Significance for Reducer Life Torque calculation is of utmost importance when it comes to the lifespan of a reducer. The maximum torque value during acceleration (TP) needs to be carefully considered to ensure that it does not exceed the maximum load torque of the reducer. If the torque exceeds the rated limit, it can lead to premature wear and tear of the reducer’s internal components, such as gears and bearings. This can significantly reduce the service life of the reducer and may even result in sudden failure, causing disruptions in the operation of the entire mechanical system. For example, in a robotic arm application, if the torque calculation is inaccurate and the servo reducer is subjected to excessive torque during rapid movements, the gears may start to deform or the bearings may overheat, ultimately leading to a loss of precision and functionality of the robotic arm.
Acceleration Torque and Maximum Load Torque Relationship The acceleration torque is a crucial factor as it determines the force required to bring the load from a stationary state to a desired speed. It is essential to calculate this accurately and compare it with the maximum load torque specified by the reducer manufacturer. If the acceleration torque is too close to or exceeds the maximum load torque, it indicates that the selected reducer may not be suitable for the application. In such cases, either a more powerful reducer needs to be chosen or the acceleration profile of the system needs to be adjusted to reduce the peak torque requirements. For instance, in a conveyor system that requires frequent start-stop operations, if the torque calculation is not done properly, the servo reducer may experience excessive stress during each startup, leading to a shorter lifespan and potential breakdowns.
Calculation and Significance of Reduction Ratio The reduction ratio is calculated as the ratio of the servo motor’s rotational speed to the output shaft speed of the reducer. This ratio plays a vital role in determining the overall performance of the system. A well-chosen reduction ratio can optimize the torque output and speed of the mechanical system. For example, in a CNC machine tool, the correct reduction ratio can ensure that the spindle rotates at the appropriate speed while providing sufficient torque to cut through different materials. If the reduction ratio is too high, the output speed may be too low, affecting the machining efficiency. On the other hand, if it is too low, the torque may not be sufficient, leading to issues such as tool chatter or inaccurate cutting.
Choosing the Appropriate Model Based on Reduction Ratio When selecting a reducer, it is advisable to choose a model with a reduction ratio that closely matches the requirements of the application. Manufacturers usually provide a range of reducer models with different reduction ratios. By carefully analyzing the speed and torque needs of the system, one can select the most suitable model. This not only ensures optimal performance but also helps in reducing energy consumption and wear on the components. For example, in a packaging machine, if the reduction ratio is properly selected, the servo reducer can efficiently drive the conveyor belts and other moving parts, ensuring smooth and accurate packaging operations.
Applicable Power and Work Coefficient The applicable power of a servo reducer is typically designed to match the power of commonly available servo motors in the market. These reducers generally have a high level of applicability, with a work coefficient that can usually be maintained above 1.2. However, the final selection can also be based on specific user requirements. For example, in a high-precision optical equipment application, where the load is relatively light but accuracy is of utmost importance, a reducer with a slightly lower power rating but higher precision characteristics may be chosen.
Key Points in Selection
Output Shaft Diameter Compatibility: It is crucial to ensure that the diameter of the output shaft of the selected servo motor does not exceed the maximum allowable shaft diameter specified in the reducer’s technical table. If the shaft diameter is too large, it may not fit properly into the reducer, leading to misalignment and potential damage during operation.
Torque and Speed Considerations: If, after torque calculation, it is found that the rotational speed can meet normal operating requirements but there is a deficiency when the servo motor operates at full output, measures need to be taken. One option is to implement current limiting control in the motor driver. This helps in restricting the current flowing to the motor, thereby reducing the torque output and preventing overloading of the reducer. Another approach is to install torque protection devices on the mechanical shaft. These devices can sense excessive torque and take appropriate actions, such as disengaging the drive or sending an alarm signal, to protect the reducer and the overall system.
IV. Precautions for Using Servo Reducers
Operating within Rated Torque The servo reducer should always be used within its rated torque. Operating above the rated torque can cause severe damage to the reducer’s internal components and significantly reduce its service life. For example, in a material handling system, if the load being lifted exceeds the rated torque of the reducer, the gears may strip, and the bearings may fail, leading to costly repairs and downtime.
Proper Motor and Reducer Combination Selecting a suitable motor to match the reducer is essential. The motor’s power, speed, and torque characteristics should be compatible with those of the reducer. An improper combination can result in inefficient operation, overheating, and premature failure. For instance, if a motor with too high a speed and insufficient torque is paired with a reducer, the reducer may not be able to handle the load effectively, leading to performance issues.
Lubrication and Disassembly This series of reducers is designed for lifetime lubrication, which means there is no need for additional oiling. It is strictly prohibited to disassemble the reducer without proper authorization. The internal lubrication system is carefully engineered to ensure smooth operation and long-term durability. Disassembling the reducer may disrupt the lubrication balance and introduce contaminants, leading to damage.
Operation in Harsh Environments If the servo reducer is to be used in harsh working conditions, such as high-temperature environments or in the presence of corrosive substances, it is necessary to contact the manufacturer. Special precautions or modifications may be required to ensure the reducer can withstand such conditions. For example, in a chemical processing plant, where the ambient temperature is high and there are corrosive gases in the air, the reducer may need to be equipped with additional cooling and protective coatings.
Shaft Diameter Selection and Tolerance The shaft diameters of the output and input shafts should be selected according to the GB1568 – 79 standard for proper fit. Incorrect shaft diameter selection can lead to issues such as excessive play or tight fit, affecting the transmission efficiency and the service life of the reducer.
Effect of Continuous Operation on Service Life Continuous operation can reduce the service life of the servo reducer by half. Therefore, it is important to consider the duty cycle of the application and provide appropriate breaks or maintenance intervals to prolong the reducer’s life. For example, in a continuous production line, it may be necessary to schedule regular maintenance checks and replace the reducer at a certain interval to avoid unexpected failures.
Installation and Protection Ensure that the reducer is installed correctly to prevent any external damage. The installation process should be carried out by trained professionals following the manufacturer’s instructions. Any improper installation, such as misalignment or over-tightening of bolts, can cause stress on the reducer and lead to premature failure. Additionally, measures should be taken to protect the reducer from external impacts, such as installing protective covers or enclosures.
Professional Installation, Operation, and Maintenance The installation, operation, and maintenance of servo reducers should only be performed by professional personnel. These individuals have the necessary knowledge and skills to handle the complex technical aspects of the reducers. They can ensure proper installation, diagnose and troubleshoot any operational issues, and carry out routine maintenance tasks effectively.
V. Other Considerations
Installation Site and Lubricant
Lubricant in Different Environments: When ordering a servo reducer, it is important to note that the lubricant used is semi-solid and does not require regular oil change. However, if the reducer is to be used in an environment below 0 degrees Celsius, it is necessary to inform the manufacturer so that an antifreeze agent can be added. In an acidic or alkaline environment, the manufacturer should also be notified to install appropriate protective measures to prevent damage to the reducer due to chemical corrosion.
Installation Site Requirements: The installation site should be clean and free from excessive dust, moisture, or other contaminants that could affect the performance of the reducer. Adequate space should be provided around the reducer for proper ventilation and access during maintenance.
Servo Motor and Reducer Connection When ordering a servo motor, it is essential to provide the manufacturer with the required dimensions of the coupling flange and the shaft. This ensures that the motor can be properly connected to the reducer without any misalignment or fitment issues. The connection between the motor and the reducer should be rigid and accurate to transmit torque efficiently.
Installation of the Reducer The reducer itself is a highly precise product. During installation, great care must be taken to avoid any impacts or hammering on the shaft or any other part of the reducer. Even a small impact can cause internal damage, such as misalignment of gears or damage to the bearings, which can affect the performance and service life of the reducer. The reducer should be carefully mounted on a stable and rigid base to ensure proper alignment and support.
В заключение, proper torque calculation, selection of an appropriate reduction ratio and reducer model, and strict adherence to the usage precautions are essential for ensuring the reliable and efficient operation of servo reducers. By considering all these factors and following the recommended guidelines, users can maximize the performance and lifespan of their servo reducer systems, reducing maintenance costs and downtime in various industrial and mechanical applications.
