As the most commonly used transmission equipment in the field of machinery, the normal and smooth operation of the gearbox is very important. Once the gearbox failure, especially oil leakage problems, will not only lead to safety accidents, reduce the economic benefits of enterprises, but also waste oil use. This article discusses the causes of the oil leakage problem of the gearbox and effective control and preventive measures.
Analysis of the cause of oil leakage in the gearbox
During the long load operation of the gearbox, the oil leakage problem will occur in different degrees due to the factors of design process and production and manufacturing, pressure and vibration. In combination with their work experience and the oil leakage problems caused by cranes, excavators and steel-grinding gearboxes, the mechanical industry workers summed up the following factors leading to the oil spill.
1. Welding and casting box leakage factors
Welding box is mainly stitched by steel plate, during welding, if there is no complete melt through weld, or there is a false welding situation, long-term use of the box, there will be cracking conditions, lubricant leakage with the weld phenomenon.
Moreover, the casting box because of different degrees, different types of casting defects, such as the inevitable existence of slag, shrink holes or pores, will lead to the box force cracking, small cracks, resulting in oil leakage.
2. Box section combination is not strict factor
If the sectional binding of the box is not tight, a gap will be caused at the weld of the box, causing the lubricant to seep out of the inter-seam area. At the same time, in the case of sectional binding width and thickness design results are not up to standard, the box casting and welding stress can not be fully played.
If the sealant is not applied as required, acting on the box to close the fastener tightening torque is not sufficient, then the reducer during operation will produce cross-variable load and vibration, resulting in deformation of the box and fastener loose condition, and finally section the face position gap.
3. The high-speed shaft of the reducer and the oil leakage factor at the low-speed shaft
First, the sealing ring is worn out. After friction on the long coaxial surface of the oil-sealed lip, it is easy to trigger lip burns and carbonization problems, loss of rubber flexibility and elasticity, hard wear, and thus coaxial contact to form a gap.
And the shaft connecter, whether high-speed shaft or low-speed shaft, needs to be coaxial over-linking, during the heating installation, the oil seal is subject to heat transfer and radiation problems, will form a pre-metamorphosis and deformation.
Second, the shaft surface wear failure. During the contact of shaft co-seal, due to high pressure and high temperature and other factors, the shaft surface is raised roughness, which makes the damage shaft, can not cooperate well with the oil seal.
Finally, the mechanical seal leaks oil. When the return hole is blocked or small, and the return channel is not smooth, the accumulated oil will be accompanied by a splash of oil ring in the oil collection cover section facial position leakage phenomenon.
4. Observe the oil leakage and the blockage factor of the air filter
If the observation hole has a thin cover thickness, and then screw the bolt is easy to trigger the deformation of the cover plate, in contact with the gap site to produce leakage. Usually the observation hole application lysophore is easy to observe, easy to form cracking damage during assembly and application resulting in oil leakage.
In addition, during the production of the gear reducer, the gear encounters rolling and sliding friction effect, there will be a greater heat, and then increase the pressure of the gas, with the external pressure to form a difference, resulting in oil leakage along the tank gap.
5. Other oil leakage factors
Other factors include leakage problems at the oil release hole site, leakage of the oil lubrication distribution pipe, failure of fastener pre-tightening torque during the maintenance of the gearbox to meet the standard requirements for leakage, and leakage problems possible if the reducer that implements oil bath splash lubrication does not comply with the requirements for filling the oil.
Effective prevention and control measures for oil leakage in the gearbox
Through the reason analysis, in the technology, production process, quality control and other aspects of the implementation of effective improvement and improvement measures to prevent and control oil spills.
1, welding box steel plate, in strict accordance with the requirements of the specification, improve the casting process, so that the design has a scientific rationalization standards.
2, should be on the input and output shaft, add surface hardening treatment shaft sleeve, the surface roughness to improve, to ensure that the same oil seal lip contact hardness and roughness is appropriate, and increase the special lubrication of the seal, to prevent the production of early oil seal wear.
3, strict assembly quality requirements, the correct installation, use, maintenance of the reducer, in addition to ensuring that the ball valve and seal quality to meet the standard requirements.
4, the use of oil lubrication and mechanical sealing of the gearbox, the upper oil return hole of the housing needs to be increased, in accordance with the requirements of flow calculation, the thyst thing sleeve is set, at the same time for each lubrication point flow to implement accurate distribution, to prevent the problem of unecontributed oil supply caused by excessive or shortage of oil.
A gasket is taken between the gearbox observation hole cover and the box to increase the thickness of the view hole cover and reduce the roughness at the combined site.
The threads at the oil-discharge holes are changed to welded and processed to fully ensure that the threads have a high degree of fit and tolerance requirements. And improve the area of contact between the screw block and the end face of the oil release hole, to ensure that the end face of the gasket has a tight contact effect.
For a variety of oil leakage reasons, take corresponding measures to reduce the leakage of lubricants, maintain the good efficiency of the reducer, to ensure the safe operation of the host. Not only can maintenance costs be reduced, but the hazards of oil leakage can also be avoided. Welcome to the message to communicate your problems.