Some standard content:
Machinery Industry Standard of the People's Republic of China
Worm reducer
1 question content and scope of application
Loading test method
IB 5558 91
This standard ship Specifies the requirements for the loading test of the power transmission door worm reducer (hereinafter referred to as the worm reducer), the test bench and test equipment, the loading test method and data processing, etc. This standard is suitable for the product shaping and quality of the worm reducer. In the complete machine loading performance test of the identification and scientific research prototype, the scorpion rod speed of the tested coupling reducer did not exceed 1500r/min, and the average sliding speed of the worm pair meshing table did not exceed 17m/s2. Reference standard
(36-101 Method for determination of noise power level of gear devices (8513 Determination of mechanical vibration of gear devices in acceptance test 3 General requirements for test pieces
3.1 The test piece is a product or prototype to be shipped out of the factory: the number of test (or sampling) units is according to the test door and corresponding requirements are determined. 3.2 The materials, heat treatment, mechanical processing, etc. of the main parts should all meet the specified technical requirements. After passing the inspection, it will be recorded as an inspection agent. If necessary, check the production inspection record or randomly inspect the main items before the test. 4. Test bench and testing device
4.1 Loading test bench
The driving and loading method of the test bench should be preferably hydraulic or electrically loaded closed type with low energy consumption. For the test: Stimulate the baby to ask: The loading and turning speed is stable, and the fluctuation should not exceed 5%: During operation, it is required to be able to load and unload. Smooth operation 4.2 Load and speed range measuring instrument
Instrument type, specification, The range and accuracy should be consistent with the test requirements. The test item is loading rotation (power), and the rotation speed test error should not exceed 1% of the reading. Priority is given to the torque speed sensor and rotation speed measuring instrument, which should be tested. The input of the speed transmitter is equipped with a sensor at the input end to directly measure the input, output rotation (power) and speed of the sample (attached coupling to the instrument), as shown in the figure! 4.3 Installation and debugging
All The test device (not including electronically controlled power supply equipment) should be installed on the same (or group) platform. It is necessary to find water and centering of each component. When the system is running hot, perform static zero adjustment first, and then perform dynamic zero adjustment. The zero adjustment quality allows the first digits of the multi-digit readings of the torque display value of the instrument to be zero and the length is not large 4. Measure the space of the specimen 5 after the coupling 6 (see Figure 1) is disconnected
4.4 Temperature, noise, and vibration testing instruments. The oil pool temperature and bearing temperature of the reducer should be tested using a flat conductor or digital temperature sensor with a measuring range of 10 that has been certified by the metrology department: ||tt ||Noise impact instrument and test methods shall comply with the provisions of B640. Vibration test instruments and test methods shall comply with the requirements of B85.13. Approved by the Ministry of Mechanical and Electronic Industry of the People's Republic of China on 1991-08-14 28
1992- 07.01 Implementation
JB5558---91
Sensor installation example
Picture
Sensor: 5 Test piece: 9·Loader
1 Motor: 2 , 4.6.8 Coupling; 3.7
Loading test method and data processing
5
5.1 Test items, steps, methods
Generally should be carried out according to the items in Table 1 . For prototypes or small batch reducers produced according to user requirements, the manufacturer is allowed to let the user select several items in Table 1 according to specific test purposes, or negotiate special loading test method items. Table 1
Class
Type
No-load test
Running test
Load performance test
Within
At the rated speed, the forward and reverse operation should last for no less than 1 hour:
1) Smooth operation, no impact, abnormal movement and noise; 2) No looseness of connecting parts and fasteners: | |tt||3) Oil leakage and oil seepage at each seal and junction box: 4) Sufficient lubrication. Check the oil pool and bearing temperature: 5) The initial contact spots on the worm gear tooth surface should comply with relevant standards or design requirements| |tt||After passing the on-board test, conduct a partial load running-in test. Load the load step by step at rated speeds of 25%, 50%, and 75% respectively. The load test at each level is to increase the level after 2 hours to reach oil balance: Requirements: Worm gear tooth surface contact spots along the tooth length and tooth The average value of the high square is less than 75.H should be biased towards the throat outlet
The load performance test is carried out after the running-in test is completed. The test time under constant speed and rated load is no less than 2h after reaching oil temperature balance. It is required to measure:
1) Rotation (or power):
2, efficiency; ||tt| |3) Speed ??and running time:
A) Oil pool temperature:
5) Noise and vibration:
6) Tooth surface contact spots and damage
Say
For a speed reducer with a center distance m, the minimum running time must not be less than 0.:
For a double speed reducer or a rotary speed reducer, the Carry out forward and reverse two-way tests. Single-room test is allowed for single-room testers. The speed and rotation direction during the test must be consistent with their working conditions
!
Overload test
Fatigue life test
At rated speed
JB5558-91
Continued Table 1
Competition||tt| |Suitable rotation at 120% rated load for 5 minutes:
Operation at 150% rated load 1tnin:
Operation at 200% rated load 0.:nin+
250% rotation at rated load 0.5min:
Check the damage of the worm gear tooth surface and other parts under load. The number of stress cycles when the worm gear surface is loaded in a single room +*--generally should reach 5×10 times;
The chair test items are related to the items in the running test, load performance test and overload test
said
The overload test should be started and then loaded with a jump load to activate braking
1) Test the front contact fatigue life of the worm gear teeth
2) It is allowed to use a speed standard test with increased load Method
Sichuan "industrial application test is allowed to replace the fatigue life test. However, the actual load of industrial application must reach more than 5 times the rated load!, and there should be accurate daily records, so that the worm gear tooth surface should be loaded in one direction The number of stress cycles reaches 5×10\. 5.2 Test data collection
The data collected in the test include: loading torque (power), rotation speed, noise, vibration, temperature, time, tooth surface contact spots, etc. The data collected at least once every half hour include input and output speed, input and output speed (power) lubricating oil, and load temperature. Data collected from the digital instrument or printer data should be collected every time. Collect at least one set of data at least once, and record the time of the collected data. The vibration of the reducer should be measured once at each load level and each speed level, and record the vibration value and the negative range of the material, speed and speed. time.
The noise of the reducer should be measured at a rotational speed level in the firmly loaded state, and the corresponding noise value should be recorded to record the changes in damage, pitting, gluing, fracture and contact spots on the rotating section. , observe and record at least once per mountain. When the test is normal and the tooth surface is damaged, the recording time interval can be lengthened. Otherwise, if the tooth surface is damaged, the recording time interval should be shortened. Unusual phenomena, damage and the type and brand of lubricant used in the test should be recorded.
5.3 Data Processing
5.3.1 Before processing the test data, the reasons should be analyzed and analyzed. Be careful before processing. 5.3.2 Calculate the average value of torque and speed
a. Find the average value of each collected data according to formula (1), in formula (2), T is the torque of the collected data. Average value.·mT
The torque value in each group of data.N·m:
The number of groups of data collected each time;
\,...the rotation speed of the collected data Average value, r/minn.·.The rotational speed value in each set of data. r/min. b. Find the average value of the stage load according to formula (3) and formula (1): 30
JB5558— 91
1
where...The average torque of the leveling load.m...·The average speed of the chain-level load.r/min; the number of drinks for each level of load data collection
5.3.3 The total efficiency of the reducer is calculated according to formula (5). T
T
Formula A:
T
7|| tt | The average value of N·m: reducer transmission ratio;
The total efficiency of the reducer input and output shaft end coupling. And.-t...;The efficiency of the input shaft end coupling;| |tt||The efficiency of the transmission shaft end coupling
(i
According to 500.750.1000.1500r/mim or rated speed, depict the efficiency line corresponding to 25%.50%.75%.100% rated load. Take the ordinate as the efficiency value and the abscissa as the load value. 5.3.4 Temperature rise calculation and temperature limit
a. Temperature II calculation and temperature limit are calculated according to formula (6): A/ =-/ -
Wuzhong: ·...oil pool temperature rise, (;
t| |tt||,
Oil pool temperature, (;
Laboratory temperature, (
-
When the reducer is lubricated with special worm gear oil, the maximum allowable 1. The oil temperature is 100 () b. Draw the temperature rise t line
Under the given speed and load, use time as the horizontal axis and temperature rise △ as the ordinate to draw the reducer and temperature rise line 5.3 .5 Load performance test, calculation of the number of stress cycles when the worm gear is loaded in one direction during the death test 5)
When calculating the number of stress cycles, the number of stress cycles lower than or higher than the rated load in the accelerated life test can be counted , must be converted into the number of stress cycles under equivalent rated load, which can generally be calculated according to equation (7): 5'
N\N+
Formula: N
N||tt ||T
A
K
The number of corresponding stress cycles - times;
The number of stress cycles under rated load.times;
N.| |tt||.1
The torque of the output shaft L is lower than or equal to the rated torque, N·m; rated output torque.N·m:
The number of stress cycles corresponding to the workpiece , Times:
N-60n2l.
N.- 602l:
The number of short turns with low or higher than rated torque; n
corresponds to T : The rotational speed.r/min:
corresponds to the rotational speed of the hand...r/min
. Corresponding to the test time of T:, h: 1.bzxZ.net
corresponds to T The test time.
IB5558·91
5.3.6 Fatigue life test or industrial application test qualification index is a reducer that has passed the fatigue life test or "industrial service test" under rated load. Other Qualification indicators are: The worm gear, worm and various parts must not have cracks or breaks: h. The wear and tear of the worm gear should not exceed 1/min of the tooth thickness, and the working tooth surface of the worm gear should be pitted, shaved or glued. The area of ??a single tooth should not exceed 10 each! The sum of the inquiries should be 30: d. "The oil temperature should not exceed the regulations.
Test Report
The following content should be included:
a, test door and content:
b, test piece type, number and performance indicators: basic structure, principle and testing of the test bench. Device: d test procedure,
e: test collection data, tables or curves: f. test results and analysis:
g: conclusion and suggestions,
Additional notes: ||tt ||This standard is produced by the Xi'an Machinery Research Institute of the Ministry of Mechanical and Electronic Industry. This standard is drafted by the Xi'an Machinery Research Institute of the Ministry of Mechanical and Electronic Industry. This standard was mainly drafted by Yang Junmei, Zhao Zhuliang, Chen Jianxing and Xi Yuying. 32
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