How to determine whether the trial operation of ZQ500-10.35-IZ gear reducer is qualified

The entire process of no-load trial operation meets the standard and is stable. After the load trial operation is completed by graded loading, there are no abnormalities in the entire process, and the core indicators meet the specifications. If there are no hidden dangers during shutdown re inspection, the trial operation can be judged as qualified; If any indicator exceeds the standard or malfunctions occur in any link, the machine needs to be shut down for troubleshooting and retesting. Only when it meets the standard again can it be considered qualified.
1、 Requirements for determining the qualification of no-load trial operation

Running time: Continuous operation in both forward and reverse directions at rated speed for ≥ 1 hour, cumulative operation for ≥ 2 hours, without any intermediate shutdown faults;

Temperature index: The temperature rise of each bearing part is ≤ 40 ℃, and the maximum working temperature is ≤ 80 ℃; The temperature rise of the box body oil is ≤ 35 ℃, and the maximum oil temperature is ≤ 75 ℃. After the temperature rises, it tends to stabilize without local sudden rise or continuous heating phenomenon;

Noise and vibration: There is no obvious abnormal noise during operation, the gear meshing sound is normal and uniform without any noise or impact sound, the vibration amplitude of the box body is ≤ 0.1mm, there is no obvious vibration sensation in the bearing part, and there is no resonance or movement phenomenon;

Sealing and lubrication: There is no dripping or oil leakage in all parts of the input/output end oil seal, box joint surface, oil level gauge, oil drain plug, breathable plug, etc; The lubricant oil level is stable at the middle line/specified scale of the oil level gauge, without oil emulsion, excessive foam, abnormal oil level fluctuation, and insufficient oil supply in the lubrication system;

Operating status: Smooth operation in both forward and reverse directions, without any jamming, pressure holding, or shaft end movement. The coupling transmission has no deflection or abnormal noise; After stopping the machine, manually rotate it in both forward and reverse directions for 3-5 turns, running smoothly without any jamming or abnormal noise, and showing no signs of loose components.

2、 Requirements for determining the qualification of load trial operation
Only after passing the no-load trial run can the load trial run be carried out, and it is necessary to follow the
25% → 50% → 75% → 100% rated load
Step by step loading, run for at least 30 minutes under each level of load until the oil temperature and vibration are stable. Only when the previous level meets the standard can the next level be loaded. After completing full load operation, meet all of the following requirements:

Loading process: The entire process is completed according to the grading requirements, without overloading or exceeding the level. There are no abnormal shutdowns or fault alarms in each loading stage;

Full load operation duration: Continuous and stable operation for ≥ 2 hours at 100% rated load, without any intermediate indicators exceeding the standard or faults;

Core indicators (to be met during the entire loading phase):

Temperature: The temperature rise and maximum temperature of the bearing, as well as the temperature rise and maximum temperature of the box oil, all meet the temperature judgment criteria for no-load trial operation. The temperature remains stable without continuous increase under full load;

Noise and vibration: There are no abnormal noises in each load stage, and the gear meshing sound is uniform at full load. There are no harsh noises or impact sounds due to increased load. The vibration amplitude of the box body is ≤ 0.1mm, and there is no severe vibration or resonance;

Sealing and lubrication: There is no oil leakage or dripping throughout the entire process, and the oil level and quality are consistent with the no-load requirements. There is no abnormal splashing of lubricating oil or insufficient oil supply at lubrication points under full load;

Operating status: The operation of each load stage is smooth, without any jamming, impact, or shaft movement. The coupling and foundation bolts are not loose, and the transmission system has no sway or abnormal noise. The accessory components (if any) are working normally;