Practical Example of Modification of a Gearbox Lubrication System

Abstract

This paper presents the optimization of the lubrication method of a helical bevel gearbox, which is part of a pickling line. The first gear stage of this gearbox showed frequent failures. The bevel gearing and bearings were damaged. Damage analysis was performed, based on which a change in bevel gearing and bearing lubrication was proposed. In this case, the original transmission was lubricated by dip lubrication. The bevel gear wheel was insufficiently submerged below the lubricating oil level. Due to insufficient lubrication of the bevel gearing, both gear wheels, the bevel pinion, and the bevel wheel were damaged. Central circulating lubrication has been proposed for the bevel gear pair and first gearbox shaft bearings. This paper deals with the design of circulating lubrication components. Changes and modifications to an existing lubrication system are proposed. The layout of the gearbox in question was not originally designed and adapted for the circulating lubrication required. To improve the original lubrication system, it was decided that it should be redesigned with central circulating lubrication, which meant implementing the necessary gearbox casing modifications. Our novel contribution is the proposition of an innovative transmission lubrication system aimed at increasing the service life parameters of the transmission. After the implementation of the proposed modifications to the lubrication method, a period of monitoring the operating characteristics of the gearbox followed. With the modification of the lubrication system of the bevel gear pair, the temperature on the gearing surface was lowered by 39%. The service life of the gearbox increased from the original 1.9 years to at least 5 years. On the basis of the long-term monitoring of changes caused by the adjustment of the lubrication method, we can state that the requirement was met, and the frequent failures of this gearbox were eliminated.