1. Design Aspects
Inappropriate parameter selection: For instance, excessively low overlap ratio may result in insufficient gear meshing, causing impact and vibration that subsequently generate noise.
Improper or absent profile modification: Profile modification enhances gear meshing performance while reducing vibration and noise. If profiling is improper or omitted, significant impact and noise may occur during gear meshing.
Unreasonable Structure: Structural flaws in the output shaft gear design—such as insufficient shaft stiffness or improper bearing support—can cause vibration and noise during gear operation.
2. Manufacturing Aspects
Excessive Pitch Error and Profile Error: Pitch error and profile error are critical factors affecting gear meshing performance. Excessive deviations in these parameters cause significant impact and vibration during meshing, subsequently generating noise.
Excessive Flank Clearance: Flank clearance refers to the gap between the flanks of meshing gears. Excessive clearance causes significant impact and noise during gear operation.
Excessive Surface Roughness: Gear surface roughness also influences noise levels. Excessive roughness increases friction and vibration between gears, thereby generating noise.
3. Assembly Issues
Assembly eccentricity: If the output shaft is eccentrically mounted during assembly, it causes uneven load distribution during gear operation, leading to vibration and noise.
Low contact accuracy: Contact accuracy refers to the engagement condition between gear tooth surfaces. Low accuracy results in significant impact and vibration during meshing.
Poor Shaft Parallelism: If the output shaft exhibits poor parallelism with other shafts, it causes uneven load distribution and vibration during gear operation.
Insufficient Bearing/Support Rigidity: The rigidity of bearings and supports also impacts gear performance. Insufficient rigidity leads to significant deformation and vibration during gear operation.
Inadequate bearing rotational accuracy and improper clearance: Bearing rotational accuracy and clearance also affect gear performance. Low rotational accuracy or improper clearance can cause vibration and noise during gear operation.
4. Material-related factors
Poor material quality: If the output shaft gear shaft has poor material quality, such as internal defects or insufficient hardness, it can cause significant deformation and vibration during gear operation.
Insufficient dimensional strength: If the output shaft gear shaft lacks sufficient dimensional strength to withstand design loads, it may cause gear damage and noise during operation.
5. Other Factors
Fluctuations in input torque and load torque: Variations in input torque and load torque can result in uneven load distribution and vibration during gear operation.
Torsional Vibration of the Shaft System: Torsional vibration refers to the twisting motion generated within the shaft system during operation. Excessive torsional vibration can cause significant impact and noise during gear operation.
Balancing of the Motor and Other Transmission Components: The balancing condition of the motor and other transmission components also affects gear operational performance. Poor balancing can lead to vibration and noise during gear operation.