Complete guide for maintenance and repair of rotary bending fatigue testing machine (with common troubleshooting table attached)

As a high-precision mechanical testing equipment, the scientific and standardized daily maintenance of the rotary bending fatigue testing machine is the basis for ensuring testing accuracy and extending equipment life.

Lubrication system maintenance. The spindle bearing is the core rotating component of the testing machine, and the lubricating grease status of the bearing should be checked weekly. It is recommended to use ISO VG32 grade high-temperature lubricating grease. The hydraulic oil in the circulating oil circuit needs to be replaced every 500 hours of operation, and the filter element should be cleaned at the same time.

Key component monitoring. Before starting up daily, the radial runout of the spindle should be checked, with a requirement of no more than 0.02mm. The coaxiality of the motor and spindle should be calibrated using a laser alignment instrument every month, with a deviation of less than 0.05mm/m. Ball screws need to be cleaned every six months, wiped clean, and then lubricated with butter.

Environmental control. The laboratory temperature should be maintained at 20 ± 2 ℃, and the relative humidity should be controlled between 45% and 60%. The equipment needs to be equipped with a regulated power supply to prevent high temperature, humidity, and dust from entering. Rust prone parts should be regularly coated with anti rust oil, and covered with dust covers when not in use for a long time.

Common troubleshooting and handling

Fault 1: There is no power indicator when starting up. Check the external power supply circuit and replace the same specification fuse.

Fault 2: There is a significant abnormal noise during operation. Possible causes include aging of the transmission belt, damage to the motor bearings or gearbox bearings. Check and replace the belt, inspect or replace the motor and reducer components.

Fault 3: The device cannot start and operate. Check if the counter/timer has reached the preset test cycle and triggered an automatic shutdown. Reset the counter to zero to restore it.

Fault 4: Overload alarm. Immediately stop the machine and check if there is any eccentricity in the sample clamping. The clamping eccentricity should be less than 0.1mm. At the same time, check the oil temperature. If it exceeds 65 ℃, clean the dust accumulation on the heat sink.

Fault 5: The fuse frequently burns out. Test whether the input voltage is stable and inspect whether there is a short circuit or overload in the motor.

Fault 6: The counter is not functioning properly. Adjust the distance between the proximity switch sensing screw and the sensor. If it is ineffective, replace the sensor or counter.

3、 Periodic deep maintenance plan

Quarterly maintenance requires replacement of the drive belt and tension testing, with a deviation controlled within ± 5% of the initial value. The servo motor carbon brush needs to be replaced for annual maintenance, and if the wear exceeds 30%, it needs to be replaced. At least one comprehensive verification shall be conducted annually, and the bending moment error can be checked using dimensional measurement calculation method or strain gauge specimen method to ensure compliance with the requirements of JJG 652-2012 "Verification Regulations for Rotary Bending Fatigue Testing Machines". Equipment operating under long-term high-temperature conditions, high-temperature furnaces, and temperature control systems should be included in the monthly maintenance plan to ensure that temperature fluctuations meet standard requirements.