CASE SERIES|MINING AND PROCESSING PLANT|REDUCERS · GEAR DRIVES
RESTORATION REPAIR ACTS · APRIL–MAY 2000
series of 5 acts
TsDN-710, RM-650 reduction gearboxes and EKG-10 No. 7 drives: metal grew back, no teardown
PRODUCTXADO technology® (XADO RVS)treatment of gear drives in the assembled state, without disassembling the reduction gearboxes or taking the machines out of the operating schedule
TEST OBJECTReduction gearboxes of mining and processing equipmentTsDN-710 · Ts2M500 · RM-650 · crowd, hoist and swing reduction gearboxes and the compressor of EKG-10 excavator No. 7
RESULT OF THE ENTIRE WORKYuGOK OJSC act
of 19.05.2000“The positive results achieved demonstrate the effectiveness of applying XADO technology® on industrial equipment.” XADO technology® was recommended by the plant for further roll-out
of 19.05.2000“The positive results achieved demonstrate the effectiveness of applying XADO technology® on industrial equipment.” XADO technology® was recommended by the plant for further roll-out
What repeated across the plant's reduction gearboxes
↑0.3-1.6mm
tooth thickness along the profile on the reduction gearboxes of four machines
↓2.4-3.9%
current draw of the conveyor drives at no load, 16.9 → 16.5 and 102.3 → 98.3 A
| OBJECT, SHOP | REDUCER | TOOTH CONDITION BEFORE TREATMENT | RUNNING TIME AT MEASUREMENT | ACT |
|---|---|---|---|---|
| Conveyor No. 16, crushing plant-1 | TsDN-710 | Cavities over 85 % of the 2nd-stage pinion shaft surface, tooth root wear, scuffing | over 450 h | 16.05.2000 |
| EKG-10 excavator No. 7, ore mining department | crowd, hoist, swing; compressor | Grooving at the tooth root, tooth flank wear of 1.5 mm and more, scuffing and cavities over the whole flank | 350 h | 18.05.2000 |
| Classifier No. 4-1, ROF-1 | RM-650 | Tooth profile wear over 50 %, cavities over 85 % of the surface, pitting, chipping at the tooth tip | about 400 h | 16.05.2000 |
| Conveyors No. 1-1 and No. 2-2, ROF-2 | conveyor drives | Cavities over 80 % of the tooth surface, tooth root wear 10-50 %, scuffing on the flank | 350 h and 30 h | 17.05.2000 |
| Conveyors No. 7KT and No. 8KT, crushing plant-1 | Ts2M500 | Cavities over 80 % of the tooth surface, tooth root wear of at least 1.5 mm, scuffing on the flank | 120 h and 350 h | 17.05.2000 |
Tooth thickness — by object of the series
| OBJECT, UNIT | RUNNING TIME AFTER TREATMENT | TOOTH THICKNESS GAIN |
|---|---|---|
| Conveyor No. 16, TsDN-710, 1st stage | over 450 h | 0.9-1.6 mm |
| Conveyor No. 16, TsDN-710, 2nd stage | over 450 h | 0.9-1.3 mm |
| EKG-10 excavator No. 7, hoist and swing reduction gearboxes | 350 h | 1.0-1.2 mm |
| Classifier No. 4-1, RM-650, gear M=8 Z=18 | about 400 h | 0.95 mm |
| EKG-10 excavator No. 7, crowd reduction gearbox | 350 h | 0.3-0.6 mm |
| Conveyor No. 1-1, ROF-2, pinion shaft | 350 h | 0.35 mm |
Absolute measurements: TsDN-710 — 12.9-13.2 → 13.8-14.8 mm on the 1st stage and 18.2-18.9 → 19.1-20.2 mm on the 2nd; conveyor No. 1-1 — 4.1 → 4.45 mm.
Drive current draw at no load
| OBJECT, DRIVE | BEFORE TREATMENT | AFTER RUNNING TIME | REDUCTION |
|---|---|---|---|
| Conveyors No. 7KT and No. 8KT, crushing plant-1, A30N 315 S4 motors | 102.3 A | 98.3 A | 4.0 A · 3.9 % |
| Conveyor No. 1-1, ROF-2 | 16.9 A | 16.5 A | 0.4 A · 2.4 % |
Measurements taken on 17.05.2000 on the conveyor drives of ROF-2 and crushing plant-1.
Compressor of EKG-10 excavator No. 7
| PARAMETER | BEFORE TREATMENT | AFTER TREATMENT | REDUCTION |
|---|---|---|---|
| Time to fully charge the receiver | 26 s | 22.1 s | 3.9 s · 15 % |
| Current draw at the start of charging, phase 3 | 35 A | 31.5 A | 3.5 A · 10 % |
The act reads the shorter charging time as a 15 % gain in compressor output.
What the plant's commissions recorded
The commissions of YuGOK OJSC recorded in the acts: the working surfaces of the teeth “took on the appearance of a smooth ground surface, i.e. the cavities and scuffing disappeared”, and a “build-up of a metal layer” was found in the contact zone. On the reduction gearbox of conveyor No. 16, after a running time of more than 450 hours, the tooth thickness was 13.8-14.8 mm on the 1st stage and 19.1-20.2 mm on the 2nd; on EKG-10 excavator No. 7 the tooth gained 0.3-0.6 mm on the crowd reduction gearbox and 1.0-1.2 mm on the hoist and swing reduction gearboxes; on the RM-650 the metal layer build-up was 0.95 mm — even though about half the oil volume had leaked from the reduction gearbox during that running time. The plant's final act of 19.05.2000 also notes that the repair is carried out under normal operating conditions and requires no special equipment, premises or spare parts.
The results relate to the reduction gearboxes of the mining and processing equipment of YuGOK OJSC — TsDN-710, Ts2M500, RM-650, the crowd, hoist and swing reduction gearboxes of the EKG-10 — at running times of up to 450 hours after treatment; on other units and operating modes the figures may differ. The original acts are published in full and available for download. RVS is an obsolete XADO designation, the zero-generation compounds; the current product generation is revitalizants.
Current equivalent
- Revitalizant gel for gearboxesGearboxes · transmissions · gear drives
- Revitalizant gel for compressors and bearingsCompressors · bearings · spindles
How such units are treated: