Some standard content:
ICS21.200
Machinery Industry Standard of the People's Republic of China
JB/T9050.3-1999
Cylindrical Gear Reducer
Load Test Method
Load test method of reduction cylindrical gear unitsPublished on 1999-06-28
National Bureau of Machinery Industry
Implementation on 2000-01-01
JB/T9050.3-1999
This standard is a revision of ZBJ19005-88 "Load Test Method of Cylindrical Gear Reducer". During the revision, the original standard was edited and the main technical content remained unchanged. This standard replaces ZBJ19
900588
This standard is proposed and managed by the Metallurgical Equipment Standardization Technical Committee. The drafting unit of this standard: Xi'an Heavy Machinery Research Institute. The main drafters of this standard are Xu Hongjun, Wang Peibian and Chen Yawen. This standard was first issued in June 1988.
1 Scope
Mechanical Industry Standard of the People's Republic of China
Cylindrical Gear Reducer
Loading Test Method
Loadtestmethod ofreductioncylindricalgearunitsJB/T9050.3-1999
Replaces ZBJ19005-88
This standard specifies the methods of loading test and data processing of cylindrical gear reducers, and also specifies the requirements for test pieces and test devices.
This standard is mainly applicable to the loading test of scientific research prototypes (new product development prototypes), product quality certification, and product factory acceptance of involute tooth cylindrical gear reducers. The high-speed shaft speed of the test reducer shall not exceed 1500r/min, and the gear circumferential speed shall not exceed 20m/s. 2 Referenced standards
The clauses contained in the following standards constitute the clauses of this standard through reference in this standard. When this standard is published, the versions shown are valid. All standards will be revised, and parties using this standard should explore the possibility of using the latest versions of the following standards. GB/T6404—1986
GB/T8543—1987
Method for determination of sound power level of noise of gear device Determination of mechanical vibration of gear device during acceptance test GB/T10095—1988
Precision of involute cylindrical gears
3 Requirements for test pieces
3.1 General provisions for test pieces and their quantity
The test pieces are products or prototypes to be shipped out of the factory. The number of test benches is determined by the purpose and requirements of the test and should not have other restrictions. 3.2 Material and processing accuracy of test pieces
The materials, heat treatment and machining of the main parts should be qualified and have inspection records. If necessary, check the production inspection records or spot check its important items before the test.
4 Requirements for test equipment
4.1 Loading test bench
The driving and loading methods and devices of the test are not restricted. The open test bench is shown in Figure 1a), and the closed power flow test bench is shown in Figure 1b). The closed power flow type with lower energy consumption is preferred. The loading torque and speed are stable, and the fluctuation should not exceed 1%. Loading and unloading can be carried out during operation.
4.2 Load and speed test instruments
The type of instrument is not limited, but its specifications, range and accuracy should be adapted to the test. The test items are loading torque (power) and speed test accuracy not exceeding 1% of the reading. Torque and speed sensors and torque and speed measuring instruments are preferred, and a sensor should be installed at the input and output ends of the reducer under test to directly measure the input and output torque (power) and speed of the test piece (only with additional coupling), as shown in Figure 1a) and Figure 1b).
Approved by the State Bureau of Machinery Industry on June 28, 1999, and implemented on January 1, 2000
4.3 Installation and commissioning
JB/T9050.3-1999
a) Open test bench
b) Closed power flow test bench
1—Sensor: 2—Test piece: 3 Sensor: 4—Motor: 5, 6, 7, 8—Coupling: 9—Loader: 10 Transmission box: 11—Transmission shaft Figure 1
All test devices (excluding electric control power supply equipment) should be installed on the same (or combined) platform, and all components should be level, centered, and the system should operate flexibly. Perform static zero adjustment first, and then dynamic zero adjustment. The first digits of the multi-digit readings of the torque display value of the adjustment instrument should all be zero, and the last digit should not be greater than 4.
Disconnect the coupling 8 (see Figure 1) and measure the no-load torque of the test piece 2. 5 Temperature, noise and vibration test instrument requirements for load test The temperature of the reducer oil pool and bearing can be measured by a thermometer with a range of up to 150°C certified by the metrology department. The noise meter and test method shall comply with the provisions of GB/T6404. The vibration test instrument and test method shall comply with the provisions of GB/T8543. 6 Loading test of reducer
6.1 Test items, steps and methods
6.1.1 The test of scientific research prototype (new product development prototype) shall generally be carried out according to Table 1.
No-load test
Load performance test
Overload testwww.bzxz.net
Tooth surface contact fatigue
Life test
JB/T9050.3-1999
At rated speed, the forward and reverse directions shall run for no less than 1h. Requirements:
All connectors and fasteners are not loose;
All seals and joints are free of oil leakage and seepage; the operation is smooth and impact-free;
Fully lubricated, check the bearing and oil pool temperature. After the no-load test is qualified, conduct the thermal power test. At the rated speed, load the test step by step. After each load test reaches the oil temperature balance for 1 hour, increase the level (about 20% rated load) until the equilibrium temperature reaches the maximum temperature allowed by the lubricating oil. Then conduct the mechanical power (mechanical strength) test. At the rated speed and torque, the number of stress cycles per tooth of the high-speed gear is N≥3×10°. Requirements for measurement: Torque (or power):
Efficiency:
Speed and running time:
Bearing and oil pool temperature, temperature rise;
Noise, vibration;
Tooth surface contact rate, gear damage
At rated speed
120% rated load, running for 1min:
150% rated load, running for 1min:
180% rated load, running for 0.5min.
Inspect gears and other parts for damage
Under rated load, the stress cycle number of high-speed gears is 5×107 times for tempered gears and quenched gears, and 2×10° times for nitrided gears.
The inspection items are the same as those of items 5 to 11.
The lubrication and cooling measures of the thermal power test (i.e., the power when the reducer oil temperature does not exceed the maximum allowable equilibrium oil temperature under certain lubrication
cooling conditions) shall comply with the requirements of its thermal power table.
Any cooling measures may be taken during the mechanical power test.
The overload test shall be loaded after starting and braked after unloading.
Test the contact fatigue life of the tooth surface.
For the acceptance of reducers with output torque T>10t·m, the loading torque (power) of the load test shall be determined by negotiation between the user and the manufacturer.
It is allowed to use industrial application tests instead of fatigue life tests, but the actual load of industrial applications must reach the rated load, and there must be accurate daily records, and the test time shall not be less than 3600h.
6.1.2 Product quality certification test
Product quality identification and certification tests shall be carried out according to the items No. I~IIII in Table 1. Tooth surface contact fatigue life test can be exempted. 6.1.3 Product delivery and acceptance test
Generally, the tests No. I~III in Table 1 shall be carried out, but the load performance test and the over-test are allowed to be loaded according to the practical load, and the load test operation time is allowed to reach temperature equilibrium, without N≥3X10 times. Sampling test is allowed in batch production, and the sampling number shall not be less than 10% of the batch. If unqualified products are found in the sampling test, another 10% shall be sampled. If there are still unqualified products, all shall be tested. 6.2 Test data and data processing
6.2.1 Data acquisition
JB/T9050.3-1999
The data collected during the test include: loading torque, power, speed, temperature, noise, vibration, gear wear, time, etc. The data that should be collected at least once every half an hour include input and output speed, input and output torque, power value, lubricating oil temperature, bearing temperature, and room temperature. Collect data from the digital display or typewriter, and collect at least 5 sets of data for speed, torque, and power each time. At the same time, record the time of data collection.
Noise and vibration should be measured once for each load level and each speed level, and record the noise and vibration values and the corresponding load speed and time.
The wear, pitting, bonding, fracture and changes in the tooth surface contact rate of the gear should generally be observed and recorded at least once a day. If the test is normal and there is no damage, the recording time interval can be longer. On the contrary, if the tooth surface has been damaged, the recording time interval should be shorter. Abnormal phenomena and damage of the shaft, bearing and body during the test, as well as the type and brand of lubricating oil, should be recorded. 6.2.2 Calculate the average value of torque (power) and speed a) Calculate the average value of each data collection as shown in formula (1) and formula (2): T
Where: T—average value of torque each time, N·mn
average value of speed each time, r/min:
Number of data sets:
Ttorque value in each data set, N·m;
speed value in each data set, r/min.
b) Calculate the average value of each load level as shown in formula (3) and formula (4): To
Where:
average value of torque for each load level, N·m; average value of torque collected each time, N·m; -number of data collected for each load level;
average value of speed for each load level, r/min; average value of speed collected each time, r/min. 6.2.3 Transmission efficiency of reducer
a) Total efficiency of reducer, see formula (5)
wherein: n
Total transmission efficiency of reducer;
-The average value of output torque collected at the same time, N·m; 100%
JB/T9050.3-1999
The average value of input torque collected at the same time as T, N·m; - Transmission ratio of reducer:
Efficiency of coupling of input and output shaft of reducer. b) Gear meshing efficiency (including lubrication and oil stirring loss), see formula (6): n
wherein:
Gear meshing efficiency;
-Total transmission efficiency of reducer:
-Total efficiency of each bearing of reducer.
Several bearings
c) Draw the efficiency curve
n bearing
Draw the efficiency curve of 25%, 50%, 75%, 100%, 110% rated load at 500, 750, 1000, 1500r/min or rated speed, take the ordinate as the efficiency value and the abscissa as the load value. 6.2.4 Reducer thermal power curve
Take the thermal power at the highest allowable equilibrium temperature (
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