To check whether the gears of the ZJY90-12.5-S shaft-mounted gear reducer are worn, the following methods can be used:
Visual inspection : Use the naked eye or use a magnifying glass to observe the surface of the gear to see if the tooth surface is smooth and there are obvious wear marks, cracks, peeling, pitting and other damages. At the same time, pay attention to whether the tooth shape is complete, whether the tooth top becomes round, and whether the tooth root is worn.
Inspection of measurement tool : Use calipers, micrometers or gear measuring instruments to measure the gear's tooth thickness, tooth pitch, tooth surface roughness, radial jump parameters, etc., and compare them with the new product standard value. If the measurement value exceeds the allowable error range, it means that the gear has wear or deformation.
Color coating method : apply a thin color coating on the surface of the gear, let the gear run in a normal working state for a period of time before taking it off, and observe the wear of the color coating. The area where the color coating disappears is usually a more severely worn area.
Noise and vibration analysis : Vibration data during gear operation is collected through acceleration sensors, and the spectrum is analyzed using an FFT spectrum analyzer. If the amplitude of the meshing frequency fluctuates periodically, or abnormal sidebands appear on the spectrum diagram, it may mean that the gear is worn. Meanwhile, severely worn gears usually produce more noise and can be monitored by a noise detector.
Lubricant oil analysis : Regular sampling and analysis of the metal particles content in lubricant, you can use an atomic emission spectrometer to detect the concentration of iron, copper and aluminum. When the iron content exceeds 200ppm or the copper element exceeds 50ppm, you should be wary of the aggravated wear of the tooth surface. In addition, the abrasive particles can be observed through iron spectrum analysis and the wear type can be judged.
Functional test : Perform a load test on the gear to check its operating condition under load. If the transmission is unstable, noise increases or abnormal temperature increases, it may be a manifestation of gear wear.
Analysis of tooth contact marks : Apply red elixir powder evenly to the tooth surface, observe the contact area after rotating the gear. The ideal contact area should reach more than 70% of the tooth surface and be located near the joint circle. If the contact area is too small or the contact position is abnormal, it may indicate that the gear has wear or installation accuracy problems.
