The improved solutions of rotary kilns in steel pellet plants, U.LUBE team on-site service

某鋼鐵球團廠的回轉窯采用大型開式齒輪的邊緣傳動方式進行傳動，目前采用的潤滑劑為某牌的潤滑劑對小齒輪進行噴灑潤滑。噴灑系統為某公司的噴灑系統，系統僅有一個噴嘴，而且噴嘴距離齒面也比較遠，采用手動噴射方式，無固定的噴灑周期（手動控制）。

The rotary kiln of a steel pellet plant is driven by the edge drive of large open gears, and the lubricant currently used is a brand of lubricant for spray lubrication of the pinion. Spraying system is a company's spraying system, the system only has a nozzle, and the nozzle is also far from the tooth surface, using manual spraying method, no fixed spraying period (manual control).

優潤團隊在現場服務時，對回轉窯開式齒輪進行全面檢查，從檢查的情況來看，目前該廠的回轉窯開式齒輪主要存在的問題表現為擦傷、磨損、硬質雜質造成的壓傷；在大齒齒面上還存在較多的點蝕/剝落。造成目前齒面損傷原因有以下幾點：

During the on-site service, our U.LUBE team conducted a comprehensive inspection of the rotary kiln open gears. From the inspection, the main problems of the rotary kiln open gears in this plant at present are manifested as abrasion, wear and pressure damage caused by hard impurities; there are also more pitting/spalling on the tooth surface of the large teeth. The causes of the current tooth surface damage as followed:

1、從齒面接觸痕跡，損傷分布情況來看，設備有存在明顯的偏載或裝配上的問題。左端載荷分布較多，右端較少。

1. From contact traces of tooth surfaces, damage distribution, the equipment has an obvious bias load or assembly problems. The load distribution is more on the left end and less on the right end.

2、從噴灑系統情況來看，約 700mm 的齒寬，僅僅配置一個噴嘴，無法對整個齒面進行覆蓋，這也是齒面左端出現嚴重的干磨現象的原因。

2. From the situation of the spraying system, the approx. 700mm width tooth which only has one nozzle configuration can not cover the whole tooth surface, this is the reason for the severe dry wear on the left end on tooth surface.

3、從環境情況來看，整個齒輪罩密封不良，有很大的空隙，在球團廠粉塵嚴重的環境中，齒面容易受到環境粉塵的污染（齒根處堆積大量的泥砂等硬質雜質）并造成齒面壓傷以及出現磨料磨損。

3. From the environmental situation, the whole cover of gear is poorly sealed, with a large gap. In the environment of a pellet plant with serious dust, the tooth surface is easily contaminated by environmental dust (a large amount of mud and sand and other hard impurities accumulate at the root of the tooth) and cause crushing of the tooth surface and abrasive wear.

4、目前使用的某牌的潤滑劑，40℃時粘度僅為 500 cSt，這對于回轉窯開式齒輪來說，目前選用的油品所形成的油膜強度無法支撐齒輪嚙合時的壓力，容易造成齒面損傷的出現，如過度磨損，點蝕/剝落，疲勞裂紋，甚至斷齒等嚴重損傷，造成齒輪無法達到其預期的設計壽命。

4. The viscosity of the lubrication product currently used is only 500 cSt at 40℃, which for rotary kiln open gear, the oil film formed by the current choice of oil strength can not support the pressure of gear meshing, easy to cause tooth damage, such as excessive wear, pitting/spalling, fatigue cracks, and even broken teeth and other serious damage, resulting in the gear can not reach its expected design life.

▲ 小齒動態檢查，齒面左端中端明顯無油，齒面處于干磨狀態，齒根堆積大量砂粒和金屬磨屑，齒面擦傷嚴重，出現嚴重偏載。

▲ The dynamic inspection of the pinion shows that there is obviously no oil in the middle of the left end of the tooth surface, the tooth surface is in a dry grinding state, a large amount of sand and metal abrasive chips are accumulated at the root of the tooth, the tooth surface is seriously abraded, and there is a serious bias load.

▲ 大齒動態檢查，齒面左端中端明顯無油，齒面處于干磨狀態，齒根堆積大量砂粒和金屬磨屑，齒面擦傷嚴重，出現點蝕剝落、嚴重偏載。

▲ The dynamic inspection of the big tooth, the left middle end of the tooth surface is obviously without oil, the tooth surface is in dry grinding state, the root of the tooth accumulates a lot of sand particles and metal abrasive chips, the tooth surface is seriously abraded, pitting and spalling, and serious bias load.

針對目前回轉窯開式齒輪存在的問題，優潤團隊建議：

For the current problems of rotary kiln open gear, the U.LUBE team recommends:

1、應盡快全面檢查偏載或裝配問題，及時聯系設備廠家進行調整，解決左端載荷分布較多，右端較少的問題。

1. WE should fully check the offset load or assembly problems asap, timely contact the equipment manufacturers for adjustment, to solve the problem of more load distribution at the left end and less at the right end.

2、噴灑系統僅有一個噴嘴不能覆蓋全齒面，建議對齒輪的配合進行檢查以及調整，消除齒輪的偏載現象，增加噴嘴數量（按每個噴嘴覆蓋 150mm 齒寬計算，應設置5個噴嘴）縮短噴嘴到齒面的距離，采用壓縮空氣對噴出的油品進行霧化，以便更均勻的覆蓋齒面。

2. The spraying system with only one nozzle can not cover the whole tooth surface, it is recommended to check and adjust the gear fit, eliminate the gear bias load phenomenon, increase the number of nozzles (according to each nozzle covers 150mm tooth width, should be set up 5 nozzles) to shorten the distance from the nozzle to the tooth surface, the use of compressed air atomization of the sprayed oil, in order to more uniform coverage of the tooth surface.

3、整個齒輪罩密封不良問題，則建議利用大修的機會對齒輪罩密封進行改善，減少環境粉塵對設備、油品等的污染。

3. Regarding the poor sealing problem of whole gear cover , it is recommended to use the opportunity of the overhaul of the gear cover seal to improve, reduce the environmental dust on the equipment, oil and other pollution.

4、目前使用的某牌的潤滑劑，40℃時粘度僅為 500 cSt，這對于回轉窯開式齒輪來說，目前選用的油品所形成的油膜強度無法支撐齒輪嚙合時的壓力，容易造成齒面損傷的出現，如過度磨損，點蝕/剝落，疲勞裂紋，甚至斷齒等嚴重損傷，造成齒輪無法達到其預期的設計壽命。為了滿足大型開式齒輪的潤滑要求，通常對其采用一個完整的潤滑體系，如優潤開式齒輪ET G-OG/O-OG系列潤滑體系：包括齒輪初始安裝時的涂底潤滑，運行初期的磨合潤滑，正常生產時的操作潤滑，以及齒輪出現損傷是采用的修復潤滑。同時，還需要結合定期的設備檢測，及時對設備存在的問題（安裝問題，環境問題等等）進行調整，才能使設備得到良好的潤滑，建議使用合乎大型開式齒輪潤滑規范的潤滑劑如優潤開齒潤滑劑，以達到良好的保護齒輪的運行，抑制疲勞性損傷，齒面裂紋的擴展以及齒面磨損，擦傷等問題的進一步惡化，延長齒輪的使用壽命。

4. The viscosity of the lubrication product currently used is only 500 cSt at 40℃, which for rotary kiln open gear, the oil film formed by the current choice of oil strength can not support the pressure of gear meshing, easy to cause tooth surface damage, such as excessive wear, pitting / spalling, fatigue cracks, and even broken teeth and other serious damage, resulting in the gear can not reach its expected design life. In order to meet the lubrication requirements of large open gears, a complete lubrication system is usually used for them, such as the U.LUBE open gear ET G-OG/O-OG series lubrication products: including the initial installation of the gear primer lubrication, break-in lubrication at the beginning of operation, operation lubrication during normal production, and gear damage repair lubrication. At the same time, it also needs to be combined with regular equipment testing, timely adjustment of equipment problems (installation problems, environmental problems, etc.), in order to make the equipment get good lubrication, it is recommended to use lubricants in line with the large open gear lubrication specifications such as the excellent U.LUBE open gear lubricants, in order to achieve good protection of gear operation, inhibit fatigue damage, tooth surface crack expansion and tooth surface wear, abrasion and other problems of further deterioration, and extend the service life of gears.