period of time will far exceed the fatigue limit, leading to rapid large-scale bonding, severe plastic deformation and indentation of the bearing raceway, and even immediate damage such as shaft neck twisting and box cracking.

This type of overload often occurs in extreme working conditions such as sudden lifting of heavy objects by cranes or sudden jamming of belt conveyors, which can directly cause the gearbox to lose its transmission capacity.

3. Hidden immediate abnormalities after overloading

Even if there is no obvious structural damage, observable abnormal signals will immediately appear after overloading:

The motor current continues to exceed the rated value, and the operating noise of the gearbox suddenly increases by more than 15 decibels.

The temperature of the box rapidly rises, and the lubricating grease becomes overheated and deteriorated in a short period of time, resulting in early Brinell marks on the bearing raceway.

The vibration amplitude of the output shaft increases to 2-3 times the normal value, and the sealing component experiences instantaneous oil leakage due to impact.