Extruder Drive Gearbox
A gearbox with dedicated oil filtration and water separation — this feature also changes the formulation: not the gel for gearboxes, but the gel for power steering.
Industrial gearbox of an extruder screw drive
Rule for selecting the formulation: if the lubrication system includes filtration, water separation or hydraulic system components, use the gel for power steering rather than the one for gearboxes. The rate is the same, 3.0 ml per litre. Gearboxes with oil filtration →
What is treated
- A serviceable gearbox with no parts worn to 100 % and no macro-mechanical damage.
- Oil leaks have been eliminated — otherwise the concentration of the formulation will not hold.
What is measured before and after
| Parameter | Instrument | How and when |
|---|---|---|
| Vibration level at the bearing supports | vibrometer | Vibration acceleration, vibration velocity and vibration displacement in three directions. |
| Noise level at fixed points | sound level meter | — |
| Power consumption or current of the electric motor | current clamp meter, wattmeter | At no load and under a fixed load, at the same oil temperature. |
| Oil temperature conditions | liquid thermometer or pyrometer | — |
| Gear tooth thickness | gear tooth caliper with a scale division no coarser than 0.05 mm | Along the constant chord; chord height h = 0.748·m, where m is the tooth module. |
| Condition of the contact patterns on the marked teeth | visually or with a camera | — |
| Oil analysis for metal particle content | laboratory | The percentage and qualitative content is a direct sign that wear has stopped. |
Dosage rates
| Compound | Rate | How and when |
|---|---|---|
| Gel for power steering (industrial) | 3.0 ml per 1 litre of the standard oil per stage | 38 l sump: 38 tubes of 9 ml for the full cycle, 12 + 13 + 13. |
Treatment stages
- Dilute the gel in the standard oil heated to 40–60 °C (1 part gel to 5–10 parts oil) and introduce it with the equipment shut down through the inspection hatch or the oil filler opening.Start of operating time count
- The second stage is performed in the same way as the first.After 8–12 hours of total operating time
- The third stage is performed in the same way as the first.After another 8–12 hours
After treatment
- The treatment is complete after 400 hours of total operating time.
Points to watch
- Vibration, noise and power measurements are taken at a constant torque on the output shaft.
- The declared service life increase is not less than 2 times.
Where extruder gearbox has already been treated
- ROSAVA JSC · 2005↑ 0.15-0.7mm — constant-chord tooth thickness on all four gearboxes
Source: XADO applied procedure, lead engineer I. N. Sharaikin. Class standard — instruction IE-24.6-25612000-005-2008, procedure No. 5.