Hazelnut farmer in Croatia, not a mechanical engineer. Built 4 grain-homogenization silos, each with a vertical mixing spiral (Ø500mm × 4m) hanging off a worm gearbox, 4kW motor, output shaft down, direct-coupled. First unit commissioned this month, at silo 1.
Equipment (from nameplates):
- Motor: YE2-112M-4, 4kW, 220/380V (Δ/Y), 14.9/8.6A, 1440rpm, Class F, IP55
- Gearbox: Tehnopan NMRV110, worm, i=1:40, flange 112B14, grey cast iron housing, output ~36rpm
- Mounting: vertical, output shaft down. Factory ports: two side ports at mid-housing height, one drain plug at bottom; no port on top as shipped.
At commissioning the motor was found wired delta on a 400V grid; measured ~85A/phase. Rewired to star. No-load current after rewiring: 5A.
Separately, the gearbox ran hot. First loaded run measured (IR + surface): housing 123°C, with the end opposite the motor (far worm bearing zone) at 130-140°C, sides 130-140°C, top ~100°C, motor flange 95°C, motor body 65°C.
Oil was changed: drained ~2.0L, black. Refilled with INA Epol SP 320 (mineral EP oil; per its technical datasheet: ISO VG 320, viscosity 320/23.6 mm²/s at 40/100°C, VI 93, density 0.902 g/cm³, flash point 250°C, copper corrosion 100°C/3h: 1b) to the side-port level.
Then logged four thermal runs, IR thermometer + clamp meter (TRMS), same housing measuring spot unless noted:
Test 1 — loaded (~10t corn), old oil, warm restart:
0min 81.2°C → 1min 83.5 → 2min 87.5 → 3.5min 92.5 → 5min 99.5 → 7min 106.0°C. Aborted, still rising.
0min 81.2°C → 1min 83.5 → 2min 87.5 → 3.5min 92.5 → 5min 99.5 → 7min 106.0°C. Aborted, still rising.
Test 2 — loaded (~10t corn), fresh INA SP 320, level to side port:
0min 36.0°C → steadily up to → 17.5min 108.4°C. Aborted, still rising. Slow oil weep at the side breather during the run.
Test 3 — no load, silo empty, same oil, windy/no sun:
0min 38.0°C → 10.5min 44.6°C. Bearing-end reading slightly warmer than the housing measuring spot. A second no-load check on a different (warmer, calmer) day: 5min = 38.7°C side / 44.0°C bearing; 10min = 43.0°C side / 48.2°C bearing.
Test 4 — loaded, after drilling a vent port on top of the housing and topping up oil (quantity not recorded), start with an unevenly-piled load:
Three tracked points — housing side, worm-bearing end, motor current (star, rated 8.6A):
0min: 36/38°C, 9.0A
5min: 60/65°C, 9.15A
10min: 82/91.5°C
13min: 90/101°C, 8.85A
16min: 101/107°C
17min (abort): 101/111°C, 8.8A. Housing wall directly next to the worm mesh measured 118°C at abort. The side reading had gone flat over the last two readings (101°C); the bearing-end reading was still rising (107→111°C). Current ranged 9.25→8.8A across the run, motor showed no signs of overload throughout.
Reference unit (separate machine, for comparison only, no thermal log kept): a Tramec KC90 right-angle helical-bevel gearbox (i=65, mounting B6) on my grain dryer, driven by a 1.1kW motor (1.1kW, 1400rpm, 4.52/2.60A, IE2), turning a Ø350mm spiral, output ≈21.5rpm. Per the owner (me), in service about 10 years with no reported issues — no instrumented data, just years of operation without complaint.
From the manufacturer's own catalogue for this gearbox family (Motovario VSF, 2017 edition — not the brand I actually have, mine is a different maker's unit built to the same NMRV110 frame size):
- Housing material: die-cast aluminum for sizes 025-110; grey cast iron only at 130-150. (My unit: cast iron.)
- Factory lubrication: synthetic polyglycol oil, listed as filled for life, 1.6L for size 110 regardless of mounting position; breather/level/drain plugs listed as present only on sizes 130 and 150. My unit has 3 plugs.
- An older manual from the same product line lists plugs also present at size 110, with a 2.5L mineral fill — the catalogue itself doesn't reconcile this difference.
- Efficiency: dynamic η at 1400rpm input for i=40 listed as 0.79; static η 0.48.
- Load limits: max radial load (Fr2) 12,000N; permissible axial load listed at 1/5 of radial.
- Mounting position guidance: B3 (horizontal) is described as giving less oil splash, better lubrication, less heating; V5 (my mounting) is flagged for sizes 063-150 as "check application / contact technical service" in the 1500<n1<3000rpm input-speed band.
Questions:
Does this temperature/time pattern look like normal worm-gearbox behavior for this duty (loaded, ~15-20min continuous run), or does it point at something specific being wrong?
What would you want measured next to narrow this down?
Is there additional data worth logging before I make any changes?