To confirm whether the modified ZD50-3.55-III reducer meets the performance requirements, four core links must be passed: parameter verification, no-load test, load test, and durability verification, as follows:
1. Compliance check of modification parameters
Refer to the original factory technical manual to review the key parameters after modification: ① Whether the transmission ratio is consistent with the design value of 3.55; ② Whether the rated torque and speed of the input/output shaft are within the allowable range; ③ Whether the installation dimensions (shaft diameter, center height, flange specifications) match the load equipment; ④ Whether the lubrication circuit and sealing structure are adapted to the new working conditions to prevent the risk of poor lubrication or oil leakage.
2. No-load trial operation test
(1) Add the specified brand of lubricating oil. Control the oil level at the center line of the oil window. Turn the engine manually for 3 to 5 turns to confirm that there is no sticking or abnormal noise.
(1) Start the reducer by jogging the motor and observe whether the running direction is correct; run continuously for 2~4 hours without load, and record data every 30 minutes: operating temperature ≤80°C, bearing temperature rise ≤40°C, vibration value meets equipment standards, and no abnormal noise.
(1) Check that there is no oil leakage at the breather plug and oil seal, and that the fasteners are not loose.
3. Load classification verification test
(1) Load step by step at 25%, 50%, 75%, and 100% rated load, run stably for 1 hour at each level of load, and monitor core indicators:
▶ Torque: Detect the output torque through a torque meter, the fluctuation range is ≤±5% of the rated value;
▶ Temperature rise: When running at full load, the maximum temperature of the shell is ≤80°C, and the temperature rise rate is stable and there is no sudden rise;
▶ Noise: no-load noise ≤75dB (A), full-load noise ≤85dB (A), no metal impact sound;
▶ Leakage: There is no oil leakage on each sealing surface and pipe joints.
(2) If it is necessary to adapt to overload conditions after modification, a short-time test at 120% of the rated load (lasting 30 minutes) is required to confirm that there are no problems such as gear damage and bearing overheating.
