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How to improve the life of the reducer

Updated:2020-04-03
Summary:Friends who have contacted the reducer all know that the service life of the reducer is determined b...

Friends who have contacted the reducer all know that the service life of the reducer is determined by the external load and the internal wear rate. Too much load on the surface can easily lead to broken teeth, broken shafts and wear of moving parts, and the wear of moving parts will cause the lubricant film to be difficult to form. Under the circumstances, the method of increasing its service life is as follows:
        One is to prevent the components driven by the reducer from generating excessive external loads.
 
        Second, the wear and tear of internal bearings or gears of the reducer should be controlled in a reasonable plan.
 
        3. It is necessary to make sure that the inside of the bearing and the gear meshing surface are satisfied with the hydrodynamic lubricant film.
 
        1 Correctly reduce the gear to prevent excessive additional force
 
    The reducer equipment must meet the corresponding needs of its equipment to prevent the excessive additional force (ie, increase the external load) caused by poor alignment, lack of cooperation accuracy, and excessive vibration, and then accelerate the damage of the reducer. Such shortcomings should be discovered and managed in a timely manner in the early stage or operation of the operation, otherwise, the vibration load may cause abnormal conditions such as accelerated wear or bearing running rings, and reduce the life of the reducer.
 
        2 Repair the driven parts and reducer in time to prevent excessive load on the surface of the reducer
 
    The components driven by the reducer can cause excessive external loads due to wear, fouling, cracks, or damage to the bearing. Therefore, in normal repair operations, targeted inspection and repair standards should be formulated and implemented to prevent excessive external loads from occurring, and then reduce the life of the reducer. For example, the reducer itself can be inspected for lubricating oil, vibration, temperature, noise, etc. through detection methods such as five senses, vibration monitoring, and lubricating iron spectrum analysis. Correct or replace damaged parts to ensure that the reducer's own working conditions meet the planning requirements, and prevent or prevent excessive internal load from appearing.
 
     3. Ensure that the structure between the bearing and the tooth surface is satisfactory to the hydrodynamic lubricant film.
 
The composition of the full fluid power lubricating oil film is the root of the operating life of the forward reducer. The following is the specific method:
 
1. Reasonable selection of lubricating oil Reasonable selection of lubricating oil is the key to ensuring adequate lubrication. When selecting lubricating oil, the factors such as linear speed, limit load, operating temperature, working environment and other factors should be considered first, and the lubricating oil should be selected reasonably.
 
 There is no doubt about the oil products recommended by imported reducer manufacturers, but the few lubricants recommended by domestic reducer manufacturers have unreasonable appearances. At the same time, when domestic lubricants are used to replace imported lubricants, there are situations where the substitutions are improper. This situation is extremely bad for the life of the reducer, because in a short time ((1 year), without relying on the analysis skills of lubricating oil, it is impossible to see the serious consequences of improper use of oil. Therefore, the choice of lubricating oil Express your attention to satisfaction.
 
Second, ensure the cleanliness of the lubricating oil
 
The thickness of the gearbox and bearing full-fluid lubricating oil film of the reducer is stable under the condition that the reducer, lubricating oil and external load are fixed, and the thickness of the oil film is also stable. The abrasive particles and external pollutants that occur in the oil can damage the oil film and accelerate the wear of the relatively moving parts (this situation is mainly due to the wear of the moving parts with high movement speed). Together, the high temperature, High pressure will also accelerate the transformation of lubricating oil. Therefore, reducing the amount of abrasive particles in the oil and advancing the cleanliness of the lubricating fluid can greatly advance the lubricating components and lubrication
 
The service life of oil. Example: After many experiments, SKF bearing manufacturers have thoroughly studied the effects of various factors such as load, oil viscosity, and particulate contaminants on bearing life. They have concluded that 2-5 micron solid particles in the lubricant are eliminated, and the rolling bearing is tired. Life can be extended to 10-50 times the original. Therefore, reducing or controlling the amount of foreign objects in the oil can not only effectively reduce equipment wear, but also effectively extend the service life of the lubricating oil.
 
 The specific methods are: new lubricants to prevent pollution; use oil to prevent external pollutants (dust, water, etc.) from entering the oil; completely clean the oil tank when changing oil; for important equipment or large and medium-sized reducers, consider adding Install oil filter to filter lubricating oil online; equipment with high cleanliness requirements or equipment that is inconvenient for oil filter can use high-precision oil filtering equipment to filter in-use lubricating oil.
 
3. Prevent the occurrence of lubrication accidents in the reducer
 
      The reducer can be dry due to oil leakage and dry burning, or it can increase wear due to the entry of moisture, dust, slurry, etc., showing a lubrication problem. Therefore, it is necessary to check the dynamic sealing points, vent plugs, oil level changes, etc. on time in the spot check operation, to prevent external contaminants from entering the reducer, to prevent poor lubrication and dry burning due to lack of oil. For reducers that use cooling water to cool lubricating oil, or work in open-air steam and other environments, it is also necessary to strengthen the inspection of lubricating oil inflow to prevent the formation of lubrication accidents due to influx.
 
4. Punctually monitor the quality of the lubricating oil, so as to "change oil according to quality"
 
Lubricating oil in use can be polluted by dust, moisture and other external pollutants entering Hunan, or it can decay due to the increase of internal abrasive particles and other odors, resulting in aging and decay, which causes the oil to be discarded early. And Yan Yichang made Chuan Shoushu. Therefore, a certain prescribed oil change method cannot meet the needs of each treatment. Sampling and analysis of i1'tl lubricating oil is carried out on time and on time, which is helpful for knowing the quality of the lubricating oil and changing the lubricant and finding the lubricating oil that should be scrapped to ensure reliable lubrication. For gear lubricating oil, if one of the operations reaches the standard in the table below, it should be replaced with new oil.
 
Fifth, ensure that the reducer lubricating oil works at a reasonable temperature plan
 
Lubricating oil has its suitable operating temperature, too high or too low is unlucky to lubricate. If the gears and bearings are operated in a 50 ° C lubricating oil than in a 3 ° C lubricating oil, the wear will increase 10-12 times: when the oil temperature exceeds 55-60 ° C, the oil temperature will increase by 5 ° C each time, The oxidation rate of oil will double. Therefore, for the general reducer using mineral oil lubrication, one must prevent {the daily temperature is too low, generally higher than the pour point; second, to prevent the oil temperature is too high, the general oil temperature can not exceed 80 ° C. For equipment with low oil temperature, heaters should be used. For reducers with high oil temperature, cooling methods such as oil level control and forced heat dissipation should be used. For example, our company's seed tank reducer uses an electric fan to force cooling.

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