What impact will the vibration of motors and ZSY200-100-VI reducers have on production quality

The core vibration control measures for the motor and ZSY180-31.5-II reducer include operating standards, implementation details, and expected effects, which can be directly implemented:

1. High precision alignment and installation benchmark optimization (basic core measures)

Laser alignment instrument is used to calibrate the coaxiality and parallelism of the motor reducer. The radial displacement deviation is required to be ≤ 0.02mm, the angular displacement deviation is required to be ≤ 0.05mm/m, and the end face clearance of the coupling is uniformly controlled at 0.2-0.5mm (fine tuned according to the coupling model). The installation surface needs to be milled to ensure a flatness of ≤ 0.03mm/m. The anchor bolts should be M20 specification and locked with double nuts and anti loosening washers, with a tightening torque of 150-180N · m. After installation, they need to be tightened twice (the first time after 1 hour of operation and the second time after 24 hours). At the same time, clean up impurities on the installation surface to avoid benchmark deviation caused by gasket stacking. This measure can solve about 40% of the vibration caused by installation deviation, reducing the equipment vibration speed by 30-40%.

2. Balance and mesh optimization of transmission system (measures to eliminate vibration sources)

Calibrate the motor rotor according to the G2.5 dynamic balance standard (allowable unbalance ≤ 2.5g · mm/kg at 1500r/min). The input shaft and gear shaft of the reducer need to achieve G4.0 dynamic balance accuracy. If uneven wear of the gear tooth surface, abnormal bonding or meshing clearance (standard clearance 0.15-0.3mm, converted by module) is detected, the tooth surface needs to be disassembled and ground or the gear needs to be replaced to readjust the clearance. Priority should be given to using plum blossom shaped elastic couplings for couplings. The condition of the elastic body should be checked regularly, and if aging, cracking, or wear exceeds 3mm, it should be replaced immediately. The tightening torque of the bolts should be uniform and consistent (according to the coupling manual, M12 bolts are usually 45-60N · m). This measure can eliminate core vibration sources such as rotor eccentricity and gear meshing impact, reducing the amplitude of high-frequency vibration (50-200Hz) by 40-50%.

3. Precise maintenance of bearings and lubrication systems (measures to ensure operational stability)

When installing the tapered roller bearings (commonly used models 30220/30222) of the reducer, adjust the radial clearance to 0.02-0.05mm and fill 1/3-1/2 of the internal space of the bearing with ZL-3 lithium based grease to avoid vibration caused by excessive clearance or insufficient lubrication. The gearbox uses 320 # industrial gear oil (recommended Shell pressure resistant and Mobil 600 series), keeping the oil level at the centerline of the oil window. The gear oil should be replaced every 5000 hours, and the oil tank and 80 mesh filter should be cleaned to avoid impurities (content exceeding 0.05%) or moisture (content exceeding 0.1%) in the oil from exacerbating gear wear. This measure can stabilize the operation status of bearings and gears, control the vibration speed of equipment below 4.5mm/s (RMS), and extend the service life of components by more than 30%.