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I. What lubricants are used in reducers?
1. Horizontal cycloidal reducer is lubricated by oil pool under normal conditions. The oil surface height can be maintained in the middle of the oil window. Cyclic lubrication can be used when the working conditions are bad and the ambient temperature is high.
2. Cycloidal pinwheel reducer is usually lubricated with 40 or 50 mechanical oil at room temperature. In order to improve the performance of the reducer and prolong the service life of the cycloidal pinwheel reducer, 70 or 90 extreme pressure gear oil is recommended. Lubrication oil should also be reconsidered when working at high and low temperatures.
3. Vertical installation of planetary cycloidal pinwheel reducer should strictly prevent oil pump from breaking, in order to avoid the damage of reducer components.
4. When refueling, the air cap on the upper part of the engine seat can be turned off to refuel. When the oil is discharged, the oil discharging plug at the lower part of the machine seat is turned off, and the dirty oil can be discharged. There is no lubricant inside the reducer when it leaves the factory.
5. New oil should be replaced after the first refueling operation for 100 hours (and the internal dirty oil should be washed out) and then work continuously. It should be replaced every six months (8 hours working system). If the working conditions are bad, the oil-changing time can be shortened appropriately. Practice has proved that frequent cleaning and oil-changing of the reducer (such as 3-6 months) can prolong the operation of the reducer. Service life plays an important role. Lubricating oil should be supplemented regularly during use.
6. The newly issued reducer has been lubricated and replaced every six months. Aluminum disulfide-2 # or 2L-2 # lithium-based grease is used as grease.
2. Lubrication Management of Gear Oil and Problems to Be Noticed in Use
1. For the centralized lubrication reducer system with dilute oil, because the temperature of lubricating oil or oil tank is more stringent, cooler (steam cooling) or cooling coil (water cooling) is usually used to cool it. Although gear oil is required to have good anti-emulsification performance, it is easy to emulsify the oil after infiltrating a considerable amount of water into the oil. After emulsifying the gear oil with extreme pressure anti-wear agent, the additive is hydrolyzed or precipitated and separated, and the original performance is lost, and harmful substances are produced, which causes the gear oil to deteriorate rapidly and lose its service performance. Therefore, emulsified oil must not continue to use. For the water (or steam) cooling lubrication system, we must pay attention to prevent water (steam) leakage, in order to avoid unnecessary damage to the reducer.
2. For the reducer system using pump for circulating lubrication, attention should be paid to the differential pressure of the pump and the timely cleaning of the filter screen. If the pressure difference of the pump is large in a short period of time, or the frequency of cleaning the filter screen increases significantly, and the sludge and metal debris on the filter screen increase significantly, in a sense, the use of lubricating oil is not very good. In addition to material and design problems, it can be said that the selection of lubricating oil is not reasonable enough: first, the viscosity is not appropriate, second, heavy load can be used to replace the medium load, that is, the use of high-grade gear oil, the effect will be significantly improved.
3. It is necessary to avoid mixing new oil with old oil (instead of filling it as required) or adding high-viscosity oil because of the decrease of viscosity but in order to achieve a certain viscosity. In this way, there may be some short-term effects, but the performance of oil products will be significantly reduced, and the lubrication conditions of equipment will become worse, resulting in increased wear and tear, which in a sense will shorten the service life of equipment. In addition, because the main agent is different, the "fight" of additives occurs in the mixing process, which makes the role of additives offset each other, and the consequences for the equipment are inconceivable.
4. Regarding the oil replacement period, theoretically speaking, the short oil replacement period can better reduce the wear of friction pairs and prolong the service life of equipment, and provide a necessary condition for ensuring its normal operation. However, from the perspective of economic benefits, oil products should be used more accurately and effectively. Whether or not to change oil and when to change oil should be considered according to the start-up time and the start-up rate of the equipment, in addition to following the rules of oil change period, so as to maximize the use of oil products.
5. Oil temperature, vibration and noise of oil equipment should be monitored regularly. When the tooth surface is damaged due to the variation of lubrication conditions, the vibration and noise can be enhanced obviously.
3. Selection of Viscosity
Viscosity is an important physical and chemical index of gear oil. The meshing speed of gears is the main index for selecting viscosities. Suitable viscosity of gear oil for reducer should make the internal friction of lubricating oil smaller, which will greatly reduce the surface wear and transmission noise, vibration and so on.
The viscosity of reducer lubricating oil is mainly realized by base oil and viscosity index improver. The viscosity of lube base oil is related to its molecular structure and molecular weight: the higher the average molecular weight, the higher the viscosity of the oil. As far as base oil is concerned, mineral oil-based lubricants include lube oil refined from paraffin-based crude oil, lube oil refined from naphthenic base crude oil and lube oil refined from intermediate base crude oil. The viscosity-temperature properties of lube oil refined from paraffin-based crude oil are better than those of other two kinds. Good adhesive finger agent requires not only high viscosifying capacity and good shear stability, but also good low temperature performance and thermal oxidation stability. The viscose finger agent with poor shear stability has a series of effects on wear and fuel consumption due to the breakage of the main chain of the polymer under shear stress and the decrease of its molecular weight. For lubricants with the same viscosities, if non-refined base oils and poor viscosifiers are selected, although a certain viscosity standard can be achieved through blending, the properties of viscosity-temperature and shear stability are not good, and the proper service life can not be reached. Therefore, for low-speed and heavy-duty cement reducers, try to avoid using such lubricants, and choose high-quality lubricants, because its base oil and viscose finger agent are better.
The higher the viscosity of gear oil, the stronger the protection ability to prevent various damage to the tooth surface, so the smaller the wear of reducer. But the viscosity is too high, the abrasive particles are not easy to precipitate, which reduces the flushing effect of lubricating oil on the tooth surface and the effect of endothermic cooling, resulting in poor lubrication. At the same time, the abrasive particles suspended in the oil enter the meshing area, which is easy to cause abrasive wear. In addition, excessive viscosity increases transmission resistance, tooth surface temperature and power consumption. Generally speaking, when the viscosity increases by one grade, the energy consumption increases by about 1%~5%, and the stability and anti-emulsification performance of the oil products will decrease. However, high viscosity has obvious advantages in reducing noise and preventing oil leakage. In addition, equipment with uneven load, frequent start-up and working in high temperature environment should have a slightly higher viscosity.
In summary, the reducer should adopt high-grade lubricating oil with suitable viscosity. For the large reducer with low speed and heavy load, the extreme pressure heavy load gear oil with high viscosity should be selected as far as possible, because it has better extreme pressure and wear resistance, thermal oxidation stability, anti-corrosion and rust resistance, as well as excellent anti-emulsification performance than the medium load gear oil, so it is easy to form chemical film on the meshing surface of the gear, thus forming a chemical film on the meshing surface of the gear. Protect the surface of gear teeth and minimize the wear of reducer as much as possible.
4. Lubrication and Maintenance of Reducer
Before the gear reducer is put into operation, the recommended type and numerical grease is loaded into the gear reducer. The reducer is lubricated with lubricating oil. For vertically mounted reducers, additional lubrication measures are adopted, since lubricating oil may not guarantee reliable lubrication of the top bearing.
Before operation, a proper amount of lubricating oil is injected into the reducer, and the stickiness of the lubricating oil is selected according to the following list. The reducer is usually equipped with an oil injection hole and a discharge plug. Therefore, the installation location must be specified when ordering the reducer. The following table lists the brands and models of lubricants recommended for general applications.
Note: For the application of unconventional working conditions, please consult the manufacturer.
The working oil temperature should not exceed 80 C.
The combined reducer with lifelong lubrication is filled with synthetic oil in the manufacturing plant. In addition, the reducer is usually supplied without lubricating oil and with filling plug and draining plug. The number of reducer lubricants listed in this sample is only an estimate. The position of oil level plug should be set according to the installation position specified at the time of ordering to ensure correct oil injection. The oil injection quantity of reducer should be determined according to different installation methods. If the transmission power exceeds the heat capacity of the reducer, an external cooling device must be provided.
5. Common knowledge of lubricating oil for reducer
In the use of reducer, special attention should be paid to the inspection and replacement of lubricating oil to ensure good lubrication of reducer. The lubricating oil used in reducer must be of specified brand and type. Different lubricating oils are prohibited from mixing. The inspection of lubricating oil level and quality should be carried out regularly. The position of oil level screw race, oil discharge screw race and ventilator is determined by the installation position. Their relative positions can be determined by referring to the installation position map of the reducer.
Inspection of oil level
Cut off the power supply to prevent electric shock! Wait for the reducer to cool down!
Remove the level screw to check whether the oil is full.
Install oil level screw plug.
Oil Quality Inspection of Reducer
The lubricating oil of reducer may deteriorate after using for a period of time due to various reasons, so the quality of lubricating oil should be checked regularly. The oil quality inspection of the reducer first cuts off the power supply and waits for the cooler to cool down, then opens the oil release bolt to obtain the oil sample, if the oil sample deteriorates, the lubricant should be replaced immediately.
For reducer with oil level screw plug
Check oil level, qualified or not
Installation of oil level screw
Replacement of Lubricating Oil for Reducer
The lubricating oil replacement of the reducer should be carried out at the operating temperature of the machine. At this time, the oil temperature is higher, the viscosity of the oil is lower, and the replacement difficulty is less. When replacing the lubricating oil, we should first cut off the power supply to prevent electric shock, and wait for the decelerator to be properly cooled to no burning danger, then start replacing the lubricating oil.
Cut off the power supply to prevent electric shock! Wait until the gear reducer cools down without burning danger!
Note: The reducer should keep warm when changing oil.
Place an oil pan under the drain plug.
Open oil level screw, ventilator and drain screw.
Remove all oil.
Install the oil discharge screw plug.
Inject the same brand of new oil.
The oil quantity should be in accordance with the installation position.
Check oil level at oil level screw plug.
Tighten oil level screw and ventilator.
6. Explanation on Lubrication Method of Reducer
Before operation, a proper amount of lubricating oil is injected into the reducer, and the stickiness of the lubricating oil is selected according to the following list. The reducer is usually equipped with an oil injection hole and a discharge plug. Therefore, the installation location must be specified when ordering the reducer. The following table lists the brands and models of lubricants recommended for general applications.
Note: For the application of unconventional working conditions, please consult the manufacturer.
Work oil temperature should not exceed 80 C: Lifelong lubricated combined reducer is filled with synthetic oil in the manufacturer. In addition, the reducer is usually supplied without lubricating oil, with oil filling plug and oil releasing plug. The number of reducer lubricants listed in this sample is only an estimate. The position of oil level plug should be set according to the installation position specified at the time of ordering to ensure correct oil injection. The oil injection quantity of reducer should be determined according to different installation methods. If the transmission power exceeds the heat capacity of the reducer, an external cooling device must be provided.
Before putting into operation, put the recommended type and number of grease in the reducer. The reducer is lubricated with lubricating oil. For vertically mounted reducers, additional lubrication measures are adopted, since lubricating oil may not guarantee reliable lubrication of the top bearing.
