Maintenance methods for gearbox oil leakage
Once the gearbox leaks oil, it not only causes energy loss, but also pollutes the environment. In severe cases, it can cause the gearbox to run out of oil or cut off oil, exacerbating the wear and tear of the gear meshing surface, leading to welding or peeling, leading to equipment accidents.
Steps/Methods
1、 Improve the breathable 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 pressures, oil leakage can be prevented. Although reducers all have breathable caps, the breathable holes are too small, which can easily be blocked by coal powder and oil stains. Moreover, every time you refuel, you need to open the inspection hole cover plate. Opening it once increases the possibility of oil leakage, causing leaks to occur in areas that were originally not leaking. To this end, an oil cup type breathable cap was made, and the original thin inspection hole cover plate was changed to a thickness of 6 mm. The oil cup type breathable cap was welded onto the cover plate, with a diameter of 6 mm for easy ventilation and pressure equalization. When refueling, oil was added from the oil cup without opening the inspection hole cover plate, reducing the chance of oil leakage. To prevent the excess lubricating oil thrown on the bearing by the gear from accumulating at the shaft seal, it is necessary to allow the excess lubricating oil to flow back to the oil pool in a certain direction, that is, to achieve smooth flow. The specific method is to create a return oil groove tilted inward in the center of the lower pad of the bearing seat, and also create a gap at the straight end of the end cover, which is facing the return oil groove. This way, excess lubricating oil flows back to the oil pool through the gap and return oil groove.
2、 Improve the shaft seal structure;
1) Improvement of the shaft seal of the gearbox with a half shaft output shaft;
The output shaft of the reducer for most equipment such as belt conveyors, screw unloaders, and impeller coal feeders is a half shaft, making the transformation more convenient. Disconnect the gearbox, remove the coupling, take out the gearbox shaft seal end cover, and machine the groove on the outer side of the original end cover according to the matching skeleton oil seal size. Install the skeleton oil seal, with the side with the spring facing inward. When reinstalling, if the end cover is more than 35 mm away from the inner end face of the coupling, a spare oil seal can be installed on the shaft on the outer side of the end cover. Once the oil seal fails, the damaged oil seal can be removed and the spare oil seal can be pushed into the end cover, thereby saving the time-consuming and laborious processes of disassembling the reducer and coupling.
2) Improvement of the shaft seal of the gearbox with a complete output shaft;
The output shaft of the gearbox with full shaft transmission has no coupling. If it is modified according to the 2.1 plan, the workload is too large and unrealistic. In order to reduce workload and simplify installation procedures, a detachable end cover was designed, and an attempt was made to open the oil seal. The outer side of the detachable end cover is machined into a groove. When installing the oil seal, the spring is first taken out, and the oil seal is sawn off into an open shape. The oil seal is then placed on the shaft from the opening, and the opening is docked with adhesive, facing upwards. Then, the spring is installed and the end cover is pushed in.
3、 Adopting new sealing materials; New sealing materials can be used to plug the leakage at the static sealing point of the gearbox. When the reducer is overhauled, D05 silicone rubber sealant is applied to the joint surface and end cover instead of 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, surface engineering technology's oil surface emergency repair agent can be used to stick and block, thus achieving the goal of eliminating oil leakage. Seriously implement the maintenance process; When repairing the gearbox, it is necessary to carefully follow the process regulations, such as oil
