水泥厂回转窑开式齿轮润滑改良，优润团队现场服务
the improved solution of rotary kiln open gear in cement plant on-site service provided by u.lube team
开式齿轮是原材料加工工业中常见的传动元件，广泛应用于水泥、电力、矿山、钢铁、化工、造纸等行业的大型设备，如：回转窑、球磨机、管磨机、棒磨机、干燥机、造粒机、鼓式碎浆机等。要保证开式齿轮获得良好的承载能力和平稳传动，齿轮的正确加工制造、传动装置的精确找正〔端跳、径跳、齿顶隙、齿侧隙等）、正确地实施初始、磨合和操作润滑体系的一系列工作程序，选用合适的高黏附性的润滑剂以及合理的润滑方式等都是缺一不可的因素。
open gears are common transmission components in the raw material processing industry and are widely used in large equipments in cement, electric power, mining, steel, chemical and paper industries, such as: rotary kilns, ball mills, tube mills, rod mills, dryers, granulators, drum pulpers, etc. to ensure the open gears to obtain good load-bearing capacity and smooth transmission, the proper processing and manufacturing of gears, accurate alignment (end jump, diameter jump, tooth top gap, tooth side gap, etc.) of the transmission devices, the correct implementation of the initial, grinding and operation of a series of lubrication system work procedures, choosing appropriate lubricants with high consistency and suitable lubrication methods, etc. are indispensable factors.
前段时间，优润团队去某水泥厂服务，对该厂回转窑进行现场考察、开式齿轮齿面检查分析发现磨损擦伤严重，现场也存在大量油品泄漏等问题。针对这些问题，根据以往资料数据及现场测量到的数据，结合以往同类设备润滑改良的成熟经验，优润团队经过共同分析和讨论后提出一些改良建议。
a few days ago,u.lube team provided the on-site service for a cement plant, and found that the rotary kiln had serious wear and abrasion, and there were also serious leakage problems on site. in view of these problems, according to the previous and current data on site, combined with the mature experience of similar equipment lubrication improvement solutions in the past, u.lube team provided improvement solutions after joint analysis and discussion.
目前回转窑开式齿轮使用的润滑剂某牌系列开齿油品，润滑方式采用油池润滑方式，齿面目前磨损擦伤严重，现场也存在大量油品泄漏。
customer previously used an open gear lubricant of a brand on their rotary kiln open gears, and applied oil pool lubrication method, however, there was serious wear and abrasion on tooth surface, the site also existed serious oil leakage.
从回转窑窑齿轮相片可看出，由于油池受到污染以及原用油品的性能不足，造成了齿面的严重擦伤和杂质压痕。需要对润滑方式进行更改，建议使用喷洒小齿的方式，并使用性能符合大型开式齿轮润滑规范的粘附性流体脂进行润滑。
from the photos, contamination of the oil pool and inadequate performance of the original oil used caused severe scrapes and indentation of impurities on the tooth surfaces. a change in the lubrication method was required, and it was recommended to use spray lubrication method on pinion and applied the adhesive fluid grease whose performance met the lubrication specifications for large open gears.
由于开式齿轮与闭式齿轮的运行条件相比，属于低速重载的工作条件，密封程度较差，容易受到外界污染物的影响以及容易产生泄漏问题。如果润滑方式不好或者使用的润滑剂不合适，大、小齿轮啮合面由于受高温、重载及冲击负荷的影响，油膜容易破裂，齿面易产生点蚀甚至凹坑，齿轮的使用寿命将大大缩短。
compared with the closed gear, open gear’s working conditions is low speed, heavy loading, and poor sealing, which easy to be affected by external pollutants and easy to cause leakage problems. if choosing a wrong lubrication method or lubricant, the matching surfaces between gear and pinion is affected by high temperature, heavy load and impact load, and the oil film is easy to rupture. the tooth surface is easy to produce pitting and even craters, and the service life of the gear will be greatly reduced.
因此，选择开式齿轮的正确润滑和合理的润滑方式，不仅能提高齿轮的承载能力、减少齿轮运转时产生的噪音、延长设备的使用寿命，而且能提高生产效率、节能降耗，降低生产成本。
therefore, the selection of the correct lubrication and reasonable lubrication method of open gears can not only improve the load capacity of gears, reduce the running noise generated by gear, extend the service life of equipment, but also improve production efficiency, energy saving and reduce production costs.
根据回转窑的运行特点，以及目前齿面的状况，优润团队建议使用开式齿轮专用磨合润滑剂 如优润et g-og系列，对齿轮进行磨合处理。通过磨合润滑操作，可有效地降低齿面的粗糙度，改善齿面的质量，增加齿面啮合/接触面积，均匀载荷在齿面的分布，提高齿面承载能；其次，可有效地消除原来损伤形成的尖锐的边缘，消除表面疲劳裂纹，防止疲劳性裂纹的扩展。良好的齿面状况以及接触状况是获得良好的润滑效果的第一步。
according to the operating characteristics of rotary kiln and the current condition of tooth surface, u.lubeteam recommended to choose a special running-in lubricant for open gears such as u.lube et g-og series. through running-in operation, it can effectively reduce the roughness of tooth surface, improve the quality of tooth surface, increase the tooth surface meshing/contact area, evenly distribute the load on the tooth surface, and improve its bearing capacity; secondly, it can effectively remove the sharp edges formed by the previous damage, remove the surface fatigue cracks, and prevent the expansion of fatigue cracks. a healthy tooth surface condition and contact condition are key factors to obtain good lubrication effect.
同时，为了减轻润滑油品的损耗、保证设备的安全稳定的运转，减少油品泄露，建议改用自动喷洒集中润滑系统如威润玛vmaxx开式齿轮自动润滑系统，对开式齿轮进行润滑。采用喷洒方式润滑开式齿轮，具有现场卫生、油品消耗量易控制、避免齿面因污染杂质颗粒造成损伤、齿面油膜稳定等诸多好处。
at the same time, in order to reduce the consumption of lubricant, ensure the safe and stable operation of the equipment, and reduce leakage, it is recommended to choose an automatic spraying centralized lubrication system such as vmaxx open gear automatic lubrication system for open gears. using this spraying method has many benefits such as tidy workplace, easy control of consumption, avoiding damage to tooth surface caused by contaminated impurity particles, and stable oil film on tooth surface, etc.
▲开放式齿轮常用润滑方式的比较
▲comparison of common lubrication methods for open gears
▲威润玛开式齿轮自动喷洒集中润滑系统喷嘴组件&优润团队热成像仪温度检测
▲nozzle assembly of vmaxx open gear automatic spraying centralized lubrication system u.lube team use thermal imager to detect equipment’s temperature