How to solve the problem of poor adaptability of the K97-27.9-15KW reducer splash lubrication system to the installation posture and working conditions

The K97-27.9-15KW reducer is a 15kW medium-to-high-power, hard-tooth surface model with a transmission ratio of 27.9. The sensitivity of the splash lubrication system to the installation posture and working conditions is rooted in the passive structure in which lubrication relies on gear oil. According to the parameter characteristics of this model, the adaptability of the system can be improved through three types of measures: installation optimization, lubrication system modification, and working condition adaptation and adjustment. The specific plans are as follows:

1. Adaptation optimization scheme for installation attitude deviation

The splash lubrication of this model of reducer is adapted to horizontal installation by default. If non-standard installation such as tilting or vertical is required, the oil level and oil guide structure must be adjusted to ensure the gear oil and bearing lubrication effect.

1. Accurately check the oil level of non-horizontal installations

(1) If inclined installation is adopted (inclination angle ≤ 15°): the immersion depth of the low-speed large gear in the oil needs to be recalculated to ensure that the immersion depth of the tooth root is still 1/3~1/2 of the tooth height. An auxiliary oil level gauge can be added to the side of the box to calibrate the oil level based on the actual installation posture to avoid insufficient oil due to the oil being deflected to one side.

(2) If vertical installation is adopted: the original horizontally installed oil pool structure cannot meet the oil-carrying demand, and the box needs to be partially modified - an annular oil groove is added below the rotation track of the low-speed gear, and the oil groove is connected to the bearing seat through an oil pipe to ensure that the oil brought up by the gear can flow to the bearing through the oil groove; at the same time, the oil level is adjusted to the effective oil-carrying position of the large gear in the vertical state to prevent oil from accumulating at the bottom of the box and unable to be brought up.

2. Install oil guide and oil collecting parts

An oil guide plate is welded on the inner wall of the box to guide the splashed oil to flow directionally to the high-speed gear meshing area and bearing seat, solving the problem of uneven oil distribution during non-horizontal installation.

An oil collection tank is added above the bearing seat to collect the oil flowing back from the inner wall and accurately inject it into the bearing raceway through the oil hole to make up for the defect of 'indiscriminate oil distribution' of splash lubrication.

3. Leveling and fixing before installation

Even if it is installed horizontally, a level must be used to calibrate the level of the reducer base (error ≤0.1mm/m), and the installation tilt can be eliminated by adjusting the anchor bolt spacers; at the same time, the connection between the base and the foundation should be strengthened to avoid box displacement due to vibration during operation and damage to the oil level balance.

2. Adaptable improvement plans for harsh working conditions

The characteristics of this model with 15kW power and 27.9 transmission ratio determine that it may withstand medium to high loads. Lubrication enhancement measures are required to solve the shortcomings of splash lubrication under heavy load, impact, high temperature and other working conditions.

1. Lubrication enhancement transformation under heavy load/impact conditions

Upgrade lubricants: replace conventional industrial gear oil (L-CKC) with extreme pressure industrial gear oil (L-CKD), which contains sulfur-phosphorus extreme pressure additives that can form a high-strength oil film under high load to prevent tooth surface agglomeration and pitting corrosion; choose No. 220 or No. 320 oil viscosity to improve the oil film's carrying capacity.

Adding an auxiliary lubrication device: For long-term heavy-load operation scenarios, an intermittent manual lubrication pump can be installed to regularly replenish lubricating oil to the high-speed gear meshing area and bearing seat to make up for the lack of splash lubrication oil supply; if the working conditions permit, it can be transformed into a semi-forced splash lubrication system - add an oil scraper in the oil pool to scrape the oil to the oil guide groove and forcefully transport it to key lubrication points.

2. Protective measures for high temperature/dust environment

Adaptation to high-temperature environments: If the operating ambient temperature is higher than 40°C for a long time, a heat sink or a small air-cooling fan needs to be installed outside the box to lower the oil temperature and slow down the oxidation and deterioration rate of the lubricating oil; at the same time, the oil change cycle is shortened by 30% to 50%, and the oil viscosity and acid value are regularly tested.

Dust/humid environment protection: Replace the ordinary breathable plug on the top of the box with a waterproof and dustproof breathable cap to prevent external dust and water vapor from intruding into the oil pool; install a magnetic oil-absorbing plug at the oil drain plug to absorb metal grinding debris in the oil and reduce impurity circulation wear; for humid environments, an anti-emulsifier can be added to the oil to prevent the oil from absorbing water and emulsifying.