ZLYJ series reducer is a high-precision gear drive device with hard tooth surface and thrust seat designed for plastic and rubber screw extruders. The product is designed according to the requirements of JB/T 8853-2001. It gears and shaft parts are made of high-strength alloy steel, and the gears are carburized, quenched and ground. The gear accuracy is Grade 6 of GB/T10095-88 and the hardness of tooth surface is HRC58-62. The front end of the hollow output shaft is equipped with a super-standard thrust bearing to bear the axial force of the screw. The main standard parts such as bearings and oil seals are domestic high-quality products, and imported products can also be provided according to users’ needs. The complete product has many advantages, such as small volume, high bearing capacity, stable transmission, low noise and high efficiency. The product performance has reached the international advanced level, and it can be used to replace equivalent imported products.

Scope of application

1. The speed of the high-speed shaft is no more than 1500 r/min;

2. The peripheral speed of gear rotation is no more than 20m/s;

3. The operating environment temperature is -40~45℃; if it is lower than 0℃, the lubricating oil shall be preheated to above 0℃ before starting. This reducer can be rotated in positive and negative directions, but the high-speed shaft on some models is equipped with an one-way oil pump, and the default rotational direction of the output shaft is clockwise against the output shaft. If the rotational direction changes, please identify it when ordering.

Reducer Model Number

The model number of the reducer contains the series code. Specification number, nominal ratio, assembly form.

Example of marking

Reducer selection

ZLYJ reducer selection must be calibrated mechanical power, axial thrust and thermal power, detailed steps are as follows.

1. Selection of speed ratio (Table 1)

Input speed n1=1000r/min, output speed n2=70r/min

i=n1 /n2=1000/ 70=14.28 Selection of speed ratio 14

2. Selection of reducer specifications (Table 1)

Select the model according to the input power and output speed provided by the user.

Output power P=26kW

Check the table: 29.2kW > 26kW, and the most economical, choose ZLYJ200.

3、Select the assembly type of reducer(Fig.1)

Select the assembly type of reducer according to the user's installation method.

4、Calculate the axial thrust

Fa=π x ds'x PS/(4 x 1000)

Screw diameter: ds=75mm screw Pressure: PS=26MPa

Thrust Fa= π x 752 x 26/(4 x 1000)=114.8KN

187KN> 114.8KN, ZLYJ200 can withstand this axial thrust.

5. Determine the coupling size (Figure 1. Table 2)

<1. Check the hole diameter, key width or spline parameter, and depth of the hole of the hollow output shaft.

<2. Check the foot mounting dimensions and the thrust including the size of the threaded hole.

6. Determine the cooling method (Table 3)

Small-size reducers are generally cooled naturally by splash lubrication. Large-size reducer adopts forced lubrication and cooler cooling. If the user's requirement exceeds the configuration in the attached table, it must be stated when ordering.

冷却方式

Installation, use and maintenance

1, reducer in the transportation and storage process should pay attention to moisture, half a year without installation should be exposed processing surface re-coated with anti-rust oil.

2、The reducer should be installed on a flat foundation. In the case of uniform tightening of the foot bolts, it should be ensured that the screw inserted into the output shaft can rotate evenly without any stagnation, so as not to add additional stress to the output shaft bearing and affect the bearing life. Do not use force to install or remove the screw.

3、After the installation of the reducer is completed, inject the lubricant to the oil level on the oil mark. The oil level should be determined after the lubricant is evenly distributed in the tank, the oil level should be checked frequently, and under no circumstances should the oil level be lower than the lower oil mark position. Please use medium extreme pressure gear oil N220, the oil should be changed once after 300 ~ 600 hours of first use. After that, the oil should be changed every 3000 hours. Replacement should be discharged when the gearbox is stopped and the lubricant has not yet cooled. The case should be flushed with oil of the same quality. If it is not suitable to flush due to high viscosity, it can be heated first or use low viscosity oil.

4, equipped with oil pump forced lubrication reducer, in the initial stage of driving, may be due to high oil viscosity. The oil pump suction resistance caused by insufficient oil, issued by the high noise. The phenomenon generally in the lubricating oil temperature rises, disappear by itself. For gearbox with motor oil pump, the motor oil pump should be turned on before loading and run for a period of time in order to facilitate adequate lubrication of lubrication points.

5、In normal operation, if the oil pump noise increases, the general situation may be too much resistance in the oil circuit. In this case, please clean the filter and other related parts. No matter which specification reducer, when it is not used for a long time or when the temperature is too low, it should be run for a period of time, and the bearings should be fully lubricated before it is loaded and operated.

6. When the oil temperature is found to rise significantly during the work, the temperature rise is more than 70°C or the oil temperature is more than 100C, the quality of the oil decreases, as well as abnormal noise and other phenomena, the operation should be stopped, check the reasons, such as due to tooth gluing and other reasons, must be repaired to eliminate the fault, replace the lubricant and then use it again.
 

Failures, causes and methods of elimination - possible failures