Strict quality inspection process: ensuring the reliability and durability of fishing vessel gearbox

1. Raw material inspection
The quality of any gearbox is closely related to the materials used. In order to ensure the reliability of the gearbox, all raw materials entering the production process must first be strictly inspected. The following are the main inspection links:

Metal composition analysis: The metal composition of the raw materials is tested by chemical analysis to ensure that it meets the design requirements. For example, the gears of the gearbox are usually made of alloy steel or other high-strength materials, which must have good tensile strength and wear resistance.
Hardness test: The hardness of the raw material directly affects the wear resistance of the gearbox. Use equipment such as Rockwell hardness tester and Vickers hardness tester to test the hardness of the material to ensure that it has enough hardness to cope with long-term load and friction.
Surface defect detection: There may be defects such as cracks and pores on the surface of the material, which will affect the performance and life of the gearbox. Manufacturers will use non-destructive testing methods such as ultrasonic and magnetic particle flaw detection to ensure that there are no hidden defects on the surface of the material.
2. Dimensional accuracy control
The components inside the gearbox, such as gears, bearings, sleeves, etc., all require extremely high precision matching to ensure the smooth operation of the gear system. Therefore, dimensional accuracy is an important part of quality inspection. The specific steps include:

Three-coordinate measuring machine inspection: The three-coordinate measuring machine (CMM) is a commonly used high-precision measuring tool that can accurately measure the dimensions of gearbox components in three-dimensional space to ensure that the dimensional error of each component is within the allowable range.
Gear meshing accuracy inspection: The meshing accuracy of the gear is crucial to the transmission efficiency and stability of the gearbox. Use a gear meshing measuring instrument to check the meshing surface of the gear to ensure that the meshing process is smooth and without jamming.
Match clearance measurement: The matching clearance of the fishing vessel gearbox must be strictly controlled. The matching relationship between gears and gears, shafts and bearings will directly affect the efficiency and noise of the gearbox. Use a special clearance measurement tool to ensure that the matching clearance of each component meets the standard.
3. Gear meshing test
Gear meshing is one of the most important functions of the gearbox, which directly determines the power transmission efficiency and stability of the gearbox. To ensure the smooth operation of the gear system in actual use, manufacturers usually conduct the following tests:

Gear meshing test: Assemble the gearbox to the test platform, simulate the load and operating conditions that it may encounter in actual work, and observe the meshing of the gears. Check the contact surface of the gears during the meshing process to ensure that there is no uneven wear, abnormal noise or other undesirable phenomena.

Noise and vibration test: The noise and vibration of the gearbox during operation are crucial to the working comfort and stability of the fishing boat. Manufacturers usually use noise testers and vibration analyzers to test the gearbox to ensure that its noise and vibration are within the standard range during operation.

4. Load test
Fishing boat gearboxes need to withstand long-term high-load operation in actual use, so load testing is very important. Load testing can simulate the working state of the gearbox under extreme use conditions to ensure that it can operate normally in various environments.

Static load test: Without rotating, the gearbox is subjected to the designed load to check whether it can withstand excessive pressure without damage. During the test, the various components of the gearbox are checked for deformation or damage.
Dynamic load test: Simulate the load conditions in actual work by connecting the gearbox to the actual power system. Test its operating stability under long time, high speed and heavy load.
5. Durability and life test
The durability of fishing vessel gearbox is an important indicator of its quality, especially in the long-term and high-intensity operation environment such as fishing vessels. Manufacturers usually conduct durability tests to ensure that the gearbox will not fail prematurely during use.

Accelerated life test: Simulate the performance of the gearbox in long-term use through accelerated testing. During the test, the gearbox will experience extreme working conditions such as high load and high speed to evaluate its performance under extreme conditions.
Long-term operation test: Run the gearbox for a long time and monitor its various performance indicators (such as temperature, noise, vibration, etc.) to ensure that there will be no performance degradation after long-term use.
6. Corrosion test
Since fishing vessels operate in marine environments, gearboxes must have strong corrosion resistance. Corrosion tests usually include the following aspects:

Salt spray test: Place the gearbox in a salt spray environment to simulate its working environment in seawater and check the corrosion resistance of the gearbox. During the test, the gearbox surface will be observed for rust, cracks or other corrosive damage.
Seawater immersion test: Some parts of the gearbox are immersed in simulated seawater to evaluate their durability in humid and corrosive environments.
7. Final product factory inspection
After the above tests, the fishing boat gearbox will be inspected at the end. Factory inspection usually includes:

Comprehensive inspection: Final check of the appearance, size and technical parameters of the gearbox to ensure consistency with the design specifications.
Performance verification: Performance verification is carried out on a professional testing platform to ensure that its various indicators meet the standards.
Identification and documentation: Check the product's identification and technical documentation to ensure that customers can perform subsequent maintenance and repairs based on the product serial number and technical manual.