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In the process of using industrial gear oil, due to the unfamiliarity of product performance, there are often problems such as incorrect use of oil products, confusing varieties, and unsuitable use levels, resulting in shortened machine life and even discontinued production. Here, based on the performance and application range of various types of equipment lubricants, combined with the accumulated experience in the work, the use and management of industrial gear lubricants.
1The characteristics of industrial gear oil gear transmission equipment are: often in high temperature, high load, multi-water and dusty pollution occasions, the gear ratio and tooth surface unit contact pressure is very large, the local temperature between the tooth surfaces is up to several hundred °C, The contact state and the load change discontinuously at any time during the movement. Therefore, good tooth surface lubrication is the key to ensure the normal transmission of life and torque.
Industrial gear oil is a kind of industrial lubricating oil. It is mainly used for lubrication of various mechanical equipment gears and worm gears. It plays the role of lubrication, cooling, cleaning, anti-corrosion and rust prevention during use. It is very different from the use of hydraulic oil, so if the hydraulic oil is misused in the gear machine, it will cause great abrasion on the gear surface and drastically reduce the service life of the machine.
Industrial gear lubricants are classified into two types: closed gear oil and open gear oil. The open gear oil has high viscosity and good adhesion, can adhere to the surface of the friction pair to form an oil film and play a lubricating role, and can be used for lubrication of non-closed gears and chains. In the same coal group, due to the impact of the working environment, mainly using closed gear oil, and from the development trend, it is also based on closed gear oil, so this article mainly introduces closed gear oil.
1.1 Closed gear oil This oil is prepared by adding refined oil fraction to base oil and adding various types of additives. According to the application and load capacity, it can be divided into anti-oxidation and anti-rust gear oil L-CKB, medium-duty or general industrial gear oil L-CKC and heavy-duty or extreme-pressure industrial gear oil L-CKD. Each product is moved at 40 °C. Viscosity can be divided into 68#, 100#, 150#, 220#, 320#, 460#, 680# and other viscosity grades, which can meet the lubrication requirements of various gear transmissions.
1.1.1 Anti-oxidation and anti-rust gear oil L-CKB performance requirements and selection of anti-oxidation anti-rust gear oil have good anti-oxidation, anti-rust, anti-emulsification and anti-foam performance, the national standard of product quality is GB5903-1995 .
Anti-oxidation and anti-rust gear oil is suitable for the lubrication of gear transmission of general mechanical equipment with tooth surface stress less than 500MPa. The conditions of use are: ratio of maximum sliding speed to pitch circle speed υg/υ<1/3, oil temperature is not high At 70 ° C, such as general load spur gears, helical gears and low-speed, low-load worm gears.
1.1.2 Performance requirements of L-CKC for medium-duty industrial gear oils. In addition to medium-load or general industrial gear oils, in addition to good anti-oxidation, anti-rust, anti-emulsification and anti-foam properties, extreme pressure anti-wear performance is better than anti-oxidation The rust gear oil has been significantly improved, and the product quality meets the technical requirements specified in the national standard GB5903-1995.
Medium-duty industrial gear oil is suitable for lubrication of sealed spur gears, helical gears and herringbone gears with tooth surface stresses from 500MPa to 1100MPa. The operating conditions are: υg/υ<1/3, oil temperature is 5°C～ 80 ° C, such as mining, chemical and building materials industries reducer. At present, the industrial gear oil commonly used in coal mining equipment of Tongmei Group is medium-duty gear oil, mainly used in SGB764/264 scraper conveyor reducer, Germany Ai Kefu SL-5W shearer, DSP1000 belt conveyor , gearboxes and gantry cranes, sliders and other equipment.
1.1.3 Performance requirements of heavy-duty industrial gear oil L-CKD and excellent heavy-duty industrial gear oil have excellent extreme pressure anti-wear, anti-oxidation, anti-rust, anti-emulsification and anti-foam performance, product quality in line with national standard GB5903-1995 The required requirements.
Heavy-duty industrial gear oil is suitable for lubrication of heavy-duty gear transmissions with tooth surface stress greater than 1100MPa. The operating conditions are: υg/υ>1/3, oil temperature is 5°C～120°C, such as rolling mills in metallurgical industry. Although the extreme pressure of the heavy-duty gear oil is higher than that of the medium-load gear oil, considering the actual use condition of the machine and the cost-effective factor, the worm gear oil of the 1.2 worm gear oil series is mainly used for the lubrication of the worm gear transmission of the factory and mining equipment. The lubricating oil product is based on refined mineral oil, with oily agent and anti-wear agent as main additives, and supplemented with antioxidants, rust inhibitors, antifoaming agents, demulsifiers and thickeners and pour point depressing according to performance requirements. Agents, etc. The reduction ratio of the worm gear is large, but the occlusal part is mainly sliding friction, and the sliding speed is large, and the load capacity is also large, so the tooth surface oil film is easily squeezed out to cause scratches, scratches, sintering and wear, etc., so the worm wheel Worm oil requirements are extremely high.
Worm gear oil can be divided into two types: ordinary type (or light load) L-CKE and extreme pressure type (or heavy load) L-CKE/P according to the load.
These two categories of products can be divided into five grades of 220, 320, 460, 680 and 1000 according to the viscosity grade (according to GB/T3141, 40 °C kinematic viscosity).
1.2.1 Light load worm gear oil L-CKE specifications and light weight worm gear oil product quality is similar to Mobil 600W series, BP EnergolDC-C and other oils, can be used interchangeably with these oils. L-CKE common series products have good oiliness (small friction coefficient, high oil film strength), good corrosion resistance, rust resistance, oxidation resistance and emulsification resistance, suitable for lubricating ordinary worm gear pair (load parameter ≤ 294N/cm2), requires smooth and no impact in the transmission, such as worm gears such as textile, instrument and ship.
1.2.2 Heavy-duty worm gear oil L-CKE/P specifications and heavy-duty (or extreme pressure type) worm gear oil in addition to good corrosion resistance, rust resistance, oxidation resistance and demulsibility, but also It has excellent anti-wear performance and is suitable for lubrication of worm gear reducer with impact load (load parameter >294N/cm2) and sliding speed less than 2.5m/s. The product quality is comparable to that of Mobil 600W series, BP EnergolCGRS, Shell's FivelaoilWA, etc., and can be used interchangeably with these oils.
2 Industrial gear oil selection Industrial gear oil and worm gear oil have more viscosity grades and quality grades, which can meet a variety of conditions. Generally, the quality grade is selected according to the load condition, and the viscosity grade is selected according to the rotation speed.
2.1 Closed industrial gear oil According to the experience in actual work and the adaptation standards of equipment, this paper has compiled a reference table for the selection of closed industrial gear oil types (see Table 1). For the gear unit of the reducer, the oil supply method is circulation or oil bath.
2.2 Compared with the gear transmission, the worm gear oil worm drive has the characteristics of large transmission ratio, good self-locking property, large sliding speed, easy wear and gluing of the tooth surface, and large friction heat generation. Therefore, the worm gear is generally made of bronze, and the worm is generally made of alloy steel or carbon steel, so as to reduce wear and gluing from the combination of materials. In principle, the choice of lubricating oil should use worm gear oil with high viscosity, good oiliness, certain anti-wear performance and no corrosion to copper. Therefore, closed industrial gear oil should not be used for the lubrication of worm gears.
3 Industrial Gear Oil Replacement Under normal circumstances, industrial gear oil users mainly decide whether to replace new oil according to corrosion, corrosion, sedimentation, sludge, viscosity change and pollution degree. In order to carry out quality control regularly, China has formulated the oil change standard SH/T0586-1994 for L-CKC medium-duty industrial gear oil (see Table 3). If one item exceeds the standard, it should be replaced with new oil.
Therefore, the gear oil should be regularly tested by a qualified testing mechanism to better maintain the machine.
4 Lubricating oil management precautions 1 In the process of storage and transportation, it should be waterproof, dustproof and sealed. Long-term storage should be stored indoors in the dark to avoid deterioration caused by exposure.
After the 2 large packages are opened for use, the remaining oil should be sealed and stored, and should be used up in a short period of time as soon as possible. The storage period after opening is preferably not more than 3 months.
3 products should be stored in batches and set up with obvious marks to avoid misuse.
4 large barrels should be stored indoors in the rain to avoid moisture ingress.
If it has to be stored outdoors in the open air due to conditions, the vat should be stored at a certain angle (about 30°), and the lid and vent should be on the same horizontal line.
5 Packing barrels should not be stacked too high, in case the lowermost layer is crushed and broken. Generally, the vats and the middle barrels should not be packed in more than 4 layers, and the small barrels should be packed in no more than 6 layers. When taking them, pay attention to light handling and avoid collision and deformation.
6 The storage location of the oil in the warehouse should be frequently changed, reflecting the principle of first-in-first-out, avoiding the inconvenient location to become a dead corner, so that the oil there can not be used for a long time.
7 Before opening the product, be sure to wipe off the dust and impurities around the mouth of the barrel to prevent these things from getting into the oil and causing pollution.
8 When using, pay attention to the date of production. If the storage time is too long (more than 2a), it should be sampled and tested before it can be used.
9 If the product is obviously batt, there is suspended matter or there is sediment at the bottom of the barrel, it should be avoided.
10 Oil products should be protected from fire and explosion during storage, away from open flames and high temperature heat sources.