The friends who have been in contact with the reducer know that the service life of the reducer is determined by the external load size and the internal wear rate. Excessive load on the surface may cause the teeth to break, the shaft to break and the moving parts to wear, and the wear of the moving parts may cause the lubricating oil film to be difficult to form. Therefore, the gear reducer has been combined with the hardened gear and the hard toothed gear is used. In this case, the method to increase its service life is as follows:
First, it is necessary to prevent excessive external load on the components driven by the reducer.
Second, the wear of the internal bearings or gears of the reducer should be controlled in a reasonable plan.
Third, it is necessary to ensure a satisfactory fluid-dynamic lubricating oil film between the inside of the bearing and the gear meshing surface.
1 Correct equipment reducer to prevent excessive additional force
It is necessary for the reducer equipment to meet the corresponding equipment requirements to prevent the large additional force (ie, increase the external load) due to poor alignment, lack of coordination precision, and excessive vibration, and then accelerate the damage of the reducer. Such shortcomings should be discovered and managed in time in the early stage of operation or in operation. Otherwise, the load can be vibrated to cause anomalies such as accelerated wear or bearing running, and the life of the reducer can be reduced.
2 Repair the driven parts and reducer in time to prevent excessive load on the reducer
Parts driven by the reducer may have excessive external loads due to wear, scale, cracks, or damage to the support bearings. Therefore, in the usual repair work, targeted inspection and repair standards should be developed and implemented to prevent excessive external loads and then reduce the operating life of the reducer. For example, the speed reducer itself can be monitored by five observations, vibration monitoring, and oil spectrum analysis of lubricating oil, and the lubricant, vibration, temperature, noise, etc. are monitored, and the shortcomings or risks are discovered in time, and timely inspection, Correct or replace damaged parts to ensure that the operation of the reducer meets the planning requirements and prevents or prevents excessive internal loads.
3. Ensure that the bearing and the tooth surface are structurally satisfactory.
The composition of the full fluid power lubricating oil film is the root of the operating life of the forward speed reducer. Here are the specific methods:
First, the rational use of lubricating oil Reasonable choice of lubricating oil is the key to ensure adequate lubrication. When selecting a lubricant, consider the factors such as line speed, ultimate load, temperature, and working environment, and choose a lubricant.
There is no doubt about the recommended oil products of the imported reducer manufacturers, but the few lubricants recommended by domestic reducer manufacturers have unreasonable appearance. Together, when using domestic lubricants instead of imported lubricants, there are cases of improper replacement. This situation is extremely unfortunate for the life of the reducer, because in a short period of time ((1 year), without the skill of lubricating oil analysis, it is impossible to see that the use of oil is not a serious consequence. Therefore, the selection of lubricating oil I want to pay attention to it.
Second, to ensure the cleanliness of lubricating oil
The thickness of the full-fluid lubricating oil film of the reducer gear and bearing is stable under the condition of reducer, lubricating oil and external load. The thickness of the oil film is stable between several micrometers and several tens of micrometers. The abrasive particles that occur in the process, as well as the external pollutants, can damage the oil film and accelerate the wear of the relatively moving parts (this situation is caused by the wear of moving parts with high moving speed), together, due to the high temperature of the oil film formation, High pressure also accelerates the transformation of the lubricant. Therefore, the amount of abrasive grains in the oil is reduced, the cleanliness of the lubricating oil is advanced, and the lubricating parts and lubrication can be greatly advanced.
The life expectancy of the oil. Example: After many experiments, SKF bearing manufacturers have intensively studied the effects of various factors such as load, oil viscosity, particle pollutants on the bearing life, and concluded that 2-5 micron solid particles in the lubricating oil are removed, and the rolling bearing is exhausted. The number of lives can be extended to the original 10-50 times. Therefore, reducing or controlling the amount of foreign matter in the oil can be useful to reduce equipment wear and to extend the useful life of the lubricant.
The specific method is: the newly participated lubricating oil should prevent pollution; the oil should be used to prevent external pollutants (dust, water, etc.) from entering the oil; the oil tank should be completely cleaned when changing the oil; for important equipment or large and medium-sized reducers, consider adding Oil filter, online filter oil; equipment with high cleanliness requirements, or equipment that is inconvenient for oil filter can be used to filter lubricants with high precision oil filter equipment.
Third, to prevent the occurrence of lubrication of the reducer
The reducer can be burnt out due to oil leakage, or it can be aggravated by the ingress of moisture, dust, slurry, etc., and it is lubricated. Therefore, it is necessary to check the dynamic sealing point, the venting plug, the oil level change, etc. in the inspection operation to prevent external pollutants from entering the reducer, preventing poor lubrication and dry burning. For gearboxes that use cooling water to cool lubricants or open-air steam, etc., it is necessary to strengthen the inspection of the influent water to prevent lubrication from entering the water.
Fourth, punctual monitoring of lubricating oil quality, to achieve "quality change oil"
Lubricating oil can be contaminated by external pollutants such as dust and moisture, or it can be decelerated due to the increase of internal abrasive grains, so it is aging and aging, causing the oil to be used early, or because of the cleanliness. And Yan Yichang made Chuan Shou number. Therefore, a certain oil change method cannot be adapted to the needs of each treatment. The punctuality of the machine is used to carry out the sampling analysis of the i1'tl oil. It is beneficial to know the quality change of the lubrication 和 and to find the lubricating oil that should be discarded to ensure reliable lubrication. For gear lubricants, if one of the operations meets the criteria in the table below, the new oil should be replaced.
5. Ensure that the lubricating oil of the reducer is operated at a reasonable temperature.
Lubricating oils have suitable operating temperatures, too high or too low. If the gears and bearings work in a 50 ° C lubricating oil than in a 3 ° C lubricating oil, the wear will increase by 10-12 times: when the oil temperature exceeds 55-60 ° C, the oil temperature rises by 5 ° C, The oxidation rate of the oil will double. Therefore, for the general reducer that uses mineral oil lubrication, one must prevent the daily temperature from being too low, generally higher than the pour point; secondly, to prevent the oil temperature from being too high, the general oil temperature cannot exceed 80 0C. For equipment with low oil temperatures, heaters should be used. For gearboxes with a higher oil temperature, the method of controlling the oil level and forcibly dissipating heat should be used. For example, our company's seed tank reducer uses a fan to forcibly cool down.