The K67AM112-15.19-2.2KW gear reducer adopts a splash lubrication system. The determination of the lubrication cycle (oil change cycle) requires a comprehensive judgment based on three core factors: equipment design parameters, operating conditions, and lubricating oil performance. The core logic is to maintain the lubrication, heat dissipation, and cleaning capabilities of the lubricating oil through periodic oil changes, and avoid gear and bearing wear failures caused by oil deterioration and failure. The specific basis and method for determination are as follows:
1. Basic cycle based on equipment design parameters
The basic oil change cycle of this type of reducer can refer to the recommended value in the manufacturer's factory manual. Its design parameters determine the lubrication requirements under basic working conditions:
1. Power and speed characteristics: This model has a power of 2.2kW and a transmission ratio of 15.19. It is a small to medium power, medium and low speed reducer with small gear meshing impact and relatively slow lubricating oil degradation. Under ** rated operating conditions (full load, continuous operation ≤8h/day, ambient temperature - 10℃~40℃)**, the first oil change interval is 500 hours of operation. The purpose is to discharge the metal wear debris generated during the running-in period of the reducer and avoid the continuous circulation of impurities to aggravate wear; the conventional oil change interval after normal operation is 2000~3000 hours, or on an annual basis (whichever comes first).
2. Characteristics of the lubrication system: splash lubrication relies on oil storage and circulation in the oil pool and does not have a forced filtration device. The accumulation of impurities in the oil is faster than that of the forced lubrication system. Therefore, the oil change cycle must be shorter than that of a forced lubrication reducer of the same power to prevent impurities from causing tooth surface pitting and bearing raceway wear.
2. Periodic correction based on actual operating conditions
The basic cycle is only applicable to ideal working conditions. In actual use, the cycle needs to be adjusted according to the working conditions. The worse the working conditions, the shorter the oil change cycle needs to be. The specific correction conditions are as follows:
1. Correction of load and running time
If the reducer is overloaded for a long time (the load exceeds 110% of the rated value), the gear meshing pressure will increase, the oil film will easily break, the lubricating oil will oxidize faster, and the oil change cycle will need to be shortened by 30% to 50%;
If the equipment operates continuously for 24 hours, the lubricating oil will continue to be in a high-temperature working state and the degradation rate will double. The regular oil change cycle needs to be shortened to 1500~2000 hours;
If the equipment operates intermittently (operating ≤ 4 hours per day) and starts and stops frequently, the gears and bearings will bear impact loads, and the lubricating oil will easily mix with air to produce foam, so the oil change cycle needs to be shortened by about 20%.
2. Correction of ambient temperature and installation conditions
If the operating ambient temperature is higher than 40°C for a long time, the viscosity of the lubricating oil will decrease and oxidation and deterioration will be accelerated. For every 10°C increase, the oil change cycle will be shortened by about 50%; if the ambient temperature is lower than -10°C, the fluidity of the lubricant will become poor, and low-temperature gear oil needs to be replaced, while the oil change cycle will be shortened by 10% to 20%;
If this type of reducer is installed non-horizontally (such as vertical or tilted installation), the oil circulation efficiency of splash lubrication will be reduced, the amount of oil carried by the gear will be unstable, the local deterioration of the lubricating oil will be accelerated, and the oil change cycle will need to be shortened by 20% to 30%.
3. Correction of working condition cleanliness
If there is a lot of dust and impurities in the operating environment of the equipment, or the aging of the seals causes external impurities to invade the oil pool, the lubricating oil will be quickly contaminated and needs to be replaced in advance;
If the reducer is used in a humid and corrosive gas environment, the lubricating oil will easily absorb water, emulsify, and be contaminated by corrosive media, so the oil change interval needs to be shortened to 1000~1500 hours.
