ZQ850 - 23.34 - IVZ is a large-scale ZQ series reducer. The trial operation must be carried out according to the process of pre-test inspection, phased test, exception handling and post-test closing to ensure the stability of the equipment operation. The specific precautions are as follows:
1. Comprehensive pre-inspection before test run
Foundation and connection inspection: Use an electronic level to check the levelness of the reducer. The axial deviation must be ≤0.02mm/m and the radial deviation ≤0.05mm/m; use a 0.05mm feeler gauge to check the joint surface between the base and the foundation to ensure that there is no continuous gap. At the same time, confirm that the anchor bolts have been tightened in place three times according to the torque-angle method. The coupling needs to be tested with a laser alignment instrument to ensure that the radial deviation is ≤0.05mm and the angular deviation is ≤0.05mm/m. A thermal expansion gap needs to be reserved at the input and output shaft ends.
Lubrication and sealing inspection: Add ISO VG220 or VG320 extreme pressure gear oil specified by the manufacturer until the oil level reaches the center line of the viewing window. If it is a circulating lubrication system, it is necessary to separately test the oil pump pressure to be between 0.2 - 0.4MPa and stable, and there is no pipeline leakage. In addition, check whether the shaft seal and box joint surface are coated with compliant sealant, and safety devices such as protective covers must be installed in place.
Component operation inspection: Manually turn the input shaft to ensure that the rotation is flexible and free of jamming, and that there are no abnormal meshing noises. Jog the device three times (each operation is ≤3 seconds, with an interval of 10 seconds), and confirm that the motor direction is consistent with the marking on the housing, and there is no abnormal sound such as metal friction.
2. Standardized trial operation in stages
No-load test run: first start at 25% of the rated speed, and then increase the speed step by step in 25% increments. Each stage runs for 30 minutes until it reaches the rated speed and runs continuously for 4 hours. During the period, the temperature of the bearing part was monitored to be ≤75°C, the final temperature of the lubricating oil was ≤65°C; the radial vibration of the input shaft was ≤2.8mm/s, and the sound pressure level 1 meter away from the equipment was ≤85dB (A); at the same time, it was observed that the lubricating oil had no emulsification or discoloration, and there was no oil leakage at each sealing point.
Graded load trial operation: run in stages at 30%, 60%, and 100% rated load, with each stage lasting at least 2 hours. During the 30% load stage, focus on checking leakage at the seal; during the 60% load stage, use a thermal imager to detect the temperature distribution of the box to avoid local overheating; during the 100% rated load stage, record current fluctuations, and the deviation must be <5%. The coloring method must also be used to detect gear contact spots, with the contact area in the tooth length direction ≥ 60% and the tooth height direction ≥ 45%.
3. Handle abnormal situations in a timely manner
If the vibration exceeds the standard, first check whether the anchor bolt pretightening force is attenuated, and then review the coupling alignment accuracy. If the vibration spectrum shows a gear meshing frequency, the machine needs to be stopped to adjust the gear meshing clearance.
If the temperature rises abnormally, such as the temperature rise exceeds 10°C within half an hour, you need to stop the machine to check whether the lubricating oil amount is sufficient and the oil quality is suitable, or check whether the bearing preload force is too large. If necessary, dismantle the bearing raceway and check whether there is damage to the bearing raceway.
If oil leakage occurs, slight leakage can be temporarily observed. If leakage occurs in drops, the machine needs to be shut down to replace the shaft seal or re-apply sealant. If there is high-frequency abnormal noise, check whether there are scratches on the tooth surface. If there is low-frequency roar, focus on checking whether the bearing clearance exceeds the standard.
4. Finishing work after test run
After the trial operation reaches the standard, drain the lubricating oil and clean the oil tank to remove metal debris generated by running-in, and then refill with new oil. Retighten the anchor bolts and connecting bolts in diagonal order to prevent loosening due to vibration during operation. At the same time, equipment files are established to record key data such as vibration spectrum, oil temperature curve, and oil contamination level, which serve as the benchmark for subsequent daily maintenance.
