What are the commonly used testing instruments in load testing of reducers

In load testing of gearboxes, a series of professional testing instruments are usually used to accurately measure key parameters to ensure their performance, reliability, and safety. The following are commonly used testing instruments and their functions:

1. Torque sensor
Used to measure the torque values of the input and output shafts of a gearbox, it is the core equipment for evaluating its load-bearing capacity and transmission efficiency. In conjunction with the data acquisition system, real-time monitoring of dynamic torque changes can be achieved.

2. Tachometer/Speed Sensor
Measuring the rotational speed of the input and output terminals of a gearbox is often used in conjunction with torque sensors to calculate power and transmission ratio. The high-precision tachometer can achieve a measurement accuracy of ± 1 rpm.

3. Power analyzer
Directly measure the input power of the motor and calculate the transmission efficiency by combining the torque and speed data at the output end. At rated load, the transmission efficiency of the hard tooth single-stage reducer should be ≥ 92%.

4. Dynamometer (such as eddy current dynamometer, magnetic powder dynamometer)
As a load simulation device, it is used to apply controllable resistance torque and achieve performance testing of the gearbox under different load conditions. Commonly used for durability and efficiency testing.

5. Multi channel temperature inspection instrument and thermocouple
Used to monitor the temperature rise of the gearbox during load operation, including lubricating oil temperature, bearing chamber temperature, and box surface temperature. The qualification standard is usually that after running at rated load for 1 hour, the surface temperature rise of the box should be ≤ 60 ℃ (based on a 25 ℃ environment).

6. Vibration analyzer
Detect the vibration intensity and spectral characteristics during the operation of the gearbox, and determine whether there are installation deviations, poor gear meshing, or bearing damage issues. Vibration meters that comply with the ISO 2372 standard are commonly used for this type of testing.

7. Sound level meter (noise meter)
The noise level of the gearbox measured under rated load is generally required to be ≤ 85dB (A), with even lower requirements for high-precision models. During testing, background noise should be subtracted to ensure accuracy.

8. Data acquisition and control system
Integrate the above sensor signals to achieve automated testing process control, real-time data recording and analysis, form a complete testing report, and support data tracking for long-term durability testing.

9. Laser interferometer/high-precision encoder (for precision reducers)
For high-precision transmission equipment such as RV reducers and harmonic reducers, it is used to measure positioning accuracy, backlash (return clearance), and repeat positioning accuracy to ensure that they meet the high-end application requirements of industrial robots.