HG/T 3139.4-2001 Vertical reducer for kettle LPJ series cylindrical gear reducer
Some standard content:
Chemical Industry Standard of the People's Republic of China
Vertical reducer for tank
LPJ series cylindrical gear reducer
Vertlcal reducer for tank
Series LPJ cylindrical gear reducerHG/T3139.4—2001
This standard specifies the product classification, requirements, test methods, inspection rules, marking, packaging, transportation, storage of LPI series two-stage and three-stage parallel shaft cylindrical gear reducers (hereinafter referred to as reducers). This standard is applicable to mixing reducers for tanks in petrochemical, pharmaceutical, light industry and food, and vertical reducers for other purposes. 2 Referenced standards
The provisions contained in the following standards constitute the provisions of this standard by being referenced in this standard. When this standard is published, the versions shown are valid. All standards will be revised, and the parties using this standard should explore the possibility of using the latest version of the following standards. GB/T1095—1979 Flat key and key profile GB/T1184--1996 Shape position tolerance tolerance value GB/I3077--1988 Alloy structural steel technical conditions GB59031995T industry closed gear oil
GB/T 9439—1988 Grey cast iron
GB/T10095—1988 Involute circular gear accuracy JB/T9050.3—1999 Circular gear reducer loading test method 3 Product classification
3.1 T.PJ type—Y type two-stage and three-stage reducer. 3. 2 LPB type—
Vertical two-stage and three-stage super long shaft reducer. 3.3 Model representation method and examples:
Approved by the State Economic and Trade Commission on 2002-D1-24 and implemented on 2002-07-01
Type code
Calibration symbol Motor code
HG/T 3139. 4--2001
Two-stage machine model
Motor name
Asynchronous motor
Explosion-proof safety asynchronous motor
Flameproof asynchronous motor
Brake asynchronous motor (additional brake)
Multi-connection asynchronous motor
Three-stage machine model
Pin code
See Table 1 (can also be connected to note P Sum
Calibration symbol
Motor code
Output shaft extension
Structure code
1 Clamp shell type
“T Ordinary type
Motor name
Flameproof multi-speed asynchronous motor
Electromagnetic speed regulating asynchronous motor
Flameproof electromagnetic speed regulating asynchronous motor
Flameproof brake asynchronous motor (additional brake) Variable frequency speed regulating special motor
3.4 The transmission ratio, output speed, input power and output shaft allowable torque of IPJ and LPB two-stage reducers shall comply with the provisions of Table 1. Transmission ratio, output speed, input power and output allowable torque Table 1
Transmission ratio
Output speed
n+T/min
Motor
46 1 45, 50
8 pole 750 1/min
6 pole 1 000 r/min
122220 181611121110987654.5
rut derailment
8368 75 83 94 105125135150165188215250300330 reducer allowable
4 pole 1 500 r/min
Wei/code
1/64/67/6
812|1620|242832
91317212529331171
10/1418222630 34PB17
2/65/68/6/10/612/614/6135
711151923.273135
3/66/69/611/613/615/024
46465370892222
4 70050 2
1 6 72 1520
13 14161820 22
28 378 47817 46017562072714 15 1719 21 23 24 26 121215825/86162/6 4/6 66 8/6 10/6 242228 25 27 P1218350
844365676 9611622212
44 14
1448887817 6656 78662142122241508806432287 68/8 2/6 4/6 6/618/610/6117 731021017 18/19/2071L
LPJ272
#221122231
512/62467
LPB272
825122 12 8 10 411311s 221203 515412 07001214 16 19 2124 272272/85/818/81612
3/8 6/89/81178161/6763/
17202225283134
10282651/94/62326 21 | | tt | | LPJ375 | 215 71277
2427 2932343638 1.PJ600
3033353739LPB60d
HG/T 3139.4—2001
3.5The installation and overall dimensions of LFJ and LPB two-stage reducers shall comply with the requirements of Figure 1 and Table 2. 1.PJ type
T-type shaftwwW.bzxz.Net
I type load
T-type shaft
Figure 1 LPJ, LPB type two-stage parallel shaft gear reducer appearance Figure 2 Installation and external dimensions of two-stage reducer
392330
40k6270
50k6 |350, 530
60m6350
24070r16
530407
400600
90m6 490:735
37590m5580
580-~-610
657-~747
672~-842
7801080
601 , 1 036--1 266
1 141~-1 306
1260~157095
5001(m67201050955
1755193511 0
600130685012401065|1950-~2355125250
400820||tt| |Installation ruler
780!10
760.182010
145:100!18
8-M16 145102062.5
228-M16
145130
19013025
190 13025
016028
12-M20190
12 M20230180
3.61.The transmission ratio, output speed, input power and output shaft permissible torque of PJ, T.PB type two-stage reducer shall comply with the provisions of Table 3.71
Transmission ratio
Output speed
m+r/tin
Motor power
P, kw
HG/T 3139. 4—2001
Table 3 Transmission ratio, output speed, input power and output shaft permissible torque35.531.5
6-pole motor 1Coo r/rnin
4-pole motor 1500r/min
P/n code
7/6:10/5
9/612/6
2/64/G
5/66/6
10 56 02
Reducer
IPJ311
LPB395
LPJ395
3.7I.The installation, connection and overall dimensions of PJ and LPB flange-grade reducers shall comply with the requirements of Figure 2 and Table 4. [.PI type
1 type shaft
Figure 2I.PJ, LPB type flange parallel shaft gear reducer appearance drawing K direction
LPB496
LPJ496
LPE555
LPJ555
Protruding shaft
Allowable torque
50k6360
44080m6
110m6580
4 Requirements
4.1 Working conditions
730-770
750--840
870--990
HG/T 3139.4---2001
Installation, connection and overall dimensions of three-stage reducer F
960-1200
1260~1365
1 040 800 1 400~1 710108400
12-923
145100
14513022
28:190150
200 17028
4.1.1 The working environment temperature of the reducer is -40~40℃. Under constant load and rated speed, the temperature rise of the oil pool of the reducer shall not exceed 45℃, and the maximum oil temperature shall not exceed 85℃.
4.1.2 The rated voltage of the motor power supply is 380V and the rated frequency is 50Hz. 4.1.3 The reducers included in this standard are suitable for continuous working and are allowed to run in both positive and negative directions. 4.1.4 The input speed should not exceed 1500r/min. 4.2 Body, box cover
4.2.1 The mechanical properties of the material should comply with the casting regulations of HT200 in GB/T9439. 4.2.2 The castings should be aged or annealed. The surface after processing is not allowed to have defects such as cracks, pores, shrinkage and slag inclusions. Other parts are not allowed to have defects that affect the performance of the casting. 4.2.3 The center deviation of the bearing holes of each gear at all levels from the plate is ±fa, which should comply with the 8th grade accuracy of GB/T10095. 4.2.4 The parallelism tolerance fx and fy values of the axis centerline of the bearing holes of each gear at all levels should comply with the 8th grade accuracy of GB/T10095. 4.2.5 The verticality of each bearing hole to the reference end face of the box body and box cover should comply with the 6th grade regulations of GB/11184. 4.2.6 The tolerance zone of each bearing hole is H7, the cylindricity shall comply with the 7th grade of GB/T1184, and the surface roughness Rz value shall not exceed 3.2um4.3 Gears and gear shafts
4.3.1 The tooth surface is allowed to be hardened by ion nitriding or fine-machined after carburizing and annealing. 4.3.1.1 Ion nitriding process: The material is 38CrMoA1, and the mechanical properties shall comply with the provisions of GI3/T3077, and it is allowed to be replaced by 42CrMo material, and the mechanical properties shall also comply with the provisions of GB/T3077. 4.3.1.2 Carburizing process: The material is 20CrMnTi or 20CrMnMa, and the mechanical properties shall comply with the provisions of GB/T3077. 4.3.2 The tooth is forged by forging process, and normalizing treatment shall be carried out after forging. 4. 3. 3
The depth and hardness of the nitrided tooth surface shall be in accordance with the requirements of Table 5 and Table 6. Table 5 Selection of gear nitriding layer depth
Module, mm
1. 5 ~~2. 5
Depth range.nin
0. 25 -~0. 40
0.35--0.59
0. 45--c. 55
38CrMaAl
12CrMo
HG/T3139.42001
Table 6 Gear tempering, nitriding hardness range
Original condition
Pretreatment
Nitrided tooth surface is not allowed to have defects such as cracks, peeling, breakage, bright spots, etc. 4. 3. 4
Hardness, HB
241-~283
Nitriding surface hardness, HV
900-1100
550-700
Recommended table for effective carburizing layer depth, tooth surface hardness, core hardness and carbon concentration of carburizing layer for carburized and quenched gears? Requirements, 4. 3. 5
Module, mm
Effective carburizing layer depth
Carbon concentration of carburized layer
Tooth surface hardness
Core hardness
Carburized layer depth, tooth surface hardness, core hardness and carburized layer carbon concentration2>1~1. 5
0.4--0. 7
>2--2. 75
2>2. 75--4
0. 6 ~1. 0
After carburizing gear finishing, there is no hair-like crack on the tooth surface0. 8~ 1. 2
0. 7~ 1. 0
32·~40
The manufacturing accuracy of gears and gear shafts should not be lower than Grade 8 accuracy in GB/T10095. 4.3.7
The radial and end face runout tolerances of the gear reference surface shall comply with the provisions of Table 8. 4.3.8
Table 8 Radial and end face runout tolerances of the gear reference surface Pitch circle diameter
1.2 -~1.7
Gear accuracy grade
Grade 7 and 8
4.3.9 The matching tolerance zone of the gear hole and shaft is H7/k6. The roundness shall comply with the 7th grade accuracy of G13/T1184. 4.3.10 The matching tolerance zone of the gear shaft journal and the bearing is k6. 4.4 Output shaft
4.4.1 The material is 45# steel, quenched and tempered 217~255HB. 4.4.2 The key on the cylindrical shaft extension shall comply with the provisions of GI3/T1095. 4.5 Assembly
4.5.1 The inner ring of the bearing must be close to the shaft shoulder or the fixed distance. Check with a 0.(75mm feeler gauge and it must not be inserted.>9~10
4.5.2 The axial clearance of the tapered roller bearing (contact angle 810°16\) shall comply with the provisions of Table 9. Turn the shaft by hand, and the bearing must run lightly and flexibly.
Axial clearance of tapered roller bearing
Bearing inner diameter d
50~~80
>8~120
>120～180
180-~260
Axial clearance-rm
HG/T 3139. 4—2001
4.5.3 The minimum normal tooth side clearance of the gear pair shall comply with the provisions of Table 10. Center distance a
Table 10 Minimum normal tooth side clearance of the gear pair>80~125125-~180180~250250~315>315~400400~500500--630630~710140
4.5.4 The height of the contact spot (contact rate) on the gear surface shall not be less than 40%, and the length shall not be less than 50%. The distribution position of the contact spot should be close to the middle of the tooth surface, and contact is not allowed at the tooth top and the edges of both ends. It is allowed to inspect the contact spot by the no-load running-in gloss method. 4.5.5 The inner and outer surfaces of the parts must be cleaned of burrs, chips, and rust before assembly. Traces, residual sand and dirt. The unprocessed surface of the casting should be primed and then painted, and the unprocessed inner surface should be painted with red oil-resistant paint. 4.5.6 There should be no oil leakage from the shaft oil seal and other sealing surfaces. 4.5.7 The appearance of the reducer should be neat, the paint layer should be uniform, and the surface should be free of damage. 4.6 Reducer lubrication and selection of lubricating oil 4.6.1 Lubrication of reducer gears: two-stage reducers use oil bath lubrication, and three-stage reducers use circulating oil spray forced lubrication. 4.6.2 The selection of oil products should be based on the ambient temperature and the pitch line speed of the low-speed gear. Use different grades of gear oil in GB5903I-CKC.
4.6.3 Bearing lubrication:
a) Use splash oil lubrication, and the oil is the same as the gear lubricating oil. h) All bearings lubricated with grease can use general lithium-based grease. 5 Test method
5.1 No-load test
The reducer must be tested no-load. Before the test, sufficient lubricating oil should be added according to the specified oil level. During the test, the machine should run for 1 hour in both the forward and reverse directions at the rated speed. The no-load test should meet the following requirements: a) All connecting parts and fasteners should not be loose. h) All seals and joints should not leak oil. c) The operation should be smooth and normal, without impact and abnormal noise. d) The oil temperature should not exceed 25℃, and the lubrication should be sufficient. e) The contact spots on the tooth surface should meet the requirements of 4.5.4. If it does not meet the requirements, it is allowed to continue running for 1 hour. 5.2 Load test
5.2.1 After the no-load test is qualified, the load test can be carried out. At the rated speed, the load test is carried out in four steps, and 25% of the rated power is loaded each time. After each load test reaches the oil temperature balance for 1 hour, the load test is increased by one level. 5.2.2 The load test should meet the following requirements: a) All seals and joints should not be submerged in oil. b) The contact spots on the tooth surface shall meet the requirements of 4.5.4, ) The speed reducer shall run smoothly and normally without impact and abnormal noise, d) The temperature rise of the lubricant oil in the speed reducer housing shall not exceed 45℃, and the maximum oil temperature shall not exceed 85℃. e) The noise measured at 1m away from the speed reducer housing shall not exceed 85dB(A). When the power P is greater than or equal to 75kW and the output speed is greater than or equal to 215r/min, the noise shall not exceed 90dB(A). 5.3 Full load test
The full load test shall be loaded to more than 90% of the rated power and run continuously for more than 24h. The test results shall meet the requirements of 5.2.2. This test is allowed to be carried out at the host site and according to the host requirements. 69
HG/T 3139. 4-2001
5.4 Overload test
5.4.1 The overload test shall be carried out after the load test is qualified. The overload test should be carried out at rated speed, and run at 120% of the rated power for 1 minute, 150% for 1 minute, and 180% for 0.5 minutes. 5.4.2 After the overload test, the reducer should meet the requirements of 5.2.2 and should be able to operate normally. This test is allowed to be carried out at the host site and according to the host requirements.
5.5 Fatigue life test
5.5.1 The fatigue life test is mainly aimed at the assessment of the fatigue life of the gear. It can be carried out on an industrial loading test bench or test. It is also allowed to use industrial application test instead of fatigue life test, but it must be tested according to the equivalent load cycle number under the actual load of industrial application, and there must be a confirmed daily record. The test time is not less than 3600h.
5.5.2 The fatigue life test must be carried out after the test of 5.15.2 is passed. The test should be carried out under rated load. The stress cycle number of the high-speed gear should reach 2×[0 working times of running time, and the load test should be carried out according to this time. 5.5.3 When the fatigue life test or industrial application test is conducted under rated load for more than 3600h, the integrity requirements of the reducer are as follows: a) There is no breakage between the gear and other parts.
b) There is no bonding or abrasion on the tooth surface.
c) The thickness of the friction wear on the tooth surface measured near the tooth root shall not exceed 4% of the gear module value. d) The limit of the pitting area on the tooth surface shall be calculated according to the formula in JB/T9050.3. 6 Inspection rules
6.1 Factory inspection
Products shall be inspected and qualified one by one before leaving the factory;
Factory inspection shall be carried out in accordance with the requirements of 5.1 and shall comply with the requirements of Section 4. 6.2 Sampling inspection
6.2.1 Sampling inspection shall be carried out in the following cases: a) For machines with an annual cumulative output of more than 100 units, sampling inspection shall be carried out at least once a year. For those with less than 100 units, the shaft sample inspection shall not be less than: - times within the period when the cumulative output reaches 100 units. b) When evaluating or certifying product quality.
) When the main technical performance is unqualified. 6.2.2 Sampling method: When the batch of the inspected reducers is 10 units, 10% shall be inspected, and one unit shall be inspected when each batch is less than 10 units. If the inspection fails, double the inspection; if it still fails, the unit shall be inspected. 6.2.3 The items of sampling inspection shall be carried out in accordance with the requirements of 5.1, 5.2, and 5.4, and it is also allowed to be carried out in accordance with the requirements of 5.1, 5.3, and 5.4. 6.3 Type inspection
6.3.1 Type inspection shall be carried out in all the following cases: a) Finalization identification before the new product is put into production.
b) After the formal production, if the design, process or material of the product has changed significantly enough to cause changes in certain characteristics and parameters. e) When the production is resumed after a long period of suspension for more than one year. d) When the user proposes and there are special requirements in the contract, 6.3.2 type inspection shall be carried out in accordance with 5.5.
7 Marking, packaging, transportation and storage
7.1 Each reducer shall be fixed with a product nameplate in the position specified in the product drawing. The nameplate shall be installed with the paint layer separated from the base body. The content of the product nameplate is as follows:
a) Product name.
b) Product model.
c) Transmission ratio.
d) Rated output speed.
e) Rated power.
f) Weight.
g) Product number.
h) Date of manufacture.
i) Manufacturer name.
HG/T3139.4—2001
7.2 The outer surface of the reducer shaft extension and key should be coated with anti-rust grease, and tightly tied with plastic cloth, or other protective measures should be adopted. Other external phosphorus processing surfaces should also be coated with anti-rust oil.
7.3 The technical documents supplied with the product include: a) Product certificate and packing list.
b) Product instruction manual.
The technical documents should be placed in a plastic bag and fixed on the inner wall of the box. 7.4 The product should be packed and shipped, and should be fixed in the box, and should meet the requirements of land and water transportation and loading. Waterproof materials should be laid in the packaging box.
7.5 The outer wall of the packaging should have obvious text markings, and the text markings should be clear and neat to ensure that they are not blurred due to rain erosion. The content includes:
a) Receiving unit and address.
b) Product manufacturer, product name, model. e) Net weight, gross weight, box dimensions and factory serial number. 7.6 During transportation and hoisting, the reducer should be stably lifted and placed upright and not inverted. 7.7 The reducer should be stored in a clean place that is protected from rain, snow and water. 713. When the fatigue life test or industrial application test is conducted under rated load for more than 3600h, the integrity requirements of the reducer are as follows: a) There is no breakage between the gear and the machine parts.
b) There is no bonding or abrasion on the tooth surface.
c) The thickness of the friction wear on the tooth surface measured near the tooth root shall not exceed 4% of the gear module value. d) The limit of the pitting area on the tooth surface shall be calculated according to the formula in JB/T9050.3. 6. Inspection rules
6.1 Factory inspection
Products shall be inspected and qualified one by one before leaving the factory;
Factory inspection shall be carried out in accordance with the requirements of 5.1 and shall comply with the requirements of Section 4. 6.2 Sampling inspection
6.2.1 Sampling inspection shall be carried out in the following cases: a) For various machine models with an annual cumulative output of more than 100 units, sampling inspection shall not be less than once a year. For those with less than 100 units, the shaft sample inspection shall not be less than: - times within the period when the cumulative output reaches 100 units. b) When evaluating or certifying product quality.
) When the main technical performance is unqualified. 6.2.2 Sampling method: When the batch of the inspected reducers is less than 10 units, 10% shall be inspected, and when each batch is less than 10 units, one unit shall be inspected. If the inspection fails, double the inspection; if it still fails, the unit shall be inspected. 6.2.3 The items of sampling inspection shall be carried out in accordance with the requirements of 5.1, 5.2, and 5.4, and it is also allowed to be carried out in accordance with the requirements of 5.1, 5.3, and 5.4. 6.3 Type inspection
6.3.1 Type inspection shall be carried out in all the following cases: a) Finalization identification before the new product is put into production.
b) After the formal production, if the design, process or material of the product has changed significantly enough to cause changes in certain characteristics and parameters. e) When the production is resumed after a long period of suspension for more than one year. d) When the user proposes and there are special requirements in the contract, 6.3.2 Type inspection shall be carried out in accordance with 5.5.
7 Marking, packaging, transportation and storage
7.1 Each reducer shall be fixed with a product nameplate in the position specified in the product drawing. The nameplate shall be installed with the paint layer separated from the base body. The content of the product nameplate is as follows:
a) Product name.
b) Product model.
c) Transmission ratio.
d) Rated output speed.
e) Rated power.
f) Weight.
g) Product number.
h) Date of manufacture.
i) Manufacturer name.
HG/T3139.4—2001
7.2 The outer surfaces of the reducer shaft extension and key shall be coated with anti-rust grease, and tightly tied with plastic cloth, or other protective measures shall be adopted. Other external phosphorus processing surfaces shall also be coated with anti-rust oil.
7.3 The technical documents supplied with the product include: a) product certificate and packing list.
b) product instruction manual.
The technical documents should be placed in a plastic bag and fixed on the inner wall of the box. 7.4 The product should be fixed in the box when it is packed and shipped, and it should be suitable for land and water transportation and loading requirements. Waterproof materials should be laid in the packaging box.
7.5 The outer wall of the packaging box should have obvious text markings. The text markings should be clear and neat to ensure that they will not be blurred due to rain erosion. The contents include:
a) Receiving unit and address.
b) Product manufacturer, product name and model. e) Net weight, gross weight, box dimensions and factory number. 7.6 During transportation and lifting, it should be stably lifted and placed, placed upright and not inverted. 7.7 The reducer should be stored in a clean place that can be protected from rain, snow and water. 713. When the fatigue life test or industrial application test is conducted under rated load for more than 3600h, the integrity requirements of the reducer are as follows: a) There is no breakage between the gear and the machine parts.
b) There is no bonding or abrasion on the tooth surface.
c) The thickness of the friction wear on the tooth surface measured near the tooth root shall not exceed 4% of the gear module value. d) The limit of the pitting area on the tooth surface shall be calculated according to the formula in JB/T9050.3. 6. Inspection rules
6.1 Factory inspection
Products shall be inspected and qualified one by one before leaving the factory;
Factory inspection shall be carried out in accordance with the requirements of 5.1 and shall comply with the requirements of Section 4. 6.2 Sampling inspection
6.2.1 Sampling inspection shall be carried out in the following cases: a) For various machine models with an annual cumulative output of more than 100 units, sampling inspection shall not be less than once a year. For those with less than 100 units, the shaft sample inspection shall not be less than: - times within the period when the cumulative output reaches 100 units. b) When evaluating or certifying product quality.
) When the main technical performance is unqualified. 6.2.2 Sampling method: When the batch of the inspected reducers is less than 10 units, 10% shall be inspected, and when each batch is less than 10 units, one unit shall be inspected. If the inspection fails, double the inspection; if it still fails, the unit shall be inspected. 6.2.3 The items of sampling inspection shall be carried out in accordance with the requirements of 5.1, 5.2, and 5.4, and it is also allowed to be carried out in accordance with the requirements of 5.1, 5.3, and 5.4. 6.3 Type inspection
6.3.1 Type inspection shall be carried out in all the following cases: a) Finalization identification before the new product is put into production.
b) After the formal production, if the design, process or material of the product has changed significantly enough to cause changes in certain characteristics and parameters. e) When the production is resumed after a long period of suspension for more than one year. d) When the user proposes and there are special requirements in the contract, 6.3.2 Type inspection shall be carried out in accordance with 5.5.
7 Marking, packaging, transportation and storage
7.1 Each reducer shall be fixed with a product nameplate in the position specified in the product drawing. The nameplate shall be installed with the paint layer separated from the base body. The content of the product nameplate is as follows:
a) Product name.
b) Product model.
c) Transmission ratio.
d) Rated output speed.
e) Rated power.
f) Weight.
g) Product number.
h) Date of manufacture.
i) Manufacturer name.
HG/T3139.4—2001
7.2 The outer surfaces of the reducer shaft extension and key shall be coated with anti-rust grease, and tightly tied with plastic cloth, or other protective measures shall be adopted. Other external phosphorus processing surfaces shall also be coated with anti-rust oil.
7.3 The technical documents supplied with the product include: a) product certificate and packing list.
b) product instruction manual.
The technical documents should be placed in a plastic bag and fixed on the inner wall of the box. 7.4 The product should be fixed in the box when it is packed and shipped, and it should be suitable for land and water transportation and loading requirements. Waterproof materials should be laid in the packaging box.
7.5 The outer wall of the packaging box should have obvious text markings. The text markings should be clear and neat to ensure that they will not be blurred due to rain erosion. The contents include:
a) Receiving unit and address.
b) Product manufacturer, product name and model. e) Net weight, gross weight, box dimensions and factory number. 7.6 During transportation and lifting, it should be stably lifted and placed, placed upright and not inverted. 7.7 The reducer should be stored in a clean place that can be protected from rain, snow and water. 71
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