Hengyu Guoqiang: precautions for industrial gearbox installation (phase IV)
Time：2021-05-10 | Source：恒宇国强 | Browse：1230502
I. precautions for installation of high-power industrial gearbox
When installing the industrial gearbox, attention shall be paid to the alignment of the transmission center axis. When the input shaft and output shaft are connected with the power and supporting machinery, if the coupling is used, the shaft and shaft shall be strictly aligned without misalignment. Good alignment can prolong the service life and obtain ideal transmission efficiency. V-belts and chains should not be too tight or too loose.
When installing the transmission parts on the output shaft, it is not allowed to knock them with a hammer. Generally, the assembly fixture and the internal thread at the shaft end are used to press the transmission parts in with bolts, otherwise the internal parts of the industrial gearbox may be damaged. It is better not to use rigid fixed coupling, because improper installation of this kind of coupling will cause unnecessary external load, resulting in early damage of bearing and even fracture of output shaft in serious cases.
The industrial gearbox shall be firmly installed on a stable horizontal foundation or base, the oil in the oil drain tank shall be drained, and the cooling air circulation shall be smooth. The foundation is unreliable, which will cause vibration and noise during operation, and cause damage to bearings and gears. When the transmission coupling has protrusions or adopts gear and sprocket transmission, it shall be considered to install protective devices. When the output shaft bears large radial load, the reinforced type shall be selected.
When installing the fixing screw, check whether it is tightened and fixed firmly from time to time. The spring gasket shall be selected as far as possible.
Install the device according to the regulations to ensure that the staff can easily access the oil standard, vent plug and oil drain plug. After the installation in place, the accuracy of the installation position and the reliability of the compression of each fastener shall be comprehensively checked in order. It shall be able to rotate flexibly after installation. The industrial gearbox adopts oil pool splash lubrication. Before operation, the user needs to remove the plug of the vent hole and replace it with the vent plug. According to different installation positions, open the screw of the oil level plug, check the height of the oil level line, add oil from the oil level plug until the lubricating oil overflows from the screw hole of the oil level plug, screw on the oil level plug, and then conduct no-load test run, which shall not be less than 2 hours. The operation shall be stable without impact, vibration, noise and oil leakage. Any abnormality shall be eliminated in time.
II. Inspection and maintenance of high-power industrial gearbox
For the high-power industrial gearbox newly put into operation, be sure to add medium extreme pressure gear oil N220 or N320 to the specified position (20-30mm above the lowest gear part) before use, and supplement it regularly.
The oil shall be changed for the first time after 200 ~ 300 hours of operation. The quality of the oil shall be checked regularly in future use. The oil mixed with impurities or deteriorated shall be replaced in time.
In general, for high-power industrial gearboxes that work continuously for a long time, the oil shall be replaced according to 5000 hours of operation or once a year. The industrial gearboxes that have been out of service for a long time shall also be replaced with new oil before they are re operated. The industrial gearboxes shall be added with oil of the same brand and shall not be mixed with oil of different brands. Oil with the same brand and different viscosity is allowed to be mixed.
When changing the oil, wait until the industrial gearbox cools down and there is no danger of combustion, but keep it warm, because after complete cooling, the viscosity of the oil increases and it is difficult to drain the oil. Note: cut off the power supply of the transmission device to prevent inadvertent power on!
During operation, when the oil temperature rise exceeds 80 ℃ or the oil pool temperature exceeds 100 ℃ and abnormal noise is generated, stop the use, check the causes, eliminate the faults and replace the lubricating oil before continuing the operation.
The user shall carefully carry out the inspection and maintenance of the gearbox, and make reasonable records of the problems found in the operation of the gearbox.
Torque calculation formula of three high power industrial gearbox
Reduction ratio = output revolutions of motor ÷ output revolutions of industrial gearbox ("reduction ratio" is also called "transmission ratio", referred to as "speed ratio")
Industrial gearbox torque = 9550 × Motor power ÷ motor power input revolutions × Reduction ratio × Service efficiency (90% - 96%) (within the same motor power and bearing range of industrial gearbox, the greater the speed ratio, the greater the output torque of industrial gearbox, and the slower the number of revolutions. Similarly, the smaller the speed ratio, the smaller the output torque of industrial gearbox, and the faster the number of revolutions)
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