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Maintenance of special reducer for concrete mixing plant equipment:
The reducer used in the concrete mixing station industry is mainly used in the main engine, screw conveyor and inclined belt conveyor of the mixing station. The maintenance of the reducer directly affects the normal work of the whole mixing station and the production constant of the mixing station. So how to maintain the reducer of the mixing station? Below are some maintenance methods, hope to help you!
1. Lubricating oil products, reducer uses extreme pressure gear extreme pressure oil N220 or N320 in GB/T5903-1986, when the ambient temperature is less than 30 degrees C, N220 is used when the ambient temperature is higher than 30 degrees C, and N320 is used when the ambient temperature is higher than 30 degrees C.
2. The cooling and lubrication system of reducer adopts normal opening mode, and the lubrication mode adopts oil-immersed circulation lubrication. Before the roll press system is opened, the lubrication system must be started to confirm that there is oil supply at each lubrication point for 3-5 minutes before the reducer can be rotated. The first installed reducer needs input of low-speed disc-driven reducer after filling oil to the middle line of the oil mark. The shaft ensures that the bearings in the reducer are lubricated with oil.
3. The reducer in the mixing station should be replaced once after 300 hours of initial operation. Before oil change, the stolen goods in the tank should be cleaned with low-viscosity oil. After that, oil should be changed every 12 months, and oil should be changed every 6 months for continuous operation of day and night. Wash the reducer with light oil before loading new oil.
4. Check the cleanliness of lubricating oil once a month. It is found that the lubricating oil becomes dirty and deteriorated. It should be replaced in time and should not be limited by time.
5. The replaced lubricating oil is discharged from the discharging screw at the lower part of the reducer.
6. Clean the gas cap and the filter of the oil station once a month with kerosene to remove impurities in the filter; the cleaning of the oil filter must be carried out when the reducer is not running.
7. Check the connection bolt between motor and reducer every month, and check the connection bolt between reducer and installation base every week.
8. Check oil level, oil temperature and oil pressure every day, check oil leakage at the output, input and pipe joints of the reducer, check whether the temperature at the bearings is normal, listen to the sound of operation is normal, and so on. If abnormal phenomena are found, they should be eliminated immediately.
9. Check the connection of all external fastening bolts every six months. Comprehensive maintenance and cleaning of concrete mixing station reducer system.
(ZJY Series) Axle-mounted Gear Reducer
1. The reducer is usually mounted in the vertical position and in the range of 20 degrees in front and back, which is used in conjunction with the main engine.
2. Before the output shaft hole of the reducer is inserted into the main shaft, grease should be applied on the surface of the shaft and the shaft hole to reduce the assembly resistance. Do not install it by force striking, otherwise it may cause bearing damage or hollow shaft end deformation. For the reducer installed with double-end taper sleeve, the following procedures can be installed:
(1) Firstly, the inner hollow cone sleeve is inserted into the main shaft of the main engine;
(2) Push the reducer into the main shaft of the main engine and hang the left end on the left cone sleeve;
(3) Install the right cone sleeve from the right side;
(4) Tighten the fastening screw of the left and right taper sleeve accordingly.
3. Install drive triangle belt. Due to the compact size of the reducer and the small size of the bearing, in order to ensure the normal use of the bearing, please pay attention to the following points:
(1) Choose high strength narrow triangular belt as far as possible. Narrow triangular belt can reduce the width and size of the pulley, as well as the tension force of the triangular belt. This can make the tension action point of the input shaft pulley close to the inner side of the input shaft, which is very helpful to improve the service life of the input shaft bearing.
(2) Triangular pulleys with all metalworking shall be selected. For belt pulleys with spoke relief holes, the requirement of static balance should be satisfied.
(3) The triangle should be tense and moderate. Generally, the tension of the triangle band can be judged by pressing the triangle band with two fingers and moving the compression point down 1-2 mm. Since the triangle belt will slip after running for a period of time due to the prolongation of initial tension, the prolongation should be compensated by secondary tension. Don't be too tense in the initial installation, add undue cantilever tension to the input shaft bearing.
4. In order to overcome the effect of friction reaction moment of hollow axle bearing on reducer box when reducer is running, anti-torsion tie rod is usually used to balance the moment. The installation position of anti-torsion tie rod is shown in Fig. 1. Anti-torsion tie rod can be used with type 00 "open lock screw", see Appendix 2. Because of the irregular size of the inner hole of the ring head of the cable mouth, it can be replaced by the processed ring head. H9/n9 can be used to match the inner hole of the ring head with the tie rod pin. The left and right sloshing of the reducer can be reduced by using the ring head with small clearance.
5. Open the oil plug in the middle of the reducer box to make the box in a vertical position. Add N220 intermediate pressure gear oil from the ring hole, and the oil level will reach the overflow height of the lower oil plug.
6. The reducer is running without load for a period of time. Check whether there are abnormal noise, oil leakage, vibration and other abnormal phenomena. If not, it can be put into load operation.
7. Lubricating oil should be replaced after 300-600 hours of first operation of reducer. Thereafter, it should be replaced every 1500-5000 hours of operation (mainly depending on the working environment) for a maximum of not more than 18 months. When changing oil, the magnetic oil plug should be cleaned at the same time (installed in the lower part of the box).
8. When oil temperature suddenly rises or abnormal noise occurs during the operation of the reducer, stop immediately for inspection. Only after troubleshooting can we continue to work.
9. When the one-way running reducer needs reverse or two-way operation, it can open the end cap opposite to the input shaft, pull the star wheel out with a pulling plate (the pulling plate can be self-made according to the position of the lifting screw hole on the star wheel) and reverse-install it, then it can be changed to run; or remove the rollers and top pins at the gap of the star wheel (small size without this part); Top spring, realize two-way operation. For non-contact backstop, it is necessary to pull the backstop out and reverse-load the outer ring as well.
10. The hollow shaft end cover is used to fix the axial position of the reducer and to disassemble the reducer. When used for fixing, the input shaft of the main engine is lifted with hexagonal bolts matching the central aperture; when used for disassembly, the hexagonal bolts can be screwed into the threaded holes on both sides and ejected from the box body.
