How to perform accuracy detection after the gear reducer is assembled

After the gear reducer is assembled, accuracy detection can be carried out from the following aspects:

1. Basic parameter verification : Check the nameplate information of the reducer, including model, speed ratio, rated power, torque range, etc. At the same time, check the level and stability of the equipment installation foundation, and use an electronic level with an accuracy of 0.02mm/m to measure. If there is settlement or offset in the foundation, it needs to be corrected first.

2. Adjust the horizontality and coaxiality : Use an electronic level to measure the horizontal deviation at the three positions of the reducer input shaft, the box base, and the output shaft installation surface, and adjust the thickness of the base gasket to ensure that the overall horizontal error is ≤0.05mm/m. The laser centering instrument detects the coaxiality between the input shaft and the motor shaft, the output shaft and the load end. It is recommended that the radial deviation be controlled within 0.05mm and the angle deviation is ≤0.1°.

3. Gear meshing accuracy detection :

• Contact spot detection : Blue Dan coloring method can be used to evenly apply the blue mark paint on the tooth surface of the pinion of 4-7 teeth. Turn the pinion to make the paint print on the tooth surface of the large gear, forming contact spots. The qualified standard is the contact area along the tooth height direction is ≥45% and the contact area along the tooth length direction is ≥60%.

• Tooth side clearance measurement : Use a feeler gauge or a dial gauge to detect the side clearance of the gear pair, and the allowable values ​​of different specifications of reducers vary.

4. Bearing clearance adjustment : Select lead pressing method or sensor to measure the clearance according to the bearing type. It is recommended to control the axial clearance of tapered roller bearings at 0.03-0.08mm.

5. Operation status detection : Start the equipment and run for 15-20 minutes without load to observe whether there is abnormal vibration, noise or excessive temperature rise. Use a vibration analyzer to detect the vibration values ​​of each bearing position and record the initial data. If the vibration value exceeds the scope specified in ISO 10816 standard, problems need to be checked and repaired.

6. Load test and data verification : After completing mechanical calibration, perform step-by-step load test. First run for 30 minutes without load to monitor temperature rise and noise; then load 30%, 60%, and 100% of the rated torque, and run for 1 hour in each stage. Use a torque sensor to detect the actual torque of the output shaft. If the deviation from the theoretical value exceeds 5% and the gear meshing parameters must be readjusted.