Verification of Installation Stiffness Compliance for DCY180-31.5-25 Gear Reducer

Verification of Installation Stiffness for DCY180-31.5-25 Hardened Tooth Surface Bevel-Cylindrical Gear Reducer

To determine whether the installation stiffness of the DCY180-31.5-25 reducer meets the required standards, the assessment focuses on four core dimensions: foundation base, installation accuracy, connection status, and operating conditions. If the installation exhibits no deformation, imposes no additional load, and ensures stable operation, it is deemed qualified. The specific criteria and methods are detailed below.

This is the core premise of installation rigidity. Insufficient rigidity results in immediate disqualification.

The foundation must be constructed from reinforced concrete or welded steel sections, free from hollow spots or cracks. The secondary grouting layer must adhere tightly to the foundation without looseness, and the base must show no signs of warping or deformation.

The base must not be fabricated from thin steel plates or cantilever structures. Under heavy-load conditions, reinforcement with rib plates is required, and there must be no signs of shaking or sinking.

Pad irons must be placed on both sides of the anchor bolts and directly below the stress points of the housing. Each group of pad irons should not exceed three pieces and must fit tightly without gaps.

This directly reflects stiffness adaptability. Key indicators must meet standards.

Levelness: Measure multiple points on the housing plane, input shaft end face, and output shaft end face using a precision spirit level. Both longitudinal and transverse levelness must be less than or equal to 0.05 mm per meter, with no obvious inclination. Exceeding this value indicates uneven stiffness distribution and results in disqualification.

Coaxiality and Runout: The alignment of the motor-reducer-driven machine shaft system must be verified using a dial gauge on the coupling. Radial runout must be less than or equal to 0.05 mm, and end-face runout must be less than or equal to 0.03 mm. When using a laser alignment instrument, the comprehensive alignment deviation must not exceed one-half of the coupling allowable compensation value. Excessive deviation generates additional bending moments, which is equivalent to insufficient stiffness.

Anchor Bolt Tightening: Bolts must be pre-tightened according to grade specifications and tightened symmetrically. Use a torque wrench to verify that the pre-tightening torque meets the standard, ensuring there is no slipping or loosening. Under impact loading conditions, anti-loosening devices or locating pins are required. Loose bolts cause rigid connection failure and result in disqualification.

This serves as auxiliary verification. Meeting these criteria confirms compliance.

Housing Deformation Check: The shell joint surface must fit tightly with no oil leakage. Joint surface bolts must be tightened symmetrically. The gap between joint surfaces, checked with a feeler gauge, must be less than or equal to 0.03 mm with no visible gaps. The housing body must be free of visible deformation or cracks.

Bearing and Shaft Stiffness: Bearing end covers must be securely fastened without looseness. Bearing clearance must be adjusted per drawing requirements, neither too tight nor too loose. During operation, there should be no axial movement, abnormal noise, or obvious radial or axial shaking at the shaft end. Suspending heavy objects or applying unbalanced loads on the shaft end is strictly prohibited. An external bearing seat must be installed for overloaded conditions. Absence of these abnormalities indicates the shaft stiffness meets the standard.

Gear Meshing Status: Use red lead powder or Prussian blue to inspect gear meshing contact patterns. The patterns should be centered and uniform. For bevel gears, contact must cover more than 60 percent of tooth length and more than 50 percent of tooth height. For cylindrical gears, contact must cover more than 65 percent of tooth length and more than 55 percent of tooth height. Tooth backlash must meet drawing requirements with no unbalanced load meshing. If the meshing status is qualified, the internal transmission stiffness is considered adapted to installation requirements.