监测变速箱油的提示

"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?"

 

“监测变速箱润滑油的主要参数是什么？我们的工厂有一个非常低速的变速箱，我们想监测它的状况，以检测故障症状。密封失效与润滑油之间是否有任何关系，例如油的酸值或磨损碎片的增加？“

 

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.

 

与其他机械部件一样，油分析可以帮助齿轮系统驱动可靠性和正常工作时间。这种预测维护技术是几种可用的工具之一，可以帮助识别何时开始发生与故障相关的症状。当你监测齿轮相关润滑剂的状况时，必须确保它们保持适当的粘度、足够的膜强度、腐蚀控制、去湿性和化学稳定性特性。

 

Gearbox Oil Analysis Parameters

变速箱油分析参数

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.

 

虽然确定要执行哪些油分析测试似乎是压倒性的，但有关这一主题的信息通常可以通过联系您的油分析实验室、审查在线参考来源和参加特定技术的培训来获得。

 

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.

 

对于变速箱，标准测试板岩应包括粘度、水分、元素分析、颗粒计数、亚铁密度、氧化和/或酸值。当怀疑油或机器故障进展时进行的异常测试将涉及分析铁谱、极端压力测试和傅里叶变换红外光谱(FTIR)的油特性。准确的测试可能会根据齿轮传动和润滑方法的类型而有所不同，但大多数应用都将密切相关。

 

Seal Concerns

密封问题

 

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.

 

机械密封通常是部件或系统的组成部分。如果在对系统进行更改时不考虑它们，则可能发生泄漏、故障或停机。

 

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.

 

来自外部和内部来源的污染是密封的一个重要问题。在您的油分析报告中，与污染趋势相关的参数之一是粒子计数号和ISO清洁度代码。如果您的样品结果随着颗粒计数的不断增加和黑色金属材料的低水平而返回，这可能导致密封损坏。

 

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.

 

粘度是任何润滑剂的关键特性，但变速箱密封往往忽略了它。这个参数是重要的，因为油必须足够厚，以保持适当的薄膜厚度之间的两个表面，但足够薄，以流动之间的配合齿轮齿表面。如果粘度超出规定的范围，可能会因齿轮磨损而产生内部污染。如上所述，这种类型的污染可能导致密封降解。

 

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.

 

请记住，表面粗糙度、齿轮几何形状和配合表面材料也将在密封件的寿命中发挥作用。然而，这些约束比维持润滑剂的限制更难操纵。

 

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.

 

虽然兼容性通常只是切换润滑剂时的一个问题，但它是密封寿命的另一个问题。改变基础油从矿物到合成，同时改变组成润滑剂的添加剂包装，可以对密封件产生显著的影响。在更换润滑剂时，不仅要考虑两种润滑剂之间的相容性，而且要考虑新润滑剂如何与密封材料反应。当密封和润滑剂在粘合环境中不起作用时，膨胀、侵蚀、起泡、解聚和过度磨损都是可能的失效机制。

 

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，虽然在技术上不是油分析测试参数，但温度是密封的另一个关键方面。随着油温度的开始升高，它不仅严重影响油的寿命，而且影响密封老化。虽然温度是几乎所有部件的一个因素，但由于最小的内摩擦和搅拌，它在低速变速箱中并不是那么关键。