How to monitor and evaluate the lubrication effect of the grader driven rake gearbox?

Monitoring and evaluating the lubrication performance of the grader driven rake gearbox in graders is a critical step to ensure its long-term stable operation. Here are specific methods for monitoring and evaluation:

Lubricating Oil Performance Testing
Viscosity Testing
Use a viscometer to measure the viscosity of the lubricating oil and ensure it meets the viscosity range required by the equipment. Viscosity is the most important physical property of lubricating oil, and adequate fluidity is key to providing sufficient lubrication under varying temperatures in gear transmission systems.
The viscosity of lubricating oil tends to increase over time, so regular monitoring is necessary, and oil exceeding the viscosity range should be replaced promptly.
Oxidation Resistance Testing
Use oxidation stability testing equipment to assess the oil's resistance to oxidation. Over time, oxidation products accumulate in the oil, leading to degradation.
Monitoring the oxidation value helps determine if the oil has undergone severe oxidation, enabling timely replacement to avoid damage to the gearbox.

Oil Analysis
Total Ferromagnetic Particle Detection
Measure the total ferromagnetic particle content in the oil using a magnetometer, expressed in ppm. The quantity and size of these particles reflect the wear condition of the gearbox.
A sudden increase in ferromagnetic particles may indicate abnormal wear inside the gearbox, requiring immediate inspection and maintenance.
Moisture Detection
Monitor the water content in the oil to prevent excessive water from compromising lubrication performance. Water can cause excessive friction heat and lead to severe wear.
Techniques such as infrared spectroscopy can detect contaminants like free water and ethylene glycol antifreeze in the oil.
Particle Counting
Count and classify particles in the oil to assess the cleanliness and wear condition of the gearbox.
Particle counting is typically conducted following ISO 4406 or SAE 4059 standards, providing valuable insights into the gearbox’s condition.
Elemental Spectroscopy Analysis
Use elemental spectroscopy to detect and quantify metal elements in the oil from wear, contamination, and additives.
This method provides fast and accurate data on contamination and wear conditions, supporting preventive maintenance and fault diagnosis.

Lubrication System Monitoring
Lubrication Method Inspection
Check whether the gearbox’s lubrication method complies with equipment requirements. For splash lubrication systems, ensure gears are fully immersed in oil. For pressure lubrication systems, inspect the pump, filters, heat exchangers, and other components.
Lubrication Interval Adjustment
Develop reasonable lubrication intervals based on the gearbox’s working conditions, mechanical load, and ambient temperature.
Regularly inspect oil contamination and adjust lubrication intervals accordingly to ensure proper gearbox operation.
Seal Inspection
Regularly check the condition of the gearbox seals and replace damaged seals promptly to ensure the lubrication system operates correctly.

Vibration and Noise Monitoring
Vibration Monitoring
Use vibration sensors to monitor the gearbox's vibration levels. Vibration signals reflect abnormal conditions such as wear and loosening.
By analyzing the frequency and amplitude of vibration signals, potential faults within the gearbox can be identified.
Noise Monitoring
Use noise sensors to monitor the gearbox’s noise levels. Changes in noise levels can indicate the effectiveness of lubrication and the wear condition of the gearbox.
A sudden increase in noise may signal abnormal wear or loosening inside the gearbox.

Comprehensive Evaluation and Measures
Data Analysis
Perform comprehensive analysis of all monitoring data to evaluate the lubrication performance and overall condition of the gearbox.
Data analysis can identify potential failure points and maintenance needs, providing a basis for maintenance planning.

Maintenance Actions
Based on the evaluation results, implement appropriate maintenance measures, such as replacing severely worn gears, cleaning and replacing lubricating oil, or adjusting lubrication intervals.
For gearboxes with significant faults, prompt overhauls or replacements should be conducted.