Outline
This product is an external meshing involute helical cylindrical gear reducer produced according to the national standard JB/T88853-2001. The product has been optimized and designed to meet the international level of the XNUMXs.
This product is widely used in metallurgy, mining, lifting, transportation, cement, construction, chemicals, textiles, printing and dyeing, pharmaceuticals, etc.
The scope of application of the reducer is as follows:
1.The speed of the high-speed shaft is not more than 1500 rpm.
2 Gear drive peripheral speed is not greater than20 meter/second.
3.Working environment temperature is -40-45 ℃.If it is lower than O℃, the lubricating oil should be preheated to above O℃ before starting. This reducer can be used for forward and reverse rotation.
<XNUMX> Features:
1．减速比范围宽：公称速比单级为1.25-5.6、双级为6.3-20、三级为22.4-100。
2.High mechanical transmission efficiency: single-stage greater than 96.5%, double-stage greater than 93%, and three-stage greater than 90%.
3.Smooth operation and low noise.
4Small size, light weight, long service life and high carrying capacity.
5.Easy to disassemble and inspect, easy to install
<XNUMX> Reducer model, specification and representation method
1 Models are: ZDY single-stage cylindrical gear reducer, ZLY two-stage cylindrical gear reducer, ZSY three-stage cylindrical gear reducer
2.Specifications are:
单级；80、100、125、160、200、250、280、315、355、400、450、500、560；
两级；112.125.140、160、180、200、224、250、280、315、355、400、450、500、560、630、710；
三级：160、180、200、224、250、280、315、355、400、450、500、560、630, 710.
IS: When a backstop is required
11.2: When facing the output, the output shaft rotates clockwise to S and counterclockwise to N
560: Assembly Type I
Y: The nominal transmission ratio is 11.2
L: The center distance of the low-speed stage is560 mm
Z: Two-stage transmission cylindrical gear reducer
*D means single-stage, L means two-stage, S means three-stage, Y means hard-toothed gear
Note: When the user wears a backstop, if a long shaft series is required, please specify when ordering.If the order is not specified, it is deemed to be manufactured according to the standard (sample).
<XNUMX> Outline and installation dimensions
1. ZDY type cylindrical gear reducer
2. ZLY cylindrical gear reducer
3. ZSY cylindrical gear reducer
<XNUMX> Carrying capacity of reducer
A.Mechanical power of cylindrical gear reducer
1.ZDY reducer power P1
B. Thermal power
1.ZDY reducer Pg1Pg2
2.ZLY reducer Pg1Pg2
3.ZSY reducer Pg1Pg2
Note: When using circulating oil lubrication, Pg2 can be appropriately increased according to the calculation of the lubrication system, and circulating oil lubrication is recommended
<XNUMX> Selection of reducer
The load-bearing capacity of this reducer is limited by the mechanical strength and thermal balance allowable power, so the selection of the reducer must pass two power meters.First, select according to the allowable nominal power P1 of the reducer's mechanical strength.If the relative error between the actual input speed of the reducer and the speed of the three gears (1500, 1000, 750) in the load capacity table does not exceed 4%, a reducer of equivalent specifications can be selected according to the nominal power of the gear speed. .If the relative error of the speed exceeds 4%, the nominal power of the reducer should be converted according to the actual speed, and then the allowable power of the reducer's thermal balance should be checked.
1.Power selection
a) Rated power of reducer P.The size should be able to meet the requirements of the working machine to work smoothly for more than 10 hours a day and start five times per hour, and the allowable starting torque
Twice the working torque.If it does not meet one of the above requirements, it is necessary to use the working condition coefficient KA to correct it.
b) Safety factor of reducer
Suppose the working condition factor is KA and the safety factor is SA, then the required power is P2m=P2XKAXSA (P2 is the rated power of the working machine) The power of the selected reducer must meet P2m≤PJ (See Table 1, Table 4, Table 5 for P6)
2 Thermal rating
The thermal rating is to check whether the power PG is exceeded. If the transmission power exceeds, an additional cooling device is required.
What kind of additional cooling device can meet the requirements must be checked.
If the required output power P2 (without considering KA) exceeds the thermal power PG, another cooling method must be adopted.
The thermal power meter listed in the sample (table 7, table 8, table 9) is suitable for ambient temperature20 ℃And the hourly load rate is 100%, when the ambient temperature and load rate are not
When the above conditions are met, it is necessary to use the environmental factor fi load factor f2 and power utilization factor f3 to modify.
P1--nominal power p2--load power
热功率通过三个系数进行修正。修正的热功率P2t=P2xf1Xf2Xf2，且P2,要小于PGl、PG2，否则要外加油冷却器。
Example: Belt conveyor reducer for conveying large items, motor speed nl=1200r/min, transmission ratio i=4.5, transmission power p2-380kW, working 24h per day, maximum ambient temperature t=38 ℃, The workshop is large, natural ventilation cooling, oil tank lubrication, it is required to select the standard reducer of the first assembly form with the same specifications.
The first step is selected according to the mechanical strength power meter of the reducer. Under normal circumstances, the working condition coefficient KA should be included. According to the attached table, the belt conveyor load is medium impact, then
得Ka-1.5，考虑安全系数SA-1.5，计算功率P2，为P2。=P2xKaxSa=380x1.5x1.5X1.5=855kW
按i=4.5及n，=1200r/min,接近公称转速1000r/min,查样本ZDY3Y5i=4.5，n1=lOOOr/min,Pi=694kW当N1=1200r/min时，折算公称功率
Pi=694x1200/1000=832.8kW
Pm-855kW is similar to P1-832.8kW
You can choose ZDY315 reducer
The second step is to check whether the thermal power P2 can pass.To count eight f, f2f3.Should satisfy Pa=P2f1f2f3≤PG1.
According to the above table, fi=l.35
f2 = 1
f3=1.15(P2/Pi=380/832.8=0.456≈50%)
P2t-380×135×1×115-589.95kW
Check the sample table 7ZDY315PGl-182-360kW
PGl
It cannot be satisfied without cooling measures.
When using disc cooling or circulating oil lubrication,
PG2=695kW
则PG2>P21因此可以选定ZOY315-4.5-1减速器并采用油池润滑，盘状水管通水冷却润滑油。
If you don't use a coiled tube for cooling.You need to choose a larger size reducer.Recalculate according to the above procedure.
<XNUMX> Installation, use and maintenance
1 The axis of the input shaft and output shaft of the reducer, as well as the axis of the connecting part, should be coaxial, and the error should not be greater than the allowable value of the coupling used.
2.After installation, the required lubricating oil must be injected into the oil sump of the tank, and the oil level should be at the height between the upper and lower engraved lines on the oil dipstick.
3 The reducer must be turned by hand before it is officially used. It must be flexible and free from jamming, and then run at no-load for no less than 2 hours.The operation should be smooth and free of shock, vibration, noise and oil leakage. If any fault is found, it should be eliminated in time.
4 When the new reducer is used for the first time, it must be replaced with new lubricating oil after 20 days of operation.In the future use, the quality of the oil should be regularly checked. If the oil is found to be mixed with impurities or deteriorated, it must be replaced at any time. At the same time, the oil level should be checked frequently. If it is lower than the specified height, it should be supplemented in time.Under normal circumstances, the oil must be changed once every three months for the reducer that works continuously for a long time.For reducers that work no more than eight hours a day, the oil must be changed every six months.
5.Selection of oil
Ambient temperature:-10 ℃Use L-CKC46-L-CKC68 (formerly N46-N68) lubricant at -o℃.
0 ℃-40。C时用L-CKC100-L-CKC220（原N100-N220）润滑油。
6.In use, when the oil temperature is found to rise significantly, the temperature rise exceeds 60. C or oil temperature exceeds 85. When C, and when abnormal noise is generated, stop using it and check the cause.If it is caused by gluing of the tooth surface, it must be repaired and troubleshooting.Use after replacing the lubricating oil.
7.If severe oil leakage or oil leakage is found on the joint surface during use, open the machine cover and apply 601 sealant. If oil leakage is found in the oil seal, please change the oil seal according to the type of crude oil seal.
8 Due to the characteristics of hard tooth surface, the input shaft is relatively thin, and it is generally difficult to use belt pulley transmission and speed change. If belt transmission is really needed, you should consult the technical department of our factory.
9.The reducer is suitable for horizontal installation. If it must be tilted, you should contact the technical department of the factory.
