To judge whether the oil pool depth of the QJS-D200-100-II gear reducer is appropriate, the core focus is on the three cores of 'lubrication effectiveness, operating state stability, and no abnormal loss'. Combined with practical methods such as oil level observation, working condition matching, and operating parameter monitoring, the following are 8 judgment criteria that can be directly implemented (in order of priority):
1. Observe the oil window/oil level gauge benchmark: After the equipment is shut down and cooled to room temperature, the oil level should be located at ±5mm from the center line of the oil window (or 2/3 of the oil level gauge scale), and meet the gear oil immersion depth of 1-2 tooth heights (the tooth height of this model of large gear is about 25-30mm, corresponding to the oil immersion depth of 25-60mm); if it is lower than the lower limit of the oil window (oil immersion <1 tooth height), it is too shallow, and if it is higher than the upper limit (oil immersion>2 teeth) tooth height) is too deep.
2. Monitor whether the operating noise is normal: During normal operation, the noise value should be ≤85dB (no load)/≤90dB (heavy load), and there should be no obvious 'friction sound' or 'buzzing sound'; if there is abnormal meshing noise (dry friction sound) or high-frequency rustling sound of the bearing, it is mostly because the oil pool is too shallow (insufficient lubrication); if there is low-frequency oil churning noise (continuous buzzing sound), it is mostly because the oil pool is too deep (oil churning resistance is too large).
3. Check whether the oil temperature rise is reasonable: after 1 hour of operation, the oil temperature should be ≤80°C, and the temperature rise (oil temperature - ambient temperature) ≤40°C; when the oil pool is too shallow, the oil volume is small, and the temperature rise can easily exceed 50°C (oil temperature >90°C); when the oil pool is too deep, stirring the oil will generate a lot of heat, and the oil temperature will also rise abnormally (>85°C), and heat dissipation is slow.
4. Observe the oil status and loss: Normal oil should be clear and free of foam and impurities, and the oil level will drop by ≤5% after one month of operation; when the oil pool is too shallow, the oil is prone to accelerated oxidation (blackening, sludge appears) due to insufficient lubrication, and metal shavings generated by wear of bearings and gears are easily stirred up (oil turbidity); when the oil pool is too deep, the oil is prone to produce a large amount of foam (excessive oil stirring), and the seal is prone to leakage due to excessive pressure.
5. Verify the effectiveness of lubrication coverage: After shutdown, remove the observation hole cover and check the gear meshing surface and the inside of the bearing end cover. They should be covered by a uniform oil film without dry friction marks. If the tooth surface is partially dry and the bearing raceway has no oil traces, it means the oil pool is too shallow (insufficient splash lubrication); if there is a large amount of sludge attached to the gear end face and box wall (oxidation caused by excessive oil stirring), it means the oil pool is too deep.
6. Compare the stability under load changes: During heavy-load operation (rated load 80%-100%), if the vibration amplitude suddenly increases (>0.2mm/s RMS) and the noise rises significantly, and after excluding gear wear and installation deviation, it is mostly because the oil pool is too shallow (the oil film bearing capacity is insufficient); if low-frequency vibration and noise occur under light load, and are positively related to the speed, it is mostly because the oil pool is too deep (oil stirring resistance causes vibration).
7. Refer to the manufacturer's design basis: Check the manual of this type of reducer. The design value of the oil pool depth is usually '15-30mm below the center line of the large gear' (corresponding to 1-2 tooth heights of oil immersion). If the actual oil level deviates from the design value by more than ±10mm, the oil pool depth needs to be adjusted (by oil draining or oil replenishment calibration).
8. Check the adaptability under abnormal working conditions: If the equipment starts and stops frequently and the impact load is large, the oil pool depth can be slightly higher than the benchmark (but no more than 2 tooth heights) to avoid instantaneous lubrication shortage; if the equipment runs at high speed (input speed > 1500r/min), the oil pool depth can be slightly lower than the benchmark (0.7-1 tooth height) to reduce oil churning noise and power consumption; if high oil temperature and loud noise still occur after adjustment, it means that the oil pool depth does not match the working conditions and needs further optimization.
