Why is Lubrication For Industrial Gearboxes So Important?
Introduction:
A gearbox reducer is a piece of machinery that uses all levels of gearbox transmission. that to slow down a vehicle’s speed and increase its torque. Why is lubrications for industrial gearbox so important? If proper lubrication is not performed. It means that friction and wear can cause mechanical equipment to be damaged by accident. Good lubrication is important to make sure that gearboxes and bearings work normally.
The Importance of Industrial Gearbox Lubrication
The lubricant like the blood in an industrial gearbox. Good lubrication is very important for the industrial gearboxes to work well for a long time. Because the industrial gearbox has many metal surfaces that move with friction. these parts are subject to fast movement. and also under bad working conditions. At the same time,the working temperatures between 400°C and 600°C. Only qualified lubricating oil can protect engine parts from wear and tear. and make them last longer when they are working in such harsh conditions. In this article, KONIC will talk about what is the type of lubricants？ what is the fuction of lubricants for industrial gearboxes？How to checking the lubricants oil？
The Type of Lubrications for Industrial Gearbox
lubrications for industrial gearbox oil classified into gear oil and grease. with gear oil further subdivided into mineral oil and synthetic oil. In comparison to mineral gear oil, synthetic gear oil has a wider temperature range and a greater viscosity index. or a more gradual rise in viscosity with temperature.
The most common temperature range for base oil as follows:
Approximately -10°C to +90°C (instantaneous +100°C). -20°C to +100°C (instantaneous +110°C) for polyethylene glycol and poly-alpha-olefin. Approximately -15°C to 90°C for synthetic esters. The top and lower temperature limits of use for different gearbox oils can vary significantly from the listed values. Refer to the technical data sheet and safety data sheet of the oil manufacturer for reduction gear oil data and characteristics.
In the absence of significant alterations in oil quality. the following oil service life as follow:
hydrocarbons and synthetic esters 2 years or 10,000 hours of operation. polyethylene glycol with poly-alpha-olefin 4 years or 2,000 hours of operation . These pertinent restrictions apply to an average gearbox oil temperature of 80 ℃. The lubricant’s service life is proportional to the operating temperature. and decreases by approximately 50 percent for every 10 K increase in temperature.
Method of Lubrications for Gearbox
The lubrication method of reducer divided into three types. for oil immersion lubrication, splash lubrication and forced pressure lubrication. The three types of lubrication are mainly based on the linear speed. According to the linear speed of the reducer to determine which lubrication need to use.
Oil Immersion Type Lubrication
The gear teeth of the large gear often immersed in the oil pool for oil immersion lubrication. so that the gear in the drive, the lubricant to the meshed tooth surface, but also the oil splash to the box shell. In multi-stage gear transmission, oil immersed the tooth surfaces of gears that are not in the oil pool by the belt gear. The speed is not very high and the gear diameter is enough for oil immersion lubrication. Linear speed < 6m / s, commonly used oil immersion lubrication.
Splash Lubrication
Partially gears and bearings immersed in oil. gears in the transmission of the lubricant to the tooth surface of the mesh. 6m / s < line speed < 15m /s, for helical gears often choose splash lubrication. line speed < 12m / s, for bevel gears usually choose splash lubrication.
Pressure Lubrication
By the oil pump or the central oil supply station with a certain pressure supply oil. through the nozzle will lubricant spray to the gear teeth meshing surface or bearing. The nozzle should be on the side of the gear tooth engagement. so that the lubricant could cool the gear teeth just engaged in time, and also to lubricate the gear teeth. 15m/s<linear speed <30m/s, commonly used pressure lubrication. pressure lubrication also use If the reducer installed with a very large inclination.
Properties and Functions of Lubricants
Rust and Corrosion Resistance
Rust resistance refers to the performance of a gear oil to prevent rusting of metals. It refers to the performance of gear oils in preventing corrosion of metals. Rusting of metal parts mainly caused by the presence of oxygen and water in the lubricant. Corrosion caused by acids and sulfides in the oil. so rust and corrosion prevention additives are usually added to lubricants.
Oxidation Stability
The lubricating oil agitated by the gear movement and is in constant contact with oxygen. at the same time, the various oxides formed under the catalytic action of the metal. which increases the viscosity of the lubricating oil, and darkens the color. even raises the acid value, increases the precipitate. and causes the corrosion of the machine parts. even resulting in the anti-foaming and anti-oxidation of the lubricating oil. which makes it necessary to replace the lubricating oil. The lubricant with good oxidation stability will have a long service life. So, antioxidants are usually added to lubricants to improve oxidation stability.
Viscosity and viscosity-temperature properties
Lubrications for industrial gearbox must have suitable viscosity and good viscosity-temperature properties. Generally speaking, high viscosity lubricants is beneficial to prevent damage and reduce noise. Low viscosity lubricants has good feature on cooling effect and transmission efficiency. For the viscous temperature , although lubricating oil is not change as the engine oil. but the surface teeth pressure also requires good viscous temperature performance. especially in cold areas when using. Otherwise, it will cause increased wear and increased oil consumption.
Anti-wearing
Anti-wear means lubricant can form and keep an oil film on the surface of between moving parts. This keeps metals from touching each other and reduces wear. Most of a gearbox lubricant’s anti-wear properties come from how oily it is and how high the pressure is. Oiliness is the ability of gear oils to form a thin film of oil on parts that rub against each other. That to prevent damage to the friction surface, such as sintering and glueing. which is also known as the bearing capacity.
Foam resistance
Under high agitation during gear movement, reducer lubricants produce a large number of tiny bubbles. The use is unaffected if the little bubbles vanish soon. Overflow will occur on the tooth surface if the stable bubbles no longer vanish. and emulsification and degradation ensue, degrading the lubricant film and increasing wear.
Step by Step to Change Gearbox Lubricant
Checking of oil level
- Cut off the power supply to prevent electric shock!
- Wait for the reducer to cool down!
- Remove the oil level screw plug to check if the oil is full.
- Install the oil level screw plug.
The oil checking
- Cut off the power supply to prevent electric shock!
- Wait for the reducer to cool down!
- Open the oil screw plug and take oil sample.
- Check the oil viscosity index, if the oil is obviously cloudy. recommended to replace it as soon as possible.
- For the reducer with oil level screw plug, check the oil level. whether it is qualified, and install the oil level screw plug.
The oil replacement
The viscosity of the oil increases after cooling oil drainage difficulties. reducer need to changed at operating temperature. Cut off the power supply to prevent electric shock! Wait until the reducer cools down without the danger of burning!
Noting:
the high-power gearbox should still kept warm when changing oil.
- Open the oil level screw plug, ventilator and oil drain screw plug.
- Remove all the oil.
- Put on the oil drain screw plug.
- Put an oil catch pan under the oil drain screw.
- Fill with new oil of the same grade.
- Check the oil level at the oil level screw plug.
- Tighten the oil level screw and ventilator. The oil quantity should be consistent with the installation position.
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