Oil flow of worm gear reducer 1.1.Pressure difference inside and outside the reducer.
During the operation of the reducer, the friction heating of the moving pair and the influence of the ambient temperature increase the temperature of the reducer.
If there is no vent or the vent is blocked, the pressure in the reducer will gradually increase.
The higher the temperature in the reducer, the greater the pressure difference with the outside world, and the lubricating oil will leak out from the gap under the action of the pressure difference.
one point two.
Unreasonable reducer structure design.(1).The inspection hole cover plate is too thin, which is easy to deform after tightening the bolts, resulting in uneven joint surface and oil leakage from the contact gap.(2).During the manufacturing process of reducer, the casting is not annealed or aged, and the internal stress is not eliminated, so it is bound to deform and produce gap, resulting in leakage.(3).There is no oil return groove on the box, and the lubricating oil accumulates at the shaft seal, end cover, joint surface, etc.
under the action of differential pressure, it leaks outward from the gap.(4).The structural design of shaft seal is unreasonable.
The early reducers mostly used the oil groove and felt ring shaft seal structure.
During assembly, the felt was compressed and deformed, and the gap on the joint surface was sealed.
If the contact between the journal and the seal is not ideal, the seal will fail in a short time due to the poor compensation performance of the felt.
Although there is an oil return hole on the oil ditch, it is easy to be blocked and the oil return function is difficult to play.
one point three.
Excessive refueling.
During the operation of the reducer, the oil pool is stirred severely, and the lubricating oil splashes everywhere in the reducer.
If the amount of oil is too much, a large amount of lubricating oil will accumulate in the shaft seal, joint surface, etc.
, resulting in leakage.
one point four.
Improper maintenance process.
During equipment maintenance, oil leakage will also be caused due to incomplete removal of dirt on the joint surface, improper selection of sealant, reverse installation of seals, untimely replacement of seals, etc.2. Countermeasures for controlling oil leakage of reducer.
two point one.
Improved ventilation cap and inspection hole cover plate.
One of the main reasons for oil leakage is that the internal pressure of the reducer is greater than the external atmospheric pressure.
If we try to balance the internal and external pressure, oil leakage can be prevented.
Although the reducers are equipped with ventilation caps, the ventilation holes are too small, which are easy to be blocked by pulverized coal and oil.
Moreover, the cover plate of the inspection hole shall be opened every time for refueling, which will increase the possibility of oil leakage once, so that there will be leakage where there is no leakage.
Therefore, an oil cup type breathable cap is made, and the original thin inspection hole cover plate is changed to 6.
Mm thick, the oil cup type vent cap is welded on the cover plate, and the vent hole diameter is 6.
Mm, which is convenient for ventilation, realizes pressure equalization, and when refueling, refuel from the oil cup without opening the inspection hole cover plate, so as to reduce the chance of oil leakage.
two point two.
Smooth flow.
In order to prevent the excess lubricating oil thrown on the bearing by the gear from accumulating at the shaft seal, the excess lubricating oil must flow back to the oil pool in a certain direction, that is, smooth flow.
The specific method is to open an oil return groove inclined to the inside of the machine at the center of the lower pad of the bearing seat, and also open a gap at the straight mouth of the end cover, which is facing the oil return groove, so that the excess lubricating oil flows back to the oil pool through the gap and oil return groove.
two point three.
Improved shaft seal structure.2.3.1.Improvement of shaft seal of reducer with half shaft output shaft.
The output shaft of reducer of most equipment such as belt conveyor, screw unloader and impeller coal feeder is half shaft, which is convenient for transformation.
Disassemble the reducer, remove the coupling, take out the reducer shaft seal end cover, turn the processing groove on the outside of the original end cover according to the size of the supporting skeleton oil seal, and install the skeleton oil seal with the spring side inward.
During reassembly, if the end cover is 35 from the inner end face of the coupling.
Mm or more, a spare oil seal can be installed on the shaft outside the end cover.
Once the oil seal fails, the damaged oil seal can be taken out and the spare oil seal can be pushed into the end cover, thus eliminating the time-consuming and laborious processes such as disassembling the reducer and dismantling the coupling.2.3.2.Improvement of shaft seal of reducer with integral output shaft.
The output shaft of the reducer driven by the whole shaft has no coupling.
If the transformation is carried out according to scheme 2.3.1, the workload is too large and unrealistic.
In order to reduce the workload and simplify the installation procedure, a separable end cover is designed, and an open oil seal is tried.
Turn the groove on the outside of the split end cover.
When installing the oil seal, first take out the spring, saw off the oil seal in an open shape, sleeve the oil seal on the shaft from the opening, butt the opening with adhesive, the opening is upward, then install the spring and push the end cover.
two point four.
New sealing materials are used.
For the leakage at the static sealing point of the reducer, a new sealing material can be used for plugging.
During the overhaul of the reducer, apply D05 silicone rubber sealant on the joint surface and end cover to replace the early products, and generally there will be no leakage.
If there is oil leakage at the static sealing point during the operation of the reducer, the oil surface emergency repair agent of surface engineering technology can be used to plug, so as to eliminate the oil leakage.
two point five.
Carefully implement the maintenance process.
During the maintenance of the reducer, the process regulations shall be carefully implemented.
The oil seal shall not be installed reversely, the lip shall not be damaged, the outer edge shall not be deformed, the spring shall not fall off, the joint surface shall be cleaned, the sealant shall be applied evenly, and the oil filling amount shall not exceed the scale of the oil dipstick.
two point six.clean.Through treatment, the static sealing points of the reducer can generally achieve no leakage, but the dynamic sealing points still have small leakage due to aging seals, poor quality, improper assembly and high shaft surface roughness.
Due to the poor working environment, coal dust sticks to the shaft and looks oily, so it is necessary to, Wipe the oil on the shaft.3. Conclusion.
Oil leakage of reducer is common and difficult to cure.
Through the treatment of more than 50 reducers, the leakage of reducer has been basically eliminated, and the equipment condition has been greatly improved.
Oil leakage occurs soon after the replacement of individual reducer shaft seal fails, which may be related to the quality of oil seal, assembly process and high surface roughness of shaft.
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