"What are the main parameters for monitoring gearbox lube oil? Our plant has a very low-speed gearbox, and we want to monitor its condition to detect failure symptoms. Is there any relation between a seal failure and the lube oil, such as an increase in the oil’s acid number or wear debris?"

 

“監(jiān)測變速箱潤滑油的主要參數(shù)是什么？我們的工廠有一個非常低速的變速箱，我們想監(jiān)測它的狀況，以檢測故障癥狀。密封失效與潤滑油之間是否有任何關(guān)系，例如油的酸值或磨損碎片的增加？“

 

Just as with other mechanical components, oil analysis can help drive reliability and uptime in gear systems. This predictive maintenance technology is one of several available tools that can aid in identifying when failure-related symptoms begin to occur. When you monitor the condition of gear-related lubricants, it will be imperative to ensure they maintain the proper viscosity, sufficient film strength, corrosion control, demulsibility and chemical stability characteristics.

 

與其他機械部件一樣，油分析可以幫助齒輪系統(tǒng)驅(qū)動可靠性和正常工作時間。這種預(yù)測維護技術(shù)是幾種可用的工具之一，可以幫助識別何時開始發(fā)生與故障相關(guān)的癥狀。當(dāng)你監(jiān)測齒輪相關(guān)潤滑劑的狀況時，必須確保它們保持適當(dāng)?shù)恼扯取⒆銐虻哪�強度、腐蝕控制、去濕性和化學(xué)穩(wěn)定性特性。

 

Gearbox Oil Analysis Parameters

變速箱油分析參數(shù)

While it may seem overwhelming to identify which oil analysis tests to perform, information on this subject can often be obtained by contacting your oil analysis lab, reviewing online reference sources and participating in technology-specific training.

 

雖然確定要執(zhí)行哪些油分析測試似乎是壓倒性的，但有關(guān)這一主題的信息通�？梢酝ㄟ^聯(lián)系您的油分析實驗室、審查在線參考來源和參加特定技術(shù)的培訓(xùn)來獲得。

 

For gearboxes, the standard test slate should include viscosity, moisture, elemental analysis, particle count, ferrous density, oxidation and/or acid number. Exception tests to perform when an oil or machine failure progression is suspected would involve analytical ferrography, extreme-pressure tests and oil characterization by Fourier-transform infrared (FTIR) spectroscopy. The exact tests may vary based on the type of gear drive and lubrication method, but most applications will be closely related.

 

對于變速箱，標(biāo)準(zhǔn)測試板巖應(yīng)包括粘度、水分、元素分析、顆粒計數(shù)、亞鐵密度、氧化和/或酸值。當(dāng)懷疑油或機器故障進展時進行的異常測試將涉及分析鐵譜、極端壓力測試和傅里葉變換紅外光譜(FTIR)的油特性。準(zhǔn)確的測試可能會根據(jù)齒輪傳動和潤滑方法的類型而有所不同，但大多數(shù)應(yīng)用都將密切相關(guān)。

 

Seal Concerns

密封問題

 

Mechanical seals are often integral parts of a component or system. If they are not considered when changes are made to the system, leaks, failure or downtime may occur.

 

機械密封通常是部件或系統(tǒng)的組成部分。如果在對系統(tǒng)進行更改時不考慮它們，則可能發(fā)生泄漏、故障或停機。

 

Contamination, both from external and internal sources, is a significant issue with seals. Among the parameters associated with contamination to trend in your oil analysis reports would be the particle count number and the ISO cleanliness code. If your sample results return with continual increases in the particle count and low levels of ferrous material, this may lead to seal damage.

 

來自外部和內(nèi)部來源的污染是密封的一個重要問題。在您的油分析報告中，與污染趨勢相關(guān)的參數(shù)之一是粒子計數(shù)號和ISO清潔度代碼。如果您的樣品結(jié)果隨著顆粒計數(shù)的不斷增加和黑色金屬材料的低水平而返回，這可能導(dǎo)致密封損壞。

 

Viscosity is a critical property of any lubricant, yet it often is overlooked with gearbox seals. This parameter is important because the oil must be thick enough to maintain the proper film thickness between the two surfaces but thin enough to flow between the mating gear tooth surfaces. If the viscosity falls out of the specified range, internal contamination due to gear wear is likely. As noted above, this type of contamination can result in seal degradation.

 

粘度是任何潤滑劑的關(guān)鍵特性，但變速箱密封往往忽略了它。這個參數(shù)是重要的，因為油必須足夠厚，以保持適當(dāng)?shù)谋∧ず穸戎�間的兩個表面，但足夠薄，以流動之間的配合齒輪齒表面。如果粘度超出規(guī)定的范圍，可能會因齒輪磨損而產(chǎn)生內(nèi)部污染。如上所述，這種類型的污染可能導(dǎo)致密封降解。

 

Keep in mind that surface roughness, gear geometry and mating surface materials will also play a role in the life of the seals. However, these constraints are more difficult to manipulate than sustaining lubricant limits.

 

請記住，表面粗糙度、齒輪幾何形狀和配合表面材料也將在密封件的壽命中發(fā)揮作用。然而，這些約束比維持潤滑劑的限制更難操縱。

 

Although compatibility typically is only an issue when switching lubricants, it is another concern for seal life. Changing the base oil from mineral to synthetic while altering the additive packages that make up the lubricant can have a dramatic effect on the seals. When changing lubricants, consider not only the compatibility between the two lubricants but also how the new lubricant will react with the seal material. Swelling, erosion, blistering, depolymerization and excessive wear are all possible failure mechanisms when seals and lubricants do not function in a cohesive environment.

 

雖然兼容性通常只是切換潤滑劑時的一個問題，但它是密封壽命的另一個問題。改變基礎(chǔ)油從礦物到合成，同時改變組成潤滑劑的添加劑包裝，可以對密封件產(chǎn)生顯著的影響。在更換潤滑劑時，不僅要考慮兩種潤滑劑之間的相容性，而且要考慮新潤滑劑如何與密封材料反應(yīng)。當(dāng)密封和潤滑劑在粘合環(huán)境中不起作用時，膨脹、侵蝕、起泡、解聚和過度磨損都是可能的失效機制。

 

Finally, while not technically an oil analysis test parameter, temperature is another key aspect to account for with seals. As an oil’s temperature begins to rise, it not only drastically affects the life of the oil but also impacts seal aging. Although temperature is a factor with almost all components, it is not quite as critical in low-speed gearboxes due to the minimized internal friction and churning.

 

最后，雖然在技術(shù)上不是油分析測試參數(shù)，但溫度是密封的另一個關(guān)鍵方面。隨著油溫度的開始升高，它不僅嚴(yán)重影響油的壽命，而且影響密封老化。雖然溫度是幾乎所有部件的一個因素，但由于最小的內(nèi)摩擦和攪拌，它在低速變速箱中并不是那么關(guān)鍵。