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Recently, news came from the third ABS unit of Jilin Petrochemical Company: after 46 days of stable operation testing, the first domestically produced reducer for Extruder No. 3 successfully passed the performance assessment, with no vibration or abnormal noises detected in the equipment. This localization substitution not only reduced the procurement cost per unit by over 3.4 million yuan, but also led to a significant improvement in the overall performance of the equipment. The extruder is a key device in the production process of ABS resin, and the reduction gearbox is one of its essential components. Its main function is to reduce the speed of the main motor while increasing the output torque, thereby enabling the transportation, mixing, and extrusion of the ABS material within the extruder and facilitating the mixing, modification, and melting of the material. The original 5 extruders of the third ABS unit, equipped with original Austrian Eisenbosen reducers, have been in operation for 12 years now, and the equipment is becoming increasingly outdated. Since the second half of 2024, breaks in drive shafts and gears have occurred frequently, requiring shutdowns for repairs; this has affected production volume and increased maintenance costs. “Imported reduction gears are not only expensive but also have long manufacturing and delivery times. ”Jiang Yang, a third-level engineer at the third ABS workshop, said that to overcome this challenge, the company organized professional technicians to work on making the gearboxes domestically produced. After conducting domestic surveys of these gearboxes, technical exchanges were held with qualified equipment manufacturing companies in China. Based on the operating parameters, the mechanical properties of the drive shafts and gears inside the gearboxes were calculated, thereby determining all the relevant parameters for those gearboxes. “We adopt a two-pronged strategy of ‘material upgrading + structural optimization’. Through technical discussions and tests with equipment manufacturers, we upgraded the materials of the six drive shafts in the gearbox; the strength of these upgraded shafts has increased by 18% ； Redesign the load-bearing structure of the housing and optimize the layout of the lubrication oil circuits. Verified through simulation and bench tests, the service life of the new gearbox can reach 15 years, which is 3 to 5 years longer compared to imported equipment. ” Jiang Yang explained. On February 19, the domestically produced reducer was successfully installed on the #3 extruder of Mixing Unit 3, and it started operating successfully on the first attempt. Liu Chunming, director of the mechanical equipment room, said, “We are working to replace the imported reduction gears in the other 4 extruders with domestic alternatives; once all of them have been replaced, it will save over 15 million yuan in procurement costs.” ”