挤压脱水机减速器空芯轴开裂的分析与对策  

ANALYSIS OF CRACK ON THE OUTPUT SHAFT OF REDUCER OF DEWATERING EXTRUDER AND COUNTERMEASURES

作　　者：苏权辉 Su Quanhui(SINOPEC Maoming Company,Maoming,Guangdong,525021)

机构地区：[1]中国石油化工股份有限公司茂名分公司,广东茂名525021

出　　处：《石油化工设备技术》2024年第5期11-18,I0001,共9页Petrochemical Equipment Technology

摘　　要：对某合成橡胶装置挤压脱水机进行检修时发现减速器空芯轴开裂和输出齿轮内孔磨损的问题。分析显示,导致上述问题的原因为:减速器空芯轴材料的抗疲劳能力不足,诱发了空芯轴的开裂;机组生产干胶时,长期在中低负荷条件下运行,同时,螺套的设计布局不够合理以及螺套与笼体间隙偏小,造成螺套与笼体的刮磨,从而引发了机组的异响和振动;在交变载荷、异常振动和润滑油元素聚集的共同作用下,加快了空芯轴的疲劳开裂。空芯轴与输出齿轮为间隙配合,空芯轴的开裂使两者间的微运动加剧,并最终导致输出齿轮内孔的磨损。考虑到输出齿轮内孔的磨损程度在可控范围内,因此,对输出齿轮内孔和齿面采用了修复的处理方案。而开裂的空芯轴则需要更换新轴。新的国产化空芯轴选用机械性能更好的34CrNi3Mo并优化了热处理工艺,与修复后的输出齿轮内孔配对加工。此外,还优化了螺套的布局,适当减小了螺套的外径并提高了机组的运行负荷,以使挤压脱水机的运行更加安全稳定。During maintenance,it was found that the output shaft of reducercracked and the inner hole of the output gear was worn.The analysis indicated that the fatigue resistance of the output shaft of reducer material was insufficient,which induced the cracking of the output shaft of reducer.The expeller operated under medium and low loads for a long time when producing dry rubber.Meanwhile,the design layout of the screw was unreasonable and the clearance between the screw and the barrels was small,which caused scraping and grinding of the screw and the barrels,thus triggering the abnormal noise and vibration.The fatigue cracking of the output shaft of reducerwas accelerated under the combined action of alternating loads,abnormal vibration and accumulation of lubricating oil elements.The clearance fit between the output shaft of reducer and the output gear intensified the micro motion between them due to the cracking of the output shaft of reducer,which eventually led to the wear of the inner hole of the output gear.In view of the fact that the wear of the output gear inner hole was within controllable limits,the treatment plan was adopted to repair the inner hole and the surface of the output gear.And the cracked output shaft of reducer needed to be replaced by a new one.The new domestically produced output shaft of reducer adopted 34CrNi3Mo with better mechanical performance and the heat treatment process was optimized.And then,it was paired with the repaired output gear inner hole.In addition,the layout of the screw has been optimized;the outer diameter of the screw has been appropriately reduced and the operating load of the unit has been increased in order to make the operation of the dewatering extruder safer and more stable.

关 键 词：挤压脱水机 空芯轴 疲劳开裂 热塑性弹性体橡胶 输出齿轮修复 螺套调整 

分 类 号：TQ330.4[化学工程—橡胶工业]