Professional Documents
Culture Documents
Lubrication of Large Gear Drives PDF
Lubrication of Large Gear Drives PDF
1. Introduction 4
2. Gear technology 5
3. Lubrication technology 9
2
page
3
1.
Introduction
Large girth gear drives have proven quence their lubrication, is of utmost
effective in plant engineering for many importance.
decades and continue to be the type
of drive unit most commonly found in Lubricating the gear drives of the
tubular mills, drums and rotary kilns in machines listed above is a very com-
the base material industry. In recent plex task. Not only do the design
years, other types of drive units have characteristics of the ‘open gears’
also been increasingly used. have to be taken into account, but
also their highly varied operating and
These other types are enclosed gears ambient conditions.
that are firmly attached to the drive
cover, central gear drives, frictional To ensure optimum lubrication of gear
drives or ring motors. Such gears are drives not only the types of lubricants
lubricated by high-quality mineral or used and their characteristics are
synthetic oils. The gear rim/pinion important, but also the method of
drives, on the other hand, are counted application to the tooth flanks. It is
among the so-called ‘open gears’ and therefore indispensable to choose
are normally built in the form of either a an application method that fits the
single or double-pinion drive. Their lubricant used to ensure that the drive
advantage over other drive types is functions under the prevailing operat-
that they are normally less expensive ing conditions.
to buy.
At Klüber, lubricants are manufactured
Large girth gear drives are used in the using the most advanced production
main cement production machines, for techniques. Raw materials are selected
ore and raw materials processing according to a demanding set of
machinery, in coal-fired power plants, criteria and their quality is checked
fertilizer plants, chemical factories, when they reach our plant. The
waste incineration and composting production process is meticulously
plants. The reliability and operational monitored and the finished product
safety of the drives, and in conse- subjected to regular inspection.
These processes are certified accord-
Fig. 1: Tube mill with girth gear drive ing to the quality standards DIN EN
ISO 9001:2000 and the environmental
standard DIN EN ISO 14001.
Fig. 2: Rotary kiln with girth gear drive Fig. 3: Possible arrangement of drive elements
in single and double-pinion drives
4
2.
Gear technology
Tooth traces
Gear drives can have helical or spur
teeth. Helical gears have the advan-
5
Loads on materials is always a compromise; depending
Along the path of contact A–E, the on the size and design of the compo-
sliding speed decreases and increases nents, gear manufacturers have devel-
with the distance from the pitch point oped their own alignment technologies
(C), i.e. it is highest immediately after for such gears. As a guideline for the
the impact of contact (A) and at the alignment of large girth gear drives, the
end of the contact (E). Here we formulas shown in diagram C may be
encounter also the highest friction used.
forces.
At the pitch point (C), the sliding speed However, the principle for the align-
is 0, i.e. we have only rolling friction. ment of new drive units should always
While between A and B, and between be: face backlash takes priority over
D and E, power is transmitted by two root clearance, which comes as a re-
pairs of teeth, only one pair of teeth is sult of face backlash. When re-align-
contact between B and D, which ing drive units in operation, the reverse
means that the force acting on the applies: root clearance takes priority
teeth is here much higher. Please see over face backlash, which comes as a
diagram B for illustration. result of root clearance.
direction of motion
of contact area
Gear 1
driving
driven gear
direction of rotation
Gear 2
contact area
driven
force at
teeth
sliding
driving gear speed
rotation
direction
of sliding speed x face backlash
y root clearance
Graphics A: Direction of sliding speed and Graphics B: Sliding speed and force at teeth Graphics C: Guideline for the alignment of
of contact area of two meshing gear wheels over the path of contact large gear drives
(acc. to Dudley / Winter 2)
6
Flank width corrections Flank profile corrections
profile
modification A E
b
load distribution
CC
unmodified b
modified a
Fig. 5: Gear drive with tiltable pinions during
b A B D E
assembly (Krupp-Polysius)
bE bE
tip A
relief
CE
b(b)
A B D E
Fig. 7: Flank width and profile modifications Fig. 6: Separate support of gear and pinions
tensioning element
pinion
Fig. 8: Pinion mounting with tensioning element
7
pinion(s) are supported by separate pinion design requires the flanks to
bearings, which results in difficulties be modified by tip, root and end relief.
when mounting and aligning the drive This is necessary to compensate for
components. Load-dependent de- the disadvantage of not being able to
formations, manufacturing and as- run the hardened tooth flanks in
sembling tolerances as well as kiln through initial wear.
displacement due to thermal effects
often make it impossible to avoid As these corrections have proven highly
alignment errors. This, in turn, in- successful, they are today also often
creases the problems of a uniform carried out on non-hardened pinions.
load distribution across the entire
flank width and height.
8
3.
Lubrication technology
Excessive wear and flank damage To create lubricants that have this
can be avoided if the intermeshing effect, special types of base oil are
tooth surfaces are completely selected that have the right viscosity,
separated by a lubricant film. This, contain EP (extreme pressure) additives
A
however, is almost impossible in large and sometimes also the right amount
gear drives due to the low peripheral and type of solid lubricants with a
speed, the very high flank pressure lattice layer structure. In the past few
and the relatively high flank roughness years, new lubricants were developed
and temperatures. Furthermore, since that offer the same or even better
pinion and gear rim are supported tooth flank protection without con-
separately and are aligned during taining solid lubricants. Instead, these
assembly, their axes are often not lubricants are made of innovative B
100 % parallel, which makes the special mineral and/or synthetic oils
operating conditions even more and contain adhesion improvers and
difficult. This may lead to partial even better EP additives; they have a
overloading and detrimental friction very high viscosity, and backflow from
forces on the intermeshing tooth the root depot ensures a longer-lasting
flanks carrying the load. lubricant film.
C
As a consequence, large gear drives However, even the best of lubricants
operate mostly under mixed friction will compensate for partial overloading
conditions, which makes boundary of the tooth flanks to a limited extent
lubrication so important in these appli- only. In new gear drives with their
A hydrodynamic lubrication
cations. To lubricate large gear drives production-related flank roughness B lubrication by physically adsorbed
reliably and protect them against and/or waviness, scuffings may there- layers
C lubrication by chemical reaction
damage, the lubricants applied must fore occur and cause severe damage layers
be highly adhesive, and their physical within a short period of time.
and chemical properties must be Fig. 10: Lubrication mechanism:
such that they form protective layers The surface quality is of utmost oils with additives
(so-called reaction layers) on the tooth importance for reliable lubrication and
flanks under the prevailing operating trouble-free operation. Only smooth
conditions. These protective layers tooth flanks will remain undamaged
largely prevent direct metal/metal when exposed to peak loads, provided
contact and hence minimize boundary the longitudinal and transverse load
friction. distribution is even. New or turned gear
drives should therefore undergo a
running-in procedure with special
lubricants developed for this purpose.
This ensures that the tooth flanks are
smoothed and the contact ratio is
increased.
9
running-in, the contained additives
should have a very rapid and controlled
micro-wear effect.
inaccuracy of shape
10
4.
Lubrication and
application methods
The decisions which type of lubrication
and which method of lubricant applica- TYPE OF LUBRICATION APPLICATION METHOD
¬
tion to the tooth flanks are used are of
major importance for successful lubri-
cation and maintenance. When select- K immersion lubrication
ing a type of lubrication and an appli- continuous lubrication
(long-term lubrication)
cation method it is important to check
K circulation lubrication
whether it will supply sufficient lubri-
cant to the load-carrying tooth flanks
so as to avoid deficient lubrication, K transfer lubrication with paddle wheel
damage to the gears and operational
malfunctions.
intermittent lubrication K spray lubrication
(total loss lubrication)
Of course, the type of lubricant used
must be taken into account in this
context. It may be fluid or consistent,
K
K
which makes it suitable for different
types of feeding equipment. Which Sprayable adhesive lubricants for Highly viscous mineral oil based,
types of lubrication are appropriate gears (free from solvents and synthetic or mixed gear oils or gear
bitumen), with EP additives, with and fluids (free from solvents and bitumen),
for which application methods is without solid lubricants. with EP additives, with and without
shown in Fig. 12. Consistency classes: NLGI 0, 00, 000 solid lubricants
and
K intermittent lubrication
(total loss lubrication)
11
Lubricant application methods suitable for
Klüber adhesive lubricants
(the shadowed lubricants are black products)
A A B B B C C C C C C C C C C C C D D
Continuous
lubrication = Immersion lubrication x x x x x x x x x x
long-term (pinion or gear rim
lubrication immersing in lubricant)
Circulation lubrication x x x x x x x x x
with the
Klübermatic PA system
Transfer lubrication x x x x x x x x x x
with paddle wheel
Intermittent Manual lubrication
lubrication = by brush, spatula or x x o o o x o x x x x x o o o o o x x
total loss compressed-air spray gun x x x x x x x x x x x x x x x x x
lubrication
Automatic spray x x o x x x x x x x x x x o o
lubrication
Transfer pinion x o x o x x x x x x x x x o o
lubrication
(lubricant is supplied to
the transfer pinion by
means of a pump)
o = possible lubricant
A = priming lubricants
B = running-in lubricants
C = operational lubricants
Table 1
12
Immersion lubrication (immersing pinion) Transfer lubrication (paddle wheel)
13
4.1. Continuous lubrication
Maximum:
1/2 of tooth length
Nominal:
1/3 of tooth length
14
1
K suitable viscosity-temperature
behavior such that the bath must
neither be heated nor cooled
15
a double-pinion drive. The paddle the supply of lubricant to the load-
wheels are located directly below the carrying tooth flanks may be insuffi-
pinions and are driven by them. cient, particularly at low lubricant
Transfer lubrication by means of temperatures, when the immersing
paddle wheels is mainly found in gear rim forms a channel in the
slowly operating kiln drives. lubricant, which may be highly viscous
when cold. Another type of transfer
In both immersion and transfer lubrication is by means of a transfer
lubrication, the lubricant should be pinion: the lubricant is pumped through
applied to the pinions rather than to the hub of the transfer pinion and
the gear rim. If it is the gear rim that reaches the drive pinion through bore
takes up lubricant from the bath, or holes. This application method can
receives it from the paddle wheel, be used for both fluids and greases.
(See fig. 14)
4.1.3.
Circulation lubrication
For circulation lubrication, the lubricant
is fed by an externally driven pump.
The main advantage as compared to
immersion lubrication is the fact that
the lubricant is filtered and then
applied to the load-carrying tooth
Seal flanks in abundant quantity almost
9 9
without any contaminants.
8
8 However, circulation lubrication will
only be successful if the drive cover is
sealed properly and the penetration of
contaminants from the environment
into the lubricant reservoir is prevented
as well as lubricant leakage.
7 6 5 4
Fig. 17: Klübermatic PA: arrangement of lubricant pipes. The load-bearing tooth flanks of both the
inward and the outward turning pinion are lubricated
16
Switch cabinet
1.1 Lubricant reservoir 2.4 Pressure control valve, 12 bar 3.2 Flexible line
1.2 Level control 2.5 Shut-off valve with electrical posi- 3.3 Flow sensor
1.6 Shut-off valve tion indicator 3.4 Lubricant distribution pipe
1.9 Compensator 2.6 Lubricant filter with powered
lamella cleaning unit 4 Gear rim cover
2.1 Lubricant pump 2.7 Flow sensor
2.2 Manometer and thermometer 2.8 Check valve 5 Switch cabinet
2.3 Pressure control valve, 16 bar
(integrated in pump) B1 Bypass line
4.1.3.1.
Klübermatic PA circulation
lubrication system
Most of the circulation lubrication The Klübermatic PA system is generally
systems used today are only designed suitable to lubricate gear drives with
for the application of gear oils and are one, two or more pinions in rotary kilns,
not suitable for applying fluids or highly mills and other machinery. It can be
viscous lubricants. For this reason, retrofitted to existing installations. Its
Klüber developed a circulation lubrica- main advantage is that the lubricant is
tion system called Klübermatic PA for permanently cleaned by filters – hence
the application of type B (for running-in no need to stop the machine for clean-
lubrication) and type C (for operational ing – and that it is applied to the tooth
lubrication) lubricants for large gear flank surfaces very efficiently and in
drives. abundant quantity through special
17
9 9
Seal
Fig. 19: Lubricant application through especially designed lubricant distribution pipes of the
Klübermatic PA system
18
4.2. Intermittent lubrication
5
13
4 6 12
11
7
3
2 10
1 8
19
The pressurized container is not ability for the running-in procedures on
subject to the legal regulations for girth gear drives, i.e. the systems must
pressure vessels. be designed for permanent operation
and the application of large amounts
This system is portable, easy to handle of running-in or correction lubricant.
and only needs to be connected to the Today, these lubricants are normally
compressed air network at the site applied in a quasi-permanent operation
before it can be put into operation. in specified amounts and for a defined
With the spray gun different types of period of time.
application are possible, e.g.
Consequently, running-in lubrication
K operational lubrication with an determines the maximum lubricant
extremely thin lubricant film and throughput in continuous operation
hence maximum lubrication that must be possible with the spraying
economy, equipment, while optimized operational
lubrication determines the lowest
K priming of open gear drives throughput. Due to the low consump-
to check the contact and load- tion quantity during operational
carrying pattern, lubrication, the lubricant is applied
in intervals, i.e. spraying and pause
K lubricant application for repair, times alternate.
correction and forced running-in
lubrication. For correct dimensioning of the spray
lubrication system (minimum capacity
However, manual spray gun lubrication of the lubricant pump) it is critical that
does have its limits, especially in the lubricant quantity expected for
running-in and operational lubrication running-in (maximum requirement)
over an elongated period of time. be determined.
20
Lubrication has therefore evaluated intervals of 150 to 200 operating hours
the experience gathered over several until the permissible minimum has been
decades to develop a diagram (Fig. 22) reached.
indicating approximate values of con-
sumption quantities of running-in and It should be noted that even identical
operational lubricants. drives (same machine with same power
rating) may require a different amount of
The first step is determination of the lubricant under different operating
specific lubricant quantity in g/cm of conditions (temperature, vibrations,
flank width and per operating hour – possibly existing damage, etc.). Main-
depending on the type of drive or tenance personnel should therefore
machine (see Table 2). Based on the check the lubrication condition of the
actual flank width (e.g. 60 cm for the drive to determine the required lubri-
pinion(s), the approximate quantity cant quantity for each machine
required per operating hour can then individually.
be determined. The flank width was
chosen as a reference because this
is the best way to take into account 4.2.4.
the specific power transmission in a
drive.
Application of lubricant
Ideally, the lubricant quantity sprayed
continuously onto the gears would be
NOTE just enough to ensure that the lubricant
The quantities determined using the film, which is constantly being eroded
diagram only apply when using Klüber by the friction bodies (tooth flanks),
GRAFLOSCON B-SG 00 Ultra and maintains at all times the minimum
C-SG 0 Ultra lubricants for tooth thickness that is required to safely
widths up to 1000 mm and modules up prevent scuffing.
to 30 mm. For consumption quantities
of transparent lubricants, see Table 2 However, in real life this is hardly
and Diagram 22a. feasible. If between 1 and 14 kg of
operational lubricant are to be applied
With modules of 30 mm and larger drive over 24 operating hours, it is simply
widths, the required quantity will be not possible to continuously apply a
higher, or a more viscous lubricant will lubricant film of constantly ideal thick-
have to be used, because the teeth take ness. A good compromise is interval
up more lubricant in such drives. Ex- lubrication, consisting of periods of
perience has shown that lower quan- excess lubrication during which the
tities are needed if lubricants of high lubricant film does not have to be
viscosity are used. Also drives that are sustained from outside.
subject to less severe loads, e.g. in
drums or rotary coolers, can be oper- For operational reliability the most
ated safely with lower lubricant quanti- decisive factor is the duration of the
ties. However, to determine the lowest individual spraying pulses. Reliability
possible consumption quantities, lubri- is best when the entire circumference
cation of each drive must be adjusted of the pinion or the gear is covered
step by step. The lubricant quantity can with lubricant in one pulse. The lubri-
be reduced by 0.5 to 1.0 g/cm/op. hr. at cant quantities must ensure a film
21
Consumption quantities of
GRAFLOSCON B-SG 00 Ultra and C-SG 0 Ultra
800 8 ** 5
19
[kg/24 op.hrs.]
[g/op.hrs.]
18 750
550
13
12 500 5 ** 2
Consumption quantity
11
450
10
400 4 ** 1
9
350 3.5 **
GRAFLOSCON C-SG 0 Ultra
Operational lubrication with
8 5
300 3 **
7
4
6 250 2.5 **
3
5
200 2 **
4 2
150 1.5 **
3 1
1.0 **
100
2
1 50
0
30 40 50 60 70 80 90 100 1 ... 5
Flank width (cm) = type of
installation
see table 2
Fig. 22: Diagram for determining the specific lubricant consumption quantity required for running-in and
operational lubrication
22
Consumption quantities of the
transparent Klüberfluid lubricants
5.0
200
4.5
[g / Bh]
180 1.8**
4.0 5
160 1.5**
Consumption quantity
3.5
140 4
3.0 1.3**
120
3
2.5 1.0**
100
2.0 2
80 0.8**
1.5 60 1
0.5**
1.0 40
0.5 20
0 0
30 40 50 60 70 80 90 100 1 ... 5
Flank width (cm) = type of
installation
see table 2
Fig. 22a: Diagram for determining the specific lubricant consumption quantity required for running-in and
operational lubrication
Please note:
The specific quantity of the running-in lubricant Klüberfluid B-F 2 Ultra required
is the same as of GRAFLOSCON B-SG 00 Ultra and can be found in Fig. 22.
The total recommended lubricant quantity of Klüberfluid B-F 2 Ultra is two or three
180 kg drums.
The total recommended lubricant quantity of GRAFLOSCON B-SG 00 Ultra is one
or two 180 kg drums.
23
thick enough to offer reliable flank Compared with operational lubrica-
protection throughout the ensuing tion, running-in or correction lubrica-
pause cycle. Shorter and more tion of gear drives requires much
frequent spray cycles with shortest larger amounts of lubricant. So the
possible pauses result in utmost spraying pulses must be extended
operational reliability in spray considerably to apply the larger
lubrication. amounts of lubricant, or the pause
intervals shortened accordingly.
1 4 3 6
5
1 Switch cabinet
2 Single-line piston pump
3 Nozzle plate
4 Compressed air unit (from network)
5 Lateral distance between nozzles
approx. 150 mm
6 Lubricant distributor 2
6
WOERNER spray lubrication system (example)
1
1 Nozzle plate
2 Switch cabinet
3 Compressed air unit
4 Compressor
5 Electric barrel pump
6 Lateral distance between nozzles
approx. 300 mm (block nozzle)
2
5 3
24
DE LIMON FLUHME spray lubrication system (example) 4 5
K Single or multi-line system design In fast running modern kiln drives with
modules > 30 mm, the lubricant can in
K Lubricant feeding to the spray principle also be applied to the load-
nozzles either direct from the bearing tooth flanks of the gear rim.
lubricant pump or via an inter- The sliding direction at the gear rim is
mediate progressive distributor from the tip to the root of the tooth,
which enhances longitudinal lubricant
K Auto-control spray nozzles distribution. This applies in particular
(controlled by lubricant and/or air) to modern, highly viscous, transparent
or externally controlled nozzles lubricants in combination with state-of-
with and without monitoring units the-art spray systems, which allow
longer spraying times. Depending on
The various spray systems also differ the design of the drive cover, the
by their individual degrees of controlla- nozzle plates should be arranged at
bility of lubricant throughput in continu- the angles and in the positions indi-
25
Arrangement examples
Single-pinion drives
Generally recommended positions:
1a, 1b, 1c
Position 3:
3 only permissible with suitable spray-
ing equipment, sufficient peripheral
speed of the gear rim and a suitable
lubricant
2 1
Double-pinion drives
Generally recommended positions:
1a, 1b, 1c and 2a, 2b, 2c
Position 1b Position 2b
Position 1c Position 2c
26
cated in Fig. 24. The spray nozzles
should not be installed to spray
upwards since the spray heads would
become clogged by dropping used
lubricant. This would result in insuffi-
cient spray patterns and eventually in pinion
a complete failure of the lubricant
supply system. Furthermore, main-
tenance would be impeded.
spray patterns
of fan jets
Orientation of the spray
nozzles (Fig. 25) B
A spraying angle of 30° is best to
achieve a good longitudinal distribution
of the lubricant over the load-carrying
tooth flanks. The nozzle distance “X”
should be between 200 ± 50 mm. The
exact distance depends on the position C
and the type of nozzle. Every type of
nozzle requires also a particular distance spray patterns of
between the individual nozzles, which circular jets
depends on the air pressure as deter-
mined by the manufacturer, the number D
of nozzles and the type of lubricant. It
ensures that the entire width of the tooth
flank is covered with lubricant. Opera-
tional safety is reduced if the nozzles are Fig. 26: Spray patterns depending on the number of nozzles
not arranged properly. and the spray geometry
4.2.7.
Spray patterns,
checking of spray patterns
An important factor in terms of opera-
tional reliability is a spray pattern with-
out any gaps, i.e. the lubricant must
be distributed evenly over the entire
height and width of the tooth flanks,
see Fig. 26. Even if the spray nozzles
are controlled automatically, periodic
checking of the spray pattern is an
essential part of maintenance.
27
Due to their design, older spray systems the lubricant is fed from the
systems had the disadvantage that Klüber lubricant container in various
the spray pattern in high-speed drives, configurations.
e.g. in mills, could only be checked
when the drive was stopped. Newly Feed pumps may be driven electro-
developed nozzle plates are hinged, mechanically or pneumatically. It is
which allows checking of the spray important to have a level control
pattern while the drive is in operation system which indicates in time that
(Figs. 29–31). lubricant should be refilled or the
drum replaced to prevent the gear
This is of special advantage in kiln drive from being damaged or switched
drives, which cannot be stopped off due to insufficient lubrication.
whenever desired. In addition, this
type of checking ensures maximum As environmental impact is being
protection against accidents because paid more attention and consequently
it is not necessary to remove drive sanctioned with increasing costs,
covers. lubricants are less and less supplied
in non-returnable drums but rather in
large Klüber lubricant containers,
4.2.8. which are refillable. This offers a
Lubricant pumps and number of advantages: costly disposal
of empty drums is no longer necessary
reservoirs and the exchange intervals of the
How the lubricant is fed to the spray larger containers are much longer,
nozzles from the storage container saving on manpower and hence
depends on the design of the lubrica- expenses.
tion system. A differentiation is made
between Another advantage of the Klüber
lubricant containers is the fact that
a) spray lubrication systems with several machines can be supplied
container pumps (Fig. 32), with lubricant from a single container
as long as the drives are located at a
b) spray lubrication systems with convenient distance.
barrel pumps (Fig. 33),
Fig. 27: Inadequate spray patterns;
Fig. 34 shows flow charts of different
the individual patterns do not overlap c) spray lubrication systems fed from types of systems using Klüber lubricant
Klüber lubricant containers (Fig. 35) containers.
28
position during operation
pinion
pinion
position for checking spray pattern position for checking spray pattern
Fig. 30: Hinged nozzle plate, Fig. 31: Nozzle plate, WOERNER
DE LIMON FLUHME
29
3 2 1
2
5 4
4 3 1
1 Barrel pump
1 Reservoir pump 2 Lubricant line
2 Compressed air line 3 Power cable
3 Lubricant line 4 Compressed air line
4 Nozzle plate 5 Nozzle plate
Fig. 32: Spray lubrication system with container pump, LINCOLN system Fig. 33: Spray lubrication system with barrel
pump, WOERNER system
1 7.1
S
7.1
6
5a
7 S
2 3 4
1 1 Klüber lubricant
container
2 Shut-off valve
7 3 Quick-action coupling
7.3
4 Hose
S 5 Transfer pump (a) or
feeding pump (b)
6 Shut-off valve
7.2
7 Spray lubrication
system
5a 7.1 Container pump
7.2 Lubricant drum
2 3 4 7.3 Barrel pump
S to spray system
5b
2 3 4
Fig. 34: Lubricant supply with the Klüber lubricant container system
30
Spray lubrication systems with
container pumps (Fig. 32)
The container pumps (7.1) are supplied
with lubricant directly from the con-
tainer (1) by means of a transfer pump
(5 a). The pump is switched on and off
via the level control unit in the lubricant
containers. Even if several container
pumps are connected to one container,
overfilling of the pump containers is
prevented by the shut-off valves, which
are also controlled via the level control
unit. Fig. 35: Lubricant container system from Klüber Lubrication
31
5.
Klüber A – B – C System
Lubrication
Priming lubricant type A – Running-in lubricant type B –
Operational lubricant type C
A – B – C – system lubrication
The letters A – B – C denominate the
individual steps of the system and
refer to the following:
32
Manual or automatic spray lubrication
B C
Running-in lubrication Operational lubrication
GRAFLOSCON GRAFLOSCON
B-SG 00 Ultra C-SG 0 Ultra
C-SG 1000 Ultra
Klüberfluid C-SG 2000 Ultra
K B-F 2 Ultra K
Manual lubrication by Klüberfluid Manual lubrication by
brush or spatula C-F 3 Ultra brush or manual spraying
C-F 3 S Ultra equipment
C-F 4 Ultra
C-F 5 Ultra
A C-F 7 Ultra
C-F 8 Ultra D
Priming and pre-start Repair lubrication
lubrication
K
Forced running-in
GRAFLOSCON lubrication
A-G 1 Ultra K
+ GRAFLOSCON
K
Klüberplex
AG 11-462 + D-SG 00 Ultra
Klüberfluid
D-F 1 Ultra
K
B C
Running-in lubrication Operational lubrication
Klüberfluid Klüberfluid
B-F 1 Ultra C-F 1 Ultra
B-F 2 Ultra C-F 2 Ultra
C-F 3 Ultra
C-F 3 M Ultra
K K C-F 4 Ultra
C-F 5 Ultra
C-F 7 Ultra
Note: C-F 8 Ultra
The shadowed
lubricants are black
products
33
5.1. Priming lubricants type A
Priming lubricants type A are products which make the points of contact
containing a high percentage of addi- and hence the contact ratio visible.
tives and are applied prior to the initial While the light-colored priming
operation of gear drives. They may be lubricant Klüberplex AG 11-462
used in all spur or helical girth gear has largely the same properties,
drives, irrespective of the lubrication it is less suitable for use as a con-
method used. Their main tasks are trast substance to determine the
the following: dynamic load-carrying pattern.
Example:
Reference circle
diameter: 6000 mm
Quantity to be
tooth flank width [mm]
required quantity [kg]
purchased: 30 kg
consisting of
one bucket of 25 kg*
and
one bucket of 5 kg*
Fig. 39: Diagram to determine the required quantity of type A priming lubricant
34
a b c d e f g h i a) Load-carrying pattern on the gear rim with
a wobbling pinion. Check pinion seat.
1
K
b) Load-carrying pattern with a wobbling gear rim.
Check seat and alignment of gear rim.
c) Load-carrying pattern with edge contact.
Axes not parallel, realign pinion.
d) Pressure spot caused by production defect
or thermal deformation of a certain area .
do · π
2 e) Load-carrying pattern with a pinion bent
2
upwards on both sides, caused by inexpertly
mounted tensioning elements.
f) Load-carrying pattern with slanted gear rim
halves. Check screwed connections at interface
and gear rim fixtures.
g) Load-carrying pattern with one slanted gear
1 rim half. Check assembly.
K
h) Radial deviation of the gear rim. The load carry-
ing pattern appears weaker over one half of the
gear rim and more intense over the other.
Realign.
i) Load-carrying pattern with raised surface defect
of the gear rim on both sides due to excessive
frictional heat coming from cover seals. Improve
lubrication of the seals.
Fig. 40: Contact ratio/load-carrying pattern made visible by means of priming lubricant
Fig. 43a: Surface roughness of a new pinion’s tooth flank Fig. 43b: Surface roughness of a pinion’s tooth flank after running-in with
GRAFLOSCON B-SG 00 Ultra
36
During the running-in process, the How running-in gear drives should be run in with a
intentionally caused wear is controlled lubrication works type B running-in lubricant prior to
through the amount of lubricant used Based on the technical knowledge operation under full load. Running-in
and the time it is allowed to act on the we have today about large girth gear means that some limited wear is inten-
component. The wear smoothens the drives it can be claimed that a gear’s tionally generated at the tooth flanks
tooth flanks, which creates optimum rolling strength and scuffing load while at the same time they are pro-
conditions for the prevention of pitting capacity are substantially improved tected against scuffing wear to avoid
or other damage. As the high pres- if flank roughness is reduced and the aforementioned initial damage. In
sures occurring during initial operation the effective contact ratio increased. this way, surface roughness is reduced
bear the risk of scoring damage, the The initial contact ratio of a gear – even within a short period of time and wavi-
running-in lubricants contain highly when the pinion(s) and the driven gear- ness or inaccuracies of shape are
effective EP additives to counteract wheel are properly aligned – is often compensated for as far as possible to
this effect. These lubricants of type B no higher than 50–60%. This means achieve a high contact ratio and a
are also used as correction lubricants that when new gear drives are put into good load distribution.
that can improve the surface quality operation there is always a danger
and hence increase the contact ratio in that the partial overloading of the tooth Fig. 43a and 43b illustrate what a
drives showing a deterioration in their flanks may cause damage (initial pit- Klüber type B running-in lubricant can
load-carrying pattern. tings, local scuffings) that might aggra- achieve in terms of reducing surface
vate severely during subsequent oper- roughness. These curves are based on
ation. To avoid this initial damage new positive impressions of a new pinion
Fig. 44 a Fig. 45 a
Fig. 44 b Fig. 45 b
37
flank (m = 25 mm) and of one that had lubricant are compatible, so con-
just been run in for 250 operating version from one to the other does
hours. The possible improvements are not require any cleaning of the spray-
also shown on the photos of a new and ing equipment.
a run-in pinion flank (Fig. 44a and b
and 45a and b) made with a scanning The running-in procedure should
electron microscope. The running-in never be discontinued prematurely
lubrication described enables surface because no more running-in lubricant
corrections by approx. Ra 10 μm. is available. Especially when working
with large drives, two drums of run-
ning-in lubricant should be provided.
5.2.1. Any surplus may be used for correc-
Running-in with tion lubrication that may become
necessary at a later date. Running-in
automatic spray is completed when the tooth flanks
lubrication are smooth and the contact ratio is
Prior to starting the running-in pro- sufficient. When this is the case will
cess, the automatic spraying equip- be determined by the plant staff and
ment should be set to quasi-perma- possibly a service technician of Klüber
nent operation with short pauses and Lubrication.
the throughput volume shown in the
diagram. The spray pattern should be
checked and, if necessary, corrected. 5.2.2.
Spraying should commence before
the drive starts running. The lubricant
Running-in lubrication
quantities can be determined by
with immersion
means of the tables and diagrams in Fill lubricant of type B into the bath
this brochure. If possible, start the until the teeth of paddle elements are
running-in at low machine load and fully immersed. Upon starting the drive,
raise it step by step; this is easy with observe the lubricant level, which may
ball mills. For drives that need to be decrease considerably due to the
run at full load from the start, “forced amount of lubricant carried away by
running-in lubrication” is a viable the teeth. To avoid insufficient lubrica-
option. tion, the bath should be refilled to at-
tain a level where the teeth are half
The total amount of lubricant needed or the paddle elements fully immersed.
for the running-in depends on the type Should not be enough type B running-
of machine and the size of the drive, in lubricant be available to make up
normally between 180 and 360 kg for lubricant losses during the running-
(one to two drums). Should this turn in procedure, use a type C operating
out not to be enough and the running- fluid of the same lubricant group for
in lubricant be used up before the refilling.
procedure is completed, drive opera-
tion may continue with the same The purpose of the running-in process
throughput volume of operating lubri- should normally be attained after
cant of type C until more running-in approx. six months, i.e. the tooth
lubricant has been supplied. The run- flanks should be smooth and the
ning-in lubricant and the operating load-carrying area sufficient. Whether
38
x Bh I II
100
K
x Bh
90 200 Bh
120 Bh
80 75 Bh
this is the case is determined by the
70
customer and a Klüber service engi- 120 Bh
neer together. The running-in lubricant 60
25 Bh
load [%]
should then be drained immediately, 50
96 Bh
the gear rim cover cleaned and the 40
operating lubricant filled in. The run-
30
ning-in of kiln drives with immersion
20 24 Bh
lubrication has some specific require-
ments: normally, kilns are not stopped 10
for an exchange of lubricant, so the 0
lubricant may stay in the immersion 100 200 300 400 500
bath for several months and may tend running-in period [op. hours] K
to thicken due to foreign particles,
abrasion and ground solid lubricant.
To prevent such thickening, the lubri- Fig. 46: Running-in schedule for stepwise increase of load in a ball mill
cant should be drained from the reser-
voir as far as possible while the drive
continues to operate, and be replaced
by fresh running-in lubricant. This en-
sures the lubricant remains fluid until
the running-in procedure is completed. Whenever the drive is stopped, e.g.
During the short interval between to add grinding media for the next
draining and refilling, the drive should higher load stage, the lubrication
be lubricated manually, preferably system should always be switched on
with manual spraying equipment and its function checked before the
Klübermatic LB. The running-in drive is started again. Upon comple-
lubricant should be fully replaced by tion of the running-in procedure, the
the operating lubricant after 7,000 running-in lubricant is completely
operating hours maximum. replaced by the operating lubricant.
This is the case after 7,000 operating
hours maximum.
5.2.3.
Running-in lubrication
with Klübermatic PA 5.2.4.
Running-in with stepwise
If necessary, clean the lubricant reser-
voir and fill it with running-in lubricant
increase of load
of type B. New or turned gear drives should
not be operated under full load from
Prior to starting the drive, the lubri- the start because the contact ratio
cation system should be switched on often is initially too low. Instead, they
and the lubricant distribution pipes be should be run in according to a pre-
checked to see if a continuous flow of determined load/time schedule, with
lubricant ensures sufficient lubricant the transition to the next load stage
supply to the load-bearing tooth flanks only being carried out when a specific
of the pinion. The lubricant reservoir contact ratio has been reached. In
must contain a constantly sufficient mills the load can be increased by fill-
supply of lubricant. ing in the grinding elements. Fig. 46
39
load-carrying pattern
load distribution
good bad
40
6.
Forced running-in (accelerated running-in)
41
6.1. 6.2.
Forced running-in of Forced running-in of
drives with automatic drives with immersion
spray lubrication lubrication
In such drives, a type B running-in The running-in lubricant of type B
lubricant is continuously sprayed onto is filled into the bath to support lubri-
the tooth flanks, observing the normal cation. In addition, the active com-
instructions for running-in in terms of pound (lubricant type D) is sprayed
quantity etc. In addition, the active onto the tooth flanks manually by
compound (lubricant type D) is applied Klübermatic LB. To prevent the active
manually by Klübermatic LB. compound from being washed off by
the running-in fluid, the bath should
only be filled to a level where one third
of the tooth height is immersed at
maximum.
6.3.
Forced running-in
of drives lubricated by
Klübermatic PA
The circulation lubrication system
remains inactive during the forced
running-in process. To prevent the
active compound from entering the
Klübermatic PA lubrication circuit,
which would cause wear during
operation later, the lubricated com-
ponents and the reservoir must be
disconnected from the lubrication
lines. Upon completion of the running-
in process, the gear rim cover and
the lubricant reservoir must be
cleaned to remove all residues of
the active compound.
42
7.
Operational lubricants type C
Type C lubricants are modern adhesive ciency, low environmental impact and cycles are a short as possible. Brief
lubricants tailored to suit the opera- low disposal costs, resulting in a con- and more frequent spraying is better
tional conditions of girth gear drives. siderable cost reduction for the opera- for an even distribution of the lubricant
They meet all extreme pressure re- tor. on the drive, which enhances opera-
quirements of gear drives, e.g. of tional reliability.
ball mills or rotary kilns. Type C operational lubricants are com-
patible with type B running-in lubri- The pause cycles should not exceed
In addition, the adhesive spray cants of the same product line. This is 5 minutes in mills and 10 minutes in
lubricants also fulfill the special of advantage since lubricant losses kilns. However, the exact cycle times
requirements of modern spraying during the running-in stage in an depend on the lubricant used, the
equipment. Type C operational immersion-lubricated drive can be condition of the drive, the operating
lubricants are characterized by the topped up with the operational lubri- conditions, the spray systems and
following properties: cant as the running-in lubricant is other influences and must therefore
being used up. Spray lubrication sys- be decided individually at the site.
K excellent adhesion tems can proceed directly from run- Both shorter and longer pause times
ning-in lubrication to operational lubri- are possible, provided sufficient lubri-
K good load-carrying capacity cation, which is important in machines cant is supplied to the components.
which are difficult to stop. Another The specific consumption quantities
K maximum wear protection
advantage over bituminous lubricants can be obtained from the tables in
K protection against scoring is that the tooth flanks can be this brochure, taking into account the
inspected any time without difficulty. type of drive, tooth flank width and
K good corrosion protection This can be done while the machine is the lubricant quantities required per
in operation with a stroboscope or
All these lubricants were designed when the machine is shut down with-
to offer the prerequisites for thin-film out having to clean the tooth flanks.
lubrication (e.g. base oil viscosity). Transparent lubricants are even better
Consistency, EP additives and solid in this respect than the black ones.
lubricant content were selected to
ensure that the tooth flanks receive
maximum protection even under diffi-
cult operating conditions. 7.1.
Operational lubrication of
A main advantage as compared to spray-lubricated drives
conventional lubricants is the fact that
Klüber's operational lubricants are free The transition to operational lubrica-
from bitumen and heavy metals as well tion is generally made when the run-
as raw materials containing solvents or ning-in process has been completed,
chlorine. They are thus easy to handle, i.e. when the tooth flank surface has
gears and pinions are easier to clean reached its maximum smoothness
and the disposal of the used and old and when a contact ratio of at least
lubricant is less problematic. This is of 80% has been attained. After the
importance primarily in applications transition, the lubricant volume of the
with total loss lubrication (e.g. spray running-in stage should be retained
lubrication). for another 50 operating hours. After
that, the quantity should not be re-
An essential advantage of Klüber duced abruptly but in steps of 0.5 to
adhesive spray lubricants is the fact 1.0 g/cm every 150 to 200 operating
that only a small quantity of lubricant hours.
is required to lubricate a gear drive reli-
ably, and consequently the amount of As the lubricant is being reduced, the
used lubricant is also quite low. Small spray system should be adjusted such
quantities always ensure high cost-effi- that the pauses between two spray
43
time unit. The specific consump- Parameters determining whether an
tion volumes listed are based on the operational lubricant is still fit for use
following assumptions: include:
44
8.
Repair and correction
lubricants of type D
Repair lubrication A decisive advantage of repair lubrica-
Not too long ago tooth flank damage tion over mechanical repair methods is
was repaired exclusively by highly that the machine remains fully operable
abrasive mechanical methods – often and that a high load even increases the
quite ineffectively. The tooth flank success of the repair lubrication. The
quality obtained often did not come short machine downtimes which are
up to expectations in terms of func- required for control and documentation
tional reliability and service life of the work are of minor significance as
drive. The costs were very high and compared to a production standstill
the repair periods quite long. of several days.
45
The repair lubricant is applied to the Repair lubrication is not suitable to
load-carrying tooth flanks of the pinion correct the following:
and the gear rim by means of the
Klübermatic LB, as described K burrs at the tip and the side of
under 6. the teeth
CAUTION:
Repair lubricants of type D must not
be used in immersion baths, circulation
lubrication systems or automatic spray
lubrication equipment.
NOTE
Since repair lubrication is a complex
task that may provoke damage if
performed inexpertly, it should only
be carried out by qualified and ex-
perienced service staff.
K damage evaluation
46
1 2 3
load distribution
Damaged tooth flank After approx. 250 operat- After approx. 20 operat-
ing hours with the running- ing hours with the repair
in lubricant, contact ratio lubricant, contact ratio
approx. 65% approx. 85%
K
contact ratio [%]
K
operating hours [h]
Fig. 51: Effect of damage repair on the load distribution across the face width
47
9.
Lubrication and maintenance
of girth gear drives
The maintenance of gear drives
depends on the lubricant application
method and may vary considerably.
In manually lubricated drives, mainte-
nance usually is restricted to observing
the lubricating condition and removing
the old lubricant at regular intervals,
which contains impurities and is there-
fore liable to damage the gear rim and
pinion.
48
Checklist for inspection and repair
1 Check functional reliability of control equipment and fault alert systems These procedures are preventive
regularly.* measures to ensure operational
reliability.
2 Check lubricating condition.*
The inspection and results, the type of
3 Check and clean lubricant filter regularly.* work carried out, the machine number
and the date should be documented in
4 Remove dust and dirt from lubrication systems regularly.* a log book. This data can be used as a
basis for corrective action if certain
5 Check spray pattern at least once a month; if required, adjust nozzle faults recur.
alignment.
9 Check feed and transfer pumps for wear of mechanical drive components
(in accordance with manufacturer’s instructions) and determine the actual
pumping capacity as compared to the nominal value once a year.*
10 Check spray nozzles and distributor for leakages and functional reliability
as required, but at least once a year, and replace components if necessary.
The equipment should only be dismantled for cleaning and repair purposes
by qualified personnel.
11 Remove old lubricant from the pinion area at least twice a year depending
on the cover design.*
49
10.
Services offered by Klüber
Fig. 53: Silicone rubber impression of a Fig. 54: Damaged tooth flank Fig. 55: Optimized spray pattern
damaged tooth flank
50
11.
Used lubricant analyses and
documentation
Determining the condition of operational lubricants type C (immersion and circulation lubrication)
11.1.
The same procedure applies to ana-
Lubricant analyses lyses carried out at regular intervals.
The condition of the operational Klüber Lubrication provides customers
lubricant has to be analyzed at regular with sample containers. Only new and
intervals in order to ensure trouble-free clean sample containers should be
operation of gears with immersion or used and tightly closed immediately
circulation lubrication systems. after being filled with the sample.
Lubricant analyses also allow drawing
conclusions on the condition of the
machines and the operating condi-
tions. Thus, early detection of failures 11.3.
is often possible. Also, lubricant
change intervals can be exactly
Documentation of the
determined. Consequently, machine lubricant sample and
uptimes are higher, repair and down- recommendations for
times can be scheduled, repair costs further steps to be taken
are lower and environmental impact
is reduced. Klüber Lubrication offers Immediately after taking samples
these extensive services to all of their attach a sample identification label,
customers, in many cases even free fill in an laboratory analysis sheet and
of charge. send the sample to Klüber Lubrication
using appropriate packing material.
51
12.
Transparent
Klüber lubricants for
large girth gear drives
52
These lubricants provide an elasto- 12.1.
hydrodynamical effect, which sepa-
rates the smooth tooth flanks. In this
Priming with
respect, a very good lubricant distrib- Klüberplex AG 11-462
ution and lubricant film thickness as For priming the light-colored grease
well as properly adjusted gear drives Klüberplex AG 11-462 has been
are of decisive importance. When formulated. If this product is not
using transparent Klüberfluid C-F ... available, Klüberfluid C-F 3 Ultra
Ultra the lubricant film on the tooth might also be used as a priming lubri-
flanks can be made visible by means cant due to its good adhesion. Appli-
of a UV lamp of min. 366 nm wave cation methods and quantities are the
length. same as in the case of graphite-con-
taining lubricants. The load patterns
The application notes made in this of light-colored and transparent lubri-
brochure on graphite-containing lubri- cants are less distinct.
cants also apply to most graphite-free
products, however, ambient and prod-
uct temperatures have to be taken into 12.2.
close consideration. If the specified Running-in lubrication
application temperature cannot be
reached, the spray system as well as
with Klüberfluid B-F 2
nozzles, lubricant drum or container, Ultra
should be heated. The same applies as said under
chapter 5.2.
In the case of immersion lubrication
it might be necessary to heat the
lubricant reservoir. When using the 12.3.
circulation lubrication equipment Forced running-in
Klübermatic PA at low ambient tem-
peratures, the whole pump and filter
lubrication with
system should be placed into a heated Klüberfluid D-F 1 Ultra
room; also the lubricant reservoir and Chapter 6 “Forced running-in lubrica-
the feed and return lines should be tion” also applies to this Klüberfluid
heated and insulated. product, however pressure marks are
hardly visible because of the lubricant’s
The A – B – C system lubrication also light grey color. Due to its trans-
applies to the transparent Klüberfluid parency, however, the tooth flank
products, i.e. condition can be monitored by
stroboscope which immediately
identifies any changes.
A = priming
B = running-in or correction lubrication Checking the load distribution on
C = operational lubrication the tooth flanks by means of infrared
temperature measurement while the
machine is running is of particular
importance.
53
12.4. Klüberfluid C-F 3 S Ultra contains a
solvent and can only be used for spray
Operational lubrication lubrication. The solvent is an eco-
K Klüberfluid C-F 3 Ultra friendly natural product.
54
13.
Lubricant film thickness
Lambda
Lambda () is the ratio of the lubricant If Lambda is greater than 2 (i.e. the If Lambda is less than 0.7, the gear
film thickness (hc) divided by the aver- lubricant film thickness is twice as high is operating under boundary lubrica-
age surface roughness of the gearing as the surface roughness Ra), the gear tion conditions, meaning that there
(Ra1 + Ra 2). Table 3 shows the Lambda is operating under full-film hydro- definitely is a metal-to-metal contact
values calculated for the individual dynamic lubrication, i.e. the tooth between the tooth flank surfaces.
lubricants: flanks are completely separated by The Lambda value should always be
the lubricant film. greater than 2.
GRAFLOSCON = adhesive grease
Klüberfluid = highly viscous oil If Lambda is between 0.7–2, the gear Since 1995 we have gained many
is operating under mixed friction condi- positive results which confirm these
hc tions, i.e. there may be metal-to-metal theoretical findings and the efficiency
Lambda = ––––––––––––––
Ra 1 + Ra 2 contact between the mating tooth sur- of the Klüberfluid products.
–––––––––– faces.
2
20 쎱 쎱
15
쎱 쎱
5
쎱 쎱
쎱 쎱 쎱
쎱 쎱 쎱 쎱 쎱 쎱
쎱 쎱
쎱 쎱 쎱 쎱 쎱
0
20 100 200 300 400 500 600
Time [sec.]
20
15
10
probable curve
5
0
10 50 100 150 200 250 300
Time [sec.]
55
Film thickness calculation
(based on continuous lubrication)
Gear rim and pinion drive of a tube mill
Input power P 1550 kW Speed factor of pinion / wheel 110 / 15.5 min –1
Torque of pinion 134 kNm Peripheral speed 4.538 m /s
Module m 25.4 mm Tooth number of pinion / wheel 31 / 220
Face width b 625 mm Pressure angle 20 º
Helix angle 0º Center distance a 3190 mm
Tooth flank roughness prior to running-in lubrication: Ra = 4.3 μm after running-in lubrication: Ra = 0.4 μm
Table 3
56
Flank roughness Film thickness Lambda
57
14.
Klüber A – B – C system
lubrication and D repair
lubrication
with black, non-transparent products containing graphite
Overview
A – Priming and pre-start lubrication
C – Operational lubrication
58
15.
Klüber A – B – C system
lubrication and D repair
lubrication
with light-colored or transparent lubricants
Overview
A – Priming and pre-start lubrication
C – Operational lubrication
59
A – Priming and pre-start lubrication
with transparent lubricants or lubricants
containing graphite
LUBRICANTS
GRAFLOSCON A-G 1 Ultra black (with graphite)
Klüberplex AG 11-462 light-colored
Klüberfluid C-F 3 Ultra transparent
Klüberfluid C-F 3 S Ultra transparent
60
Required quantities
Example:
Reference circle Ø: 6000 mm
Tooth flank width: 800 mm
required quantity [kg]
Determined
quantity: approx. 28.5 kg
Quantity to be
purchased: 30 kg
61
B – Running-in lubrication and
correction lubrication
with transparent lubricants or lubricants containing graphite
LUBRICANT
GRAFLOSCON B-SG 00 Ultra black (containing graphite) for
spray lubrication (1 or 2 180 kg drums)
Klüberfluid B-F 1 Ultra black (containing graphite) for
immersion/circulation lubrication
Klüberfluid B-F 2 Ultra transparent for immersion/circulation/
spray lubrication (2 or 3 180 kg drums)
Depending on the type and the size of the drive, one to three 180 kg drums are
normally required for running-in with spray lubrication.
62
Specific consumption quantities for running-in lubricants
Double-pinion Drive of
mill drive rotary drum
(type 5) (type 1)
Required specific
consumption quantity
[g / (cm · operating hour)] 8 4
Consumption quantity / 8 · 85 = 4 · 40 =
operating hour, [g] 680 160
63
C – Operational lubrication
with black lubricants containing graphite –
spray lubrication
LUBRICANTS
GRAFLOSCON C-SG 0 Ultra
GRAFLOSCON C-SG 1000 Ultra
GRAFLOSCON C-SG 2000 Ultra
Consumption quantities
The following table shows the required
consumption quantities which can be
used as a basis to calculate the quan-
tity required per time unit depending
on the type of installation and the flank
width. The consumption quantities can
also be determined using the diagram
Fig. 22. See also the following NOTE.
The consumption quantities indicated
in the diagram refer to GRAFLOSCON
C-SG 0 Ultra.
64
Specific consumption quantities for operational lubricants
containing graphite
K application of a type C
GRAFLOSCON operational
Examples of calculating the consumption quantity
lubricant
Double-pinion Drive of a
mill drive rotary drum
(type 5) (type 1)
Required specific
consumption quantity
[g / (cm · operating hour)] 3.5 1.5
65
C – Operational lubrication
with transparent lubricants – Spray lubrication
Consumption quantities
The following table shows the required
consumption quantities which can be
used as a basis to calculate the quan-
tity required per time unit depending
on the type of installation and the flank
width. The consumption quantities can
also be determined using the diagram
Fig. 22a.
1)
See Note on page 71
66
Specific consumption quantities for transparent operational lubricants
Required specific
consumption quantity
[g / (cm · operating hour)] 1.8 0.8
67
C – Operational lubrication
with black lubricants containing graphite –
immersion and circulation lubrication
1)
See Note on page 71
68
C – Operational lubrication
with transparent lubricants –
immersion and circulation lubrication
1)
See Note on page 71
69
D – Repair and correction lubrication
LUBRICANT
For repair lubrication and for correction or forced running-in lubrication
K pittings
How to carry out correction lubrication
K material cratering and forced running-in lubrication
Correction lubrication is carried out in
Correction lubrication the same way as running-in lubrication.
K higher tooth flank contact ratio
and smoother tooth flanks IMPORTANT
GRAFLOSCON D-SG 00 Ultra and
Application of Klüberfluid D-F 1 Ultra must not be
GRAFLOSCON D-SG 00 Ultra and used in immersion baths, circulation
Klüberfluid D-F 1 Ultra lubrication systems and automatic
The repair lubricant is applied manually spraying equipment.
NOTE by brush or with a manual spraying
unit, e.g. Klübermatic LB. Kiln drives The types of damage indicated
The following types of damage require larger quantities of the type D under “NOTE” require mechanical pre-
cannot be removed by way of repair lubricant than e.g. mill drives, which are treatment by means of a manual
lubrication: quicker to repair because of the higher grinder or an end-milling cutter.
speed and the resulting higher sliding
K burrs at the tip and the side of speed on the tooth flanks and the more It is not possible to repair progressive
the teeth frequent tooth contacts. pittings in under-dimensioned drives.
K raised areas in the pitch circle How to carry out repair lubrication
Before starting repair lubrication it is
K wear marks at the tooth root of utmost importance to determine the
primary causes of the existing damage
K sharp edges and deep pittings and to rectify them in order to prevent
the fault from recurring. Repair lubrica-
tion must always be carried out to-
70
Bibliography
Blanke, H.-J. Rohloff/Matek Publisher and design:
Das gezielte Einfahren großer Maschinenelemente Klüber Lubrication München KG
Zahnkranzantriebe und Möglichkeiten Vieweg Verlag, Ausgabe 2003
der Tragbildkontrolle Copyright:
Beitrag 10 in „Getriebeschmierung in der Saxer, B. Klüber Lubrication München KG
Anlagentechnik“, Expert Verlag 1990 Betriebsverhalten und Schmierung
von offenen und geschlossenen Reprints, total or in part, are permitted
Blanke, H.-J. Großantrieben if source is indicated and voucher copy
Schmiersysteme für Zahnkranzantriebe Beitrag 11 in „Getriebeschmierung in der
Anlagentechnik“, Expert Verlag 1990 is forwarded.
unter Berücksichtigung der Schmier-
stoffart und Auftragungsmethode
Beitrag 13 in „Getriebeschmierung in der Tabellenbuch Metall 9.2 en
Anlagentechnik“, Expert Verlag 1990 Europa Lehrmittel, 38. Auflage, 1992 Edition 01.10, replaces edition 03.08
Michaelis, K.
Verschleißarten bei Zahnradgetrieben
Beitrag 12 in „Getriebeschmierung in der
Anlagentechnik“, Expert Verlag 1990
1)
SERVICE TEMPERATURES
Service temperatures are guide values which depend on the lubricant’s composition,
the intended use and the application method. Lubricants change their consistency, shear viscosity
or viscosity depending on the mechano-dynamical loads, time, pressure and temperature.
These changes in product characteristics may affect the function of a component.
71
We are where you are.
Klüber Lubrication – the world market leader in speciality lubricants