Find effective solutions to the problem of gear breakage in gearbox due to poor bearing lubrication!
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Basic information on the heat stretching gearbox of the spinning apparatus: This gearbox uses a gear pump to deliver the lubricating oil inside it through oil pipes to the bearings and rollers located above. The gears and bearings below are generally lubricated by an oil bath, which is sufficient for providing proper lubrication. Although the lubrication system of this gearbox is relatively simple, practical operation often presents challenges. There are 9 gears in the gearbox, including 7 main shaft gears, as well as bridge gears between the first and second gears, and another bridge gear between the sixth and seventh gears. The two lower rollers are submerged in hot water. Seals, both water seals and oil seals, are installed at the points where the gearbox shafts extend outside the gearbox. However, due to the high-speed rotation of the rollers, the impact of water, and its corrosive effects, hot water from the stretching tank often penetrates into the gearbox after a short period of time. Once the lubricating oil mixes with water, its properties change and it becomes emulsified, which severely affects the formation of a proper lubricating film. This leads to wear of the bearings and, in turn, wear of the gears, reducing the equipment’s service life, increasing the costs associated with maintenance and repair, and lowering the economic efficiency of the enterprise. There has never been a good solution to this problem; generally, reducing wear is achieved by changing the oil frequently and using high-quality oil, but this also increases costs. Details of this malfunction (Monday, April 27): On weekends, usually only one technician from the process equipment department is on duty in each department, which makes it impossible to detect potential faults in a timely manner. Moreover, the current operators lack the ability to identify equipment problems; as a result, the rod bearings seized due to poor lubrication and eventually broke, leading to poor meshing of the drive gears. The excessive loading caused the gears to break in the end. The most severe damage was caused by broken gears in the bearings and fractured gears on the right side; in addition, a few gears had worn out due to tooth wear, resulting in a long downtime and significant losses! This post was last edited by jjfjj39 on 2009-4-27 21:21]
Improve the process by isolating the bearing housings of the two lowest rollers from water, and install cooling water to cool the bearings.
:Sir L, you do not understand the spinning process. . . I want to extend the service life of the bearings by using a oil mist generator or employing drip lubrication; dual lubrication may improve the lubrication effect, but upgrading all production lines requires significant manpower and financial resources. This post was last edited by jjfjj39 on 2009-4-27 21:15.]
It is recommended to improve the sealing at the shaft extension end; magnetic face seals or small mechanical seals could be tried (small non-metallic bellows seals can be used if there is enough space), as these might yield better results. Our factory uses magnetic seals for the shaft end sealing of cooling tower fans, and the results are quite good.
Spend some money to build a gas station and use recycled oil
Could you send a picture to show where it is? It would be best if it shows the area where it’s submerged in water! Good design for the sealing mechanism!
I’ll go take pictures when I have time; I’m not sure if photos will be posted in the second grade. I have never seen a magnetic seal:$ ； Building a gas station... must cost more, right!
Special working environments and improper use of lubricants. Problems: 1. High temperatures. Use high-temperature resistant lubricants with high viscosity, which can function properly in temperatures ranging from -45 degrees to 200 degrees. 2. Prone to water intrusion and emulsification. Lubricants that are resistant to water can be used; synthetic lubricants offer excellent load resistance and stability at high temperatures. This series of products is designed for applications that require excellent rust and corrosion resistance (ASTM D665, Pass Test B), as well as emulsification resistance (ASTM D1401). It maintains good stability at high temperatures exceeding 200 °C. Typical applications include piston compressors, bevel gears, helical bevel gears, helical gears, spur gears, and worm gears. This product series contains no chlorine, sulfur, lead, or other such materials. It maintains its consistent properties from below the pour point up to temperatures exceeding 250 °C. All viscosity grades can operate stably for over 10,000 hours in an operating environment of 100 °C. In closed industrial gearboxes, this product can significantly extend service life thanks to its excellent quality; in some cases, it can be used as a \"lifelong lubricant\".
I have seen the question posed by the original poster. Since the production line is fixed, the route along which the spinning yarn bundles are transported cannot be changed; as a result, the bearings of some rollers have to be located below the level of the hot water, and it is difficult to make any structural changes in this regard. It is recommended that the original drawings be consulted; generally, high standards are required for gaskets in this area. I have seen cases where special rubber-like materials are used, as they do not deform when exposed to hot water and are also resistant to oil. Therefore, it is more effective to focus on the material of the gaskets. As for regularly changing the lubricant, that is a supplementary method.