What should you pay attention to when verifying the FA series gear reducer with load?

1. Preparations before verification

‌Tooling and accuracy calibration‌: Confirm that the torque speed sensor, thermometer, and vibration meter are all within the calibration validity period, the input and output shaft coaxiality error is ≤‌0.02mm‌, and the flatness of the mounting surface is ≤0.1mm/m. It is prohibited to use paper or rubber pads for leveling, and the number of stainless steel gasket layers should not exceed 3 layers.

‌Lubrication and basic inspection‌: Add the specified type of industrial gear oil, the oil level should be stable at 1/2~2/3 of the oil window, and the breather cap is not blocked; turn the machine manually for 3~5 turns to confirm that there is no sticking or scratching feeling in the rotation, and tighten all bolts to standard torque and make anti-loosening marks.

‌No-load preheating confirmation‌: Complete a 30-minute no-load test run first, and confirm that the transmission ratio error is ≤±1%, the vibration speed is ≤2.8mm/s, the oil temperature does not exceed 60℃, and there is no abnormal noise or leakage before entering the load stage.

2. Requirements for hierarchical loading control

‌Strictly load according to the gradient‌: It is forbidden to start directly at full load, load step by step in the order of ‌25%→50%→75%→100% rated load‌, each load level should run stably for at least 1 hour, and skip loading is strictly prohibited.

‌Special working condition verification‌: After completing the rated load verification, an additional overload test of 125% rated load operation for 30 minutes and 150% impact load repeated three times for 10 seconds can be added as needed to cover on-site impact conditions.

‌Running-in phase restrictions‌: The load of the new machine must not exceed 50% of the rated value in the first 30 hours, and then gradually increase to 70%~80%. Overloading and frequent forward and reverse rotation are prohibited.

3. Key points of operating status monitoring

‌Temperature control‌: Monitor the oil pool temperature throughout the entire process, and the maximum temperature shall not exceed ‌80℃‌. The temperature rise of the bearing seat shall be ≤40℃. If local rapid overheating occurs and the shell is hot, stop the machine immediately to troubleshoot lubrication or meshing faults.

‌Vibration and Noise‌: The vibration value of the high-speed shaft is ≤2.8mm/s, the low-speed shaft is ≤4.5mm/s, and the running sound is even and soft. When periodic impact sounds or sharp friction sounds occur, immediately reduce the load and check the alignment and foot tightening.

‌Electrical parameter monitoring‌: Track the motor current in real time. The no-load current must not exceed 15% of the rated current. After loading, the current fluctuation must be stable within the design range to avoid overload triggering protection.

‌Sealing and fastener inspection‌: Pause for 2 minutes after each level of loading to check that there is no oil leakage on the shaft oil seal and the box joint surface; retighten the foot, motor, and coupling bolts respectively after 24 hours and 72 hours of operation to prevent loosening caused by vibration.

4. Verification closing and compliance requirements

‌Data retention‌: Completely record the load value, operating time, temperature, vibration, and current data at each stage as a baseline reference for subsequent daily operation and maintenance.

‌Oil change and re-inspection‌: Completely change the oil after 50 to 100 hours of cumulative operation, remove metal debris generated by running-in, clean the box and add new oil to complete the closed loop of load verification.

‌Safety Confirmation‌: Ensure that the emergency stop button and safety shield function normally throughout the entire process, test the shutdown and restart functions under load, and verify that the system can start and stop safely without rolling.