The installation site for the speed reducer (gearbox) should be isolated from heat radiation. If it is installed in a very hot or very cold place, cooling measures and measures to heat the lubricating oil to ensure normal start-up are necessary.
The concrete foundation or metal base plate on which the speed reducer is installed must have sufficient rigidity; the anchor bolts must be embedded to a sufficient depth, and when leveling with shims, the shim thickness should not be less than 1mm; to ensure stability and prevent deformation under load.
Finding the level and aligning it with the power machine and the working machine should be done separately.
The accuracy requirement for a level is generally 0.02~0.05mm/m. A level is an extended protruding surface of the machine body on the horizontal plane or a machined surface parallel to the horizontal plane. Higher alignment accuracy is better. The compensation capability and tolerance of the coupling used for alignment error must be considered. Generally, the axial angle error should not exceed 10°, and the translation error should not exceed 0.1mm.
Rust inhibitors and corrosion inhibitors on the shaft extension must be thoroughly cleaned before installing couplings, sprockets, and other components on the shaft extension. Do not use sandpaper, files, scrapers, or other tools that may damage the mating surfaces of the shaft to remove rust inhibitors and corrosion inhibitors. Do not use a heavy hammer to install couplings, sprockets, etc.; instead, use the thermal expansion and contraction method for fitting them together.
The axial force generated by the sprockets and pulleys on the shaft extension during transmission should ideally be directed towards the mounting base.
If a hydraulic coupling is used to connect to the power unit, due to the large mass of the hydraulic coupling and the significant centrifugal force during startup, the weight of the hydraulic coupling should be avoided. The centrifugal force should act entirely on the reducer shaft extension; that is, the hydraulic coupling should not be suspended from the reducer shaft extension but should be supported together with the power unit. This prevents additional bending at the shaft extension support point.
Compared to ordinary geared motors, geared stepper motors can control both speed and position, while ordinary geared motors cannot achieve positioning control.
So, what does misalignment in a stepper motor reducer mean?
Misalignment in a stepper motor reducer is called step loss, which is divided into missed steps and overstepping. When a stepper motor is working normally, it moves one step angle (one step forward) for each control pulse received. If control pulses are continuously input, the motor will rotate continuously accordingly. In a missed step, the number of steps the rotor advances is less than the number of pulses; in an overstepping step, the number of steps the rotor advances is more than the number of pulses. The number of steps in a single missed or overstepping step is an integer multiple of the number of operating cycles. Severe missed steps will cause the rotor to remain in one position or vibrate around one position; severe overstepping will cause overshoot in the driven structure.
Analysis of step loss and step skipping in stepper motor reducers:
Improper selection of stepper motor reducer, insufficient motor torque, or the moment of inertia of the moving object exceeding the motor's self-locking force can cause step loss or missing steps.
Improper driver selection, such as using a driver with insufficient current, can affect the normal operation of the motor. Many drivers on the market now have falsely advertised current ratings, misleading consumers by using peak current as rated current. The rated current of the selected driver should be 1.2-1.5 times greater than the rated current of the stepper motor reducer.
The power supply was not selected properly. The power supply should be 1.5-2 times the rated power of the driver. The power supply being overrated is more serious than the driver being overrated.
The control section should be free from interference, kept away from the frequency converter, and protected against static electricity.
