What are the precautions for load test operation of ZSY series hardened gear reducers

1、 Hierarchical loading and running standards

Gradual loading: It is strictly prohibited to run directly at full load. It should be loaded step by step at 25%, 50%, 75%, and 100% of the rated load.

Run time: Each load stage needs to run continuously for at least 30 minutes, and the next level of loading can only be carried out after all parameters have stabilized.

Preheating in high temperature environment: If starting in a high temperature workshop environment, avoid running the chiller at full load. It is recommended to conduct a no-load test run for a moment to ensure that the lubricating oil flows fully and covers all transmission components, and then gradually load to reduce the wear of gears and bearings.

2、 Key monitoring indicators and qualification standards

During the load trial operation, it is necessary to closely monitor the following parameters to ensure that they meet the qualified standards:

1. Temperature monitoring:

The temperature rise of the bearing shall not exceed 40 ℃, and the maximum temperature shall not exceed 80 ℃.

The temperature rise of the lubricating oil pool shall not exceed 35 ℃, and the maximum oil temperature shall not exceed 85 ℃.

2. Vibration and noise:

The effective value of shell vibration velocity should be controlled within 4.5mm/s (precision level requirement ≤ 2.8mm/s).

The noise pressure level at a distance of 1 meter from the equipment shall not exceed 80dB (A).

3. Sealing and leakage: Each sealing point (shaft seal, joint surface, etc.) must not have any oil leakage under load.

4. Transmission performance: The output speed deviation should be ≤± 2%, and the transmission efficiency should meet the equipment design requirements.

3、 Overload capability verification

To verify the reliability and safety margin of the gearbox under short-term overload conditions, an overload test is required:

Run for 15 minutes at 110% rated load.

Run for 10 minutes at 125% rated load.

Qualification assessment: There is no abnormal vibration, noise or temperature rise during the test period, and the protective device can effectively operate.

4、 Emergency response to abnormal situations

During the trial operation, if any of the following situations are found, the use should be immediately stopped and the cause investigated:

The oil temperature has significantly increased, exceeding 70 ℃ or 100 ℃.

Generate abnormal noise, severe vibration, or serious oil leakage.

Solution: Stop the machine and check if it is caused by tooth surface adhesion, abnormal biting, or poor lubrication. The fault must be completely eliminated and the lubricating oil replaced before it can be put back into use.