Each of the core vibration control measures for the motor and ZSY180-31.5-II reducer includes operating standards, implementation details and expected effects, and can be implemented directly:
1. High-precision alignment and installation benchmark optimization (basic core measures)
A laser alignment instrument is used to complete the coaxiality and parallelism correction of the motor-reducer. The radial displacement deviation is required to be ≤0.02mm, the angular displacement deviation is ≤0.05mm/m, and the coupling end face gap is uniformly controlled at 0.2-0.5mm (fine adjustment according to the coupling model). The mounting surface needs to be milled to ensure that the flatness is ≤0.03mm/m. The anchor bolts are of M20 specification and locked with double nuts + lock washers. The tightening torque is 150-180N·m. They need to be retightened twice after installation (the first retightening after 1 hour of operation and the second retightening after 24 hours). At the same time, clean the impurities on the installation surface to avoid the reference shift caused by the superposition of gaskets. This measure can solve about 40% of the vibration caused by installation deviation and reduce the vibration speed of the equipment by 30-40%.
2. Transmission system balance and meshing optimization (vibration source elimination measures)
The motor rotor is calibrated according to the G2.5 level dynamic balance standard (the allowable unbalance amount at 1500r/min is ≤2.5g·mm/kg). The input shaft and gear shaft of the reducer must reach the G4.0 level dynamic balance accuracy. If uneven gear tooth surface wear, gluing or abnormal meshing clearance is detected (standard clearance 0.15-0.3mm, converted according to module), the tooth surface needs to be disassembled and ground or the gear must be replaced and the clearance must be readjusted. The coupling is preferably a plum blossom-shaped elastic coupling. Check the condition of the elastomer regularly. If aging, cracks or wear exceed 3mm, replace it immediately. The bolt tightening torque must be uniform (according to the requirements of the coupling manual, usually M12 bolts are 45-60N·m). This measure can eliminate core vibration sources such as rotor eccentricity and gear meshing impact, and reduce the amplitude of high-frequency vibration (50-200Hz) by 40-50%.
3. Precise maintenance of bearings and lubrication systems (measures to ensure operational stability)
When installing the reducer tapered roller bearing (commonly used models 30220/30222), adjust the radial clearance to 0.02-0.05mm, and use ZL-3 lithium-based grease to fill 1/3-1/2 of the internal space of the bearing to avoid vibration caused by excessive clearance or insufficient lubrication. The gearbox uses 320# industrial gear oil (Shell Omala and Mobil 600 series are recommended), keep the oil level at the center line of the oil window, replace the gear oil every 5000 hours, and clean the oil tank and 80 mesh filter to avoid impurities (content exceeding 0.05%) or moisture (content exceeding 0.1%) in the oil from exacerbating gear wear. This measure can stabilize the operating status of bearings and gears, control the vibration speed of the equipment below 4.5mm/s (RMS), and extend the service life of components by more than 30%.
