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Jiangyin Deling Gearbox Co.,Ltd
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gearbox general guidance(1/2)
Jul 17, 2018

总则general guidance

安全须知:进行搬运,安装,操作,保养和检查时,必须由具有专业知识和技能的人员实施,否则有可能因为处置不当而引起人员受伤或设备破损。

Safety instructionfor handing, installation, operation, maintenance and inspection, must be carried out by the persons with specialized knowledge and skills, otherwise might cause personnel injury or equipment damage because of improper disposal.

通则:用户负责提供安全防护措施及设备的正确安装。安装齿轮箱之前,请阅读本手册。只有在严格遵守手册指导规则的条件下才能保证其工作特性,才能考虑有关保修及索赔。

General rules:Customer is responsible for providing the protective measures and installing the gearbox in the correct wayPlease read this manual before installing gearboxOnly under the condition of strictly abiding by the rules of manual instruction can ensure its working characteristics and maybe consider about the warranty and claim for compensation

 

1.1 装运条件:shipment conditions

1.1.1  齿轮箱应进行可靠的固定

The gear unit must be fastened tightly

1.1.2 采取防风,防雨,防潮措施

Anti-wind,anti-rain,and anti-moist protection must be adopted。

1.1.3 通常所有齿轮箱出厂时,均未加注润滑油。

Usually lubricating oil is not added for all the gearbox when delivery in factory

1.2收货检查:receiving inspection

1.2.1收到货物后首先确认收货单信息和订货信息是否相符,待信息确认无误后再拆卸货物及打开包装箱。

Confirm receipt information whether conform to the order.

1.2.2拆卸货物及打开包装箱时注意安全,拆卸货物时防止有异物掉落造成人员伤害事故,打开包装箱前请确认货物已放置稳妥,以防倾翻砸伤。

Take care when opening the packing. Prevent personnel injury due to unidentified object dropt

1.2.3不得拆卸铭牌。铭牌为本公司产品获取售后服务的必备条件,铭牌拆卸或丢失会给售后服务带来不便。

Do not remove the nameplate

1.3储存:storage

齿轮箱短期不使用时,应按以下注意事项进行保管:

The gear unit shall be kept in accordance with the following considerations:

1.3.1为避免损坏齿轮箱,齿轮箱不应存放在有剧烈震动的场所

Gearbox should not be stored in the places where violent vibration in order to avoid damage to the gear unit

1.3.2通常齿轮箱在室内存放期限不应超过一年,存放期间应将齿轮箱通气塞更换成密封保护塞。

Usually gearbox in indoor storage period should not be more than a yearand during storage gearbox air plug should be replaced into a sealing plug.

1.3.3外部防锈:产品出厂时安装接口裸露部分均已涂防锈油或防锈脂。出厂六个月应检查一次防锈状态,必要时再采取防锈措施。

External rust protectionthe gear unit has been painted with rust preventative oil before deliveryThe anti-rust status must be inspected in 6 months after deliveryit should be painted again if necessary

内部防锈:防锈期为六个月,储存条件:没有潮气,没有粉尘,温度变化不大,没有腐蚀性气体的环境,一般保管在工厂的室内或仓库内。

Internal rust protectionthe rust-proof life is 6 monthsStorage conditionno moistureno dustsmall temperature changeno corrosive gas environmentsuch as general warehousing indoor in the factory or warehouse

较长时间储存时应间隔一个月用手盘动输入轴一次,以保护轴承,如果出口产品需要使用出口防锈规格,应在订货说明中着重标出。

In a long storage periodin order to protect the bearingsturn the gear unit by hand at least once in every month.

1.3.4储存后的使用

油封受到温度和紫外线等的环境影响后容易老化,变质,所以经过长期保管后开始使用前,一定要进行检查,如果认为有老化变质时,应及时更换新品。

使用前要盘动齿轮箱,输入轴检查是否运转灵活无卡阻,无异响。带制动器时应确认制动器的动作是否正常。如果有异常,请及时与公司取得联系。

Affected by the temperature, ultraviolet radiation and other factors, the seals are easily aging and metamorphosing. Thus, before restart up the gear unit after long time storage, seals should be inspected, and should be changes in time if aging, deterioration be found.

When restarting up the gear unit, please check whether there is abnormal noise, vibration, or heating. If a brake is attached, please check it, and if there is any abnormal phenomenon, please contact us.

1.4使用环境environment conditions

1.4.1齿轮箱正常使用的环境温度为-10°C~50°C,环境湿度≤80%,超出正常范围时,请向本公司进行咨询。

Gearbox normal ambient temperture is -10°C~50°C,ambient humidity is ≤80% outside the normal range, please consult the company.

1.4.2工作环境应为没有灰尘的,换气良好的场所,无腐蚀性,爆炸性气体或蒸气等。

The working environment should be no dustand air exchange placeno corrosive gasexplosive gas or vapor

1.4.3齿轮箱输入转速一般不小于1500r/min;齿轮圆周速度不大于20m/s

Gearbox input speed is generally not more than 1500r/min;gears peripheral speed is not more than 20m/s.

 

安装installation

2.1 安装前检查的注意事项precautions for pre-installation check

2.1.1 成品的型号,规格是否正确

Whether the type and specification of product is correct

2.1.2零部件,附件及随机资料是否齐全

Whether the partsaccessories and attached documents are complete

2.1.3运输及存放过程中有无损伤,锈蚀

Whether there is damage or corrosion caused by transportation or storage

2.2 安装通则 installation general

2.2.1 传动装置周围不要放置可燃物,或堆放影响通风的障碍物,否则可能引起火灾

Do not place any combustible material or any combustibles near the driving device to affact the ventilation around the gear unitotherwisemay cause a fire

2.2.2检查传动装置或齿轮箱安装方式是否正确。齿轮箱有三种安装方式,上位机安装,中位机安装和下位机安装。

Inspect whether the installation position is correct, there are three installation position of gear unit:upside, middle and downside position.

2.2.3用通用溶剂仔细清除轴及法兰表面的防锈剂/防锈油。注意:溶剂不可进入油封的密封边缘上,溶剂会使油封损坏。

Carefully remove the anti-rust oil on the shaft and flange surface with common solventattentionsolvent is inaccessible to the oil seal's seling edge,otherwise may damage the seal.

2.2.4 对长期储存未用的齿轮箱,在启用时,应仔细检查齿轮是否生锈,相关外设零件是否完好,严格按产品铭牌所标示油号加油。

Before using the long-term stored gearbox you should carefully check whether the gears are rusty and related peripherals parts are intact. Please refuel the oil with the oil No. in strict accordance with the product nameplate marked.

2.2.5齿轮箱必须安装在刚性好,平整,无振动的坚固底座上。地脚安装时,可先用螺栓随意固定其中的三个地脚孔,通过调整第4个地脚孔定位平面垫片厚度,确保在安装完成后地脚平面与平台平面的平行度≤0.2mm

The gear unit must be installed on rigidflatno-vibration and solid baseAs mounting the foot margin the three foot holes can be arbitrarily fixed with bolts. Through adjusting the forth foot margin to fix the thickness of the gasket. After the installation, please ensure the degress of parallelism between the foot margin and platform is ≤0.2mm

2.2.6整个安装过程中,禁止用铁锤等敲击皮带轮,联轴器,链轮,机器轴,不得采用强力装拆螺杆机筒,避免损坏轴承,外壳,螺杆和其他零部件。

During the entire installation process, the use of hammers and other percussion pulleys, couplings, sprockets, machine shafts are prohibited, shall not use force when assembling screw and barrel. otherwiseit will damage the bearings, housing, screw and other components.

 

2.3找正 alignment

齿轮箱与主电机找正,齿轮箱与螺杆机筒的找正必须符合要求,良好的安装精度不仅可以提高设备的运行效率,还可以延长齿轮箱的使用寿命。采用下述的找正方法可以排除由输入,输出联轴器制造精度不高引起的误差累积。

The fixing of gear unit's input shaft and motor and the fixing of gear unit't output shaft and the rotors of the mixer, must accord with request of nether form. The idiographic fixing method sees nether drawing. Good installing accuracy can not only advance circulating efficacy, but also prolong service life of equipments. Adopting nether  drawing metheds can reduce cumulative error because of lower precision of input coupling and output coupling.

2.3.1齿轮箱与主电机找正 align the gear unit with the motor

齿轮箱与主电机相连接的输入轴在运转时必须与电机轴同心,为了满足这个需求,其轴向与径向跳动必须用专用测量装置来测量,具体如下图所示:

The shaft of which connects the gear unit and the main motor rotate should be concentric with the shaft of motor. For this requirement, the radial and axial run out should be measured with special measuring device. See the detail in the drawing as follows:

联轴器类型

径向跳动

轴向跳动(r=200

刚性联轴器

0.05

0.03

弹性联轴器

0.08

0.08

如需要r200mm,轴向跳动值可相应增大                                                 

2.3.2齿轮箱与螺杆机筒主机的安装与找正installation and alignment of the single screw extruder to the gear unit

与螺杆机筒主机连接前,先确定旋转方向。否则,会因旋转方向错误而引起机器损坏。安装齿轮箱时,不要对轴施加冲击力或过大的负荷,否则有可能会引起轴承或油封的损坏。齿轮箱与主机之间的安装工作必须正确细致,安装时必须检测输出轴与主机转子轴的同轴度,径向跳动小于0.15mm,端面跳动小于0.1mm。

Confirm the rotation direction before connecting to the single screw extruder.ohterwise, it may cause machine damage. Avoid bringing impact force of too much load to the shaft when installing the single screw extruder. Otherwise, it may cause broken of bearing or seal. Installing of the single screw extruder and gear unit must be correct and detailed. Using core rod to inspect the coaxiality of the positioning inner hole on the low speed hollow shaft and the step hole of the thrust bearing. The radial runout should be less than 0.15mm, while the surface runout should not exceed 0.1mm.

2.4安装步骤 steps to install

2.4.1在齿轮箱输入轴,输出轴端面上划出中垂线,打样冲眼。

Draw vertical lines on the surface of input and output shaft, then punch holes in the along axes.

2.4.2齿轮箱就位,保证齿轮箱输入轴,输出轴端面中垂线与基础轴中心线重合。

Place the gear unit, and make sure the vertical lines on the input and output shaft are coincident with the axial centering line of the foundation.

2.4.3在齿轮箱基准面上用水平仪校正水平,水平度允许误差为±0.04mm/m,找正可在箱体底面与基础面之间加垫块或斜铁调整,垫块在高度方向不得超过3块,垫块配置要避免引起箱体变形,应在地脚螺丝两侧对称排列。

Using gradienter emendates leveling on the level seat of gear unit, the leveling error should less than ±0.04mm/m. blocks or shims can be filled between bottom surface of the housing and foundation surface to help aligning. The number of blocks should not exceed three in height. Blocks should be lined symmetrically on both sides of the foundation bolts to avoid deformation of the housing.

2.4.4校正水平后,齿轮箱输入轴对电机轴,输出轴对螺杆机筒应严格对中,在轴向和径向两个方向的同轴度都必须满足要求。良好的轴向和径向对中,可使设备保持良好的性能和长久的机械寿命,齿轮箱和电机工作更加平稳,噪声小,功耗最小。

After aligningthe input shaft and the motor's shaft should be strictly centered, as same as the hollow shaft and screw bush. The axiality of both axial and radial directions must meet the designing requirments. Good aligning will make smooth running of equipment, and the power consumption will be less.

2.4.5拧紧全部地脚螺栓,在此过程中要保证齿轮箱不再移动。具体操作为将百分表固定在安装基础上,表头测量附件的齿轮箱座表面,拧紧地脚螺栓过程中观察百分表是否发生改变,如发生改变,说明基础不平或垫块没垫好,应重新校正。

Be sure there is no movement of the gearbox during fastening all foundation bolts. A dial indicator should be used during this process. First, fix a dial indicator on the installing foundation, then inspect whether the probe moves while fastening bolts, if it moves, that means the foundation is not plane enough or the blocks are not proper, and alignment should be carried out for another time.

2.4.6安装冷却水,联轴器防护罩等其他设备,按要求接好冷却水管路,保证水管在设备运行过程中不出现渗漏水,联轴器防护罩按有关标准现场安装。

Install the protective covers of lubrication station and coupling and other apparatuses. Connect pipes according to the demand on cooling water. Ensure the pipe doesn't appear leakage in the process of equipment operation. The protective cover of the coupling should be installed according to relevant standards in site.

 

2.4.7螺杆挤出机的工况比较复杂,可以在电气控制系统中设置可靠的电流过载保护,保证电机工作电流不超过额定电流,以保护齿轮箱部件不会因过载而损坏。

Screw extruder operating condition is complex reliable current overload protection can be set up in the electrical control system to ensure the motor current does not exceed the rated current and to protect the gear box and other parts will not be damaged due to overloaded.

 

启动与维护 operation and maintenance

3.1 润滑 lubrication

3.1.1 齿轮箱内的齿轮和轴承润滑,一般采用浸油润滑,飞溅润滑及强制润滑方式。

Gear and bearing lubrication generally use immersion oil lubrication, splash lubrication and forced lubrication.

3.1.2润滑油标准:当环境温度低于30°C时,使用中级压工业齿轮油ISO VG220(或L-CKC220);当环境温度高于30°C时,使用重极压工业齿轮油ISO VG320.

Lubrication criteriawhen the ambient temperature is below 30°Cuse extreme pressure industrial gear oil ISO VG220; when the ambient temperature is above 30°Cuse extreme pressure industrial gear oil ISO VG320.

3.1.3齿轮箱出厂时已将润滑油排出,所以运行前必须加入推荐的润滑油,并按照齿轮箱油位计中刻线上线位置加注润滑油。齿轮箱运转后,油位应经常检查,任何情况下,应保证油镜中有油可见。

The lubrication oil has been discharged from the gear unit before delivery, so recommended lube must be filled before operation, and the oil should be immitted until reach the middle scale line of the oil gauge. The oil level should be checked regularly, under any circumstances, should ensure that there is oil in the oil immersion visible.

3.2 换油 oil change

3.2.1 新齿轮箱使用500小时,应进行首次换油保养。以后每3000小时换油一次。或者当工作中发现油温大于75°C时必须停车检查,检修并更换新油。更换新油前应切断传动装置电源,防止无意间通电!润滑油应在齿轮箱停机后,杂质尚未沉淀时抓紧排放,但需防止润滑油烫伤危险!放油完毕后,箱体内需用同类型的油冲洗干净后加住新油,若因油粘度高不宜冲洗,可先加热或使用粘度相对较低的同类型润滑油冲洗。建议换油后对油路,过滤器进行清洗。加油时应使用过滤网或滤网。

New gearbox runs 500 hours, the first oil change should be carried out. After that, the oil change should be done once every 3000 hours. When oil temperature >75°C during running, must stop and check, repair and replace with new oil. Replace with new gear oil should be cut off the power firstly to prevent inadvertently energized! Gearbox oil should be let out immediately after shutting down the gearbox and in the condition of the oil sediment has not been settled. Pay attention to prevent the danger of scalding oil! After the oil being let out, cabinets need to use the same type of oil to rinse before filling the new oil. Due to the hige oil viscosity and cannot be rinse, then can be heated firstly or use same type of relativelt low viscosity lubricant to rinse.It is suggested to clean the oil piping and filters after charging oil. Filter or filter mesh should be used when fill in oil.

 

3.3通气 ventilation

所有齿轮箱均带有通气帽,以防止内部压力升高而损坏密封件。定期检查通气帽是否处于正常状态可以有效防止齿轮箱渗漏油。

The entire gearbox with a ventilation cap was to prevent the internal pressure rise damaging the seal. Regularly inspect the ventilation cap is in the normal state can effectively prevent the gearbox oil leakage.

 

3.4滤油器

3.4.1 当齿轮停止运行时,将普通过滤器盖子打开,把滤网拿出来,用煤油将滤网上的杂质清洗干净。若顾客选用TF型自封式吸油过滤器,将盖子拆下来取出滤网,用煤油将滤网上的杂质清洗干净即可。

When the gearbox stops running, open the ordinary filter lid, take out the filter, clean the impurities with kerosene in the filter. If customers choose TF-type self-styled oil filter, remove the red cover to take out the filter, clean the impurities on the filter with kerosene.

 

3.5 启动前准备 preparation before start-up

3.5.1检查安全控制和自动保护系统正常可靠

Check the security control and automatic protection system.

3.5.2检查油位是否正常,否则应补充至正常油位

Check the oil level, if the oil is less than required, refill to normal level.

3.5.3检查各仪器仪表,控制装置,开关等是否安装完毕,安装是否牢固可靠,能否正常工作,电器元件引出线绝缘情况是否良好

Check whether all the instrument & gauges, controlling apparatus and switches have been installed completely, and whether these devices have been assembled firmly and can realize normal functions. Check the insulation of outlet lines of electric components.

3.5.4检查各螺栓螺母等紧固件是否紧好

Check the fastness of all fastenings including bolts and nuts.

3.5.5检查旋转方向,尤其是安装了逆止器的齿轮箱的旋转方向,齿轮箱输出轴的旋转方向,除异向双螺杆外,一般为面向输出轴,顺时针运转。

Check the direction of rotation, especially, the gearbox direction of rotation with installation of the backstop, the rotating direction of the gearbox output shaft is generally facing the output shaft, clockwise operation.

3.5.6齿轮泵是否正常工作,齿轮泵的最低工作转速为300rpm。

Gear pump is working properly, the gear pump minimum operating speed is 300rpm.

3.5.7通过箱盖观察窗口观察齿轮,轴承供油是否正常,回油是否通畅,如有油管堵塞或喷嘴位置不对,应及时清洗管路或调整喷油角度,齿轮箱出厂前所有管路已经调整好,一般不需要再作调整。

Check the oil supply and oil return of gears and bearings through observation hole in the housing cover. If there is any oil pipe blocked or any oil nozzle misoriented, such pipes should be cleaned, and nozzle should be adjusted timely. Normally, all piping adjustmengt has been finished before the gear unit is delivered and no more adjustment is to be executed by the customer.

 

3.6 噪声 noise

强制润滑的齿轮箱都自带齿轮油泵,在开机初始阶段,可能会因粘度过高,齿轮泵吸油阻力加大而造成供油不足,发出过高的噪声。该现象一般在润滑油温度升高后,会自行消失。在正常运转中,如有出现齿轮泵噪声增高,一般情况下是油路阻力过大,请及时清洗滤油器及其他相关部件。如齿轮箱出现异常噪音,请立即停机,联系我们。

Forced lubrication gearbox is carrying gear pumps. On the initial stage of the running, it may has excessive noise maybe because of the oil viscosity is too high and the oil shortage caused by the increasing gear pump resistance. This phenomenon will automatically go away generally after the lubricating oil temperature increases. In the normal operation, if the gear pumps noise increasing, generally due to the oil resistance is too large. Clean the filter in time and other related components. Connect us if any abnormal noise appears.

3.7运转 running

本齿轮箱出厂前已经进行过空载试车,建议按以下步骤进行操作:

 

3.7.1 在任何情况下,齿轮箱应在空负荷状态下启动,严禁在加载状态下启动主电机。

3.7.2先让挤出机空负荷运行一小时,转速由低到高,升到额定转速15分钟后,再按20%,50%,80%载荷分别运行2,4,6小时后,再满负荷运行。

3.7.3试车过程中,应密切注意齿轮箱响声有无异常,振动是否过大,轴承温升是否异常等,出现上述异常情况时应立即停机并检查原因。故障排除后方可再次启动,原因不明时请与制造商联系。

3.7.4带负荷情况下,轴承温升最高不超过40°C,最高温度不超过80°C,润滑油温升不超过35°C,否则应立即停机。

 

3.8 冷却 cooling

3.8.1 为保证外置式冷却器正常工作,请用户必须使用软水,禁止使用氯离子含量高的沿海地下水,以免腐蚀冷却器;禁止直接使用地下硬质水源,以免管路结垢而导致冷却失效。

In order to ensure the normal operation of the external cooler, please make sure to use soft water. Prohibiting using coastal groundwater with chlorine ion directly, in order to avoid corrosion of cooler. Prohibiting using underground hard water directly to avoid cooling failure caused by pipe scaling.

 

3.9维护 maintenance

3.9.1首次运行48小时后,所有管件及紧固件做一次检查,看是否松动,并重新检查轴线队中情况,以后定期检查。

48 hours after the first start-up, all piping and fastening pieces should be checked for loosening. Alignment of axes should also be inspected. Such check and inspection should be repeated regularly.

3.9.2首次启动一周后,对过滤器的滤芯进行清洗,以后每月定期清洗一次,齿轮箱上的通气罩半年清洗一次,齿轮箱上的通气罩半年清洗一次。

Clean the filter elements inside filters one week after the first start-up. Clean them every month in future operation. Clean the vent covers on the gear unit every 6 months.

3.9.3推荐做的例行检查:

每日:检查是否漏油,有无异常振动,噪声,进回油温度及轴承温度

每周:检查过滤器是否清洁,是否堵塞

每月:检查螺栓是否松动,观察油位高度,发现不足及时补充,检查仪表工作情况

每六个月:对油质进行化验分析。如油质合格,建议将油从齿轮箱中排出,进行沉淀过滤后,重新使用;如油质已变坏,建议将油排出,并对油路系统进行清洗,注入新油。

Regular inspections are recommended as follows:

Every day: check for oil leakage, abnormal vibration, noise, inlet & outlet oil temperature and bearing temperatures.

Every week: check whether the oil filter are clean and unblocked.

Every month: check whether the ground bolts loosen, verify the oil level and refill oil when it is too low; inspect the working conditions of all instruments and gauges.

Every six months: chemical analysis for oil quality. If the oil is still up to the standard, it is suggested to discharge it from the gear unit for depositing and filtering before being reused. If the oil has deteriorated, it is suggested to discharge the oil, clean the piping system and fill with new one.


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