INDUSTRIAL A COMPREHENSIVE GUIDE TO INDUSTRIAL GEAR LUBRICANTS
GEAR
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CONTENTS
INTRODUCTION
NDUSTRIAL GEAR 4 IMARKET ANALYSIS
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INDUSTRIAL GEAR 1 APPLICATIONS • History of industrial gear • Types of industrial gears and their applications • Operating conditions • Industrial gearbox manufacturers at a glance • How industrial gearboxes work – the basics • How industrial gearboxes work – the details • Operational challenges for industrial gearboxes • Introduction to gear lubricants
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What do industrial gear lubricants do? Types of industrial gear lubricants What role do additives play? Lubrication system design and components • Industrial gear lubricants in-service: • Typical in-service lubricant requirements • In-service oil condition monitoring • Solving persistent lubrication issues • Introduction to lubricant classifications
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Original equipment manfacturer (OEM) Industrial gear manufacturers Marine gear manufacturers Railway gear manufacturers Bearing gear manufacturers
• Description of key tests • Specification cross reference tables
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THE AFTON INDUSTRIAL GEAR 6 OIL PORTFOLIO • Industrial gear range • Industrial gear portfolio overview by market segment • Industrial gear product benefits • Afton pour point depressants • Market segment overview • Applications, standards and specification overview – at-a-glance
7 APPENDICES
MAJOR OEMS AND 3 THEIR SUPPLIERS • • • • •
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KEY INDUSTRIAL GEAR 5 LUBRICANT TESTS EXPLAINED
INDUSTRIAL GEAR 2 LUBRICATION NEEDS • • • •
• Global industrial gearboxes 2012 - 2016 • Industrial gears by application • Industrial gears and motors by end-use segments • Impact of key trends and challenges on industrial gear lubrication • Global industrial gear lubricant market 2009 – 2023 • Increasing demand for high precision gearboxes • Demand for greater equipment reliability • Global equipment demand patterns • Lubricant market segmentation • Industrial gear market segmentation
• Industrial gear dictionary • Industrial gear acronyms • Industrial gear base stocks explained • Industrial gear base stock comparisons
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INTRODUCTION Afton Chemical is a leading global supplier of industrial lubricant additive packages. The Afton Industrial portfolio covers a broad range of industrial lubricant additives, including additive packages developed for Wind Turbine, Industrial Gear, Turbine, Hydraulic, Grease and Slideway applications.
WIND TURBINE
INDUSTRIAL GEAR
TURBINE
HYDRAULIC
GREASE
COLOR CODING FOR APPLICATION GROUPS
This guide focuses on industrial gear applications. It covers the different types of gears and how they work, market trends in hardware and lubrication as well as the additives and specifications for industrial gearboxes, and some examples of the many diverse end use applications. It also presents the Afton Industrial Gear Portfolio. It is a useful reference guide for our customers, our distributors, the OEMs and our internal staff. This guide is the fourth in a series of guides from Afton Industrial and forms part of a limited edition collectible box set of six guides to industrial lubricants. We hope you will find them interesting and informative! The Afton Industrial Team, May 2016
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SLIDEWAY
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INDUSTRIAL GEAR APPLICATIONS
History of
Industrial Gear Since the first rotating machines were developed as early as the 15th century, gears have been used to multiply and decrease the speeds or torque involved. Early gears were wooden, using simple pegs for cogs, and the most likely lubricant would have been animal fat as a grease. Early engineers used gearing in three main ways: •
To increase torque, such as on hoists, to make lifting heavy loads easier
•
alter the speed of a rotational power source to match the needs of the To equipment it was driving
•
To change the direction of the power transmitted, e.g. at right angles
Gears were used with horse-driven wheels, windmills and water wheels, which all turned relatively slowly, to drive equipment that required faster input speeds – such as pumps, threshers, grinders or textile machinery. In the mid-1700s the Industrial Revolution, which began in Great Britain and brought with it new iron production processes, prompted the switch to using metal gears as standard. Gear development continued throughout INTERIOR MECHANISM OF AN 18TH CENTURY WOODEN MILL the following two centuries, but it is since the 1950s that changes have been more dramatic. Advances in computer design and precision gear manufacture have played a significant part in reducing friction, noise and gearbox size while also delivering greater efficiency and reliability. Metallurgical advances, better lubrication and new gear coatings are also helping to improve gear efficiency.
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INDUSTRIAL GEAR LUBRICATION NEEDS 2
co
(A
Introduction to Gear Lubricants Lubricants play a vital role in protecting the gears inside industrial gearboxes from wear and other forms of damage. Often it’s the lubricant that makes all the difference between a failure-prone, unreliable gearbox and a high-performing gearbox with excellent reliability and durability. The industrial gear industry is very fragmented; industrial gear oils may have to work effectively across a wide range of applications and their corresponding operating conditions, loads, contamination levels, etc.
Mining
Machinery, General
Steel, Metals, Cement
Gearboxes used in mining and metals and cement processing can experience very large shock loads and require extra extreme pressure (EP) and Anti-wear (AW) protection. On the other hand, it is normal for power generation and general industrial machinery to operate continuously under constant loading creating conditions where fluid life and thermal stability are important, requiring stable base oils with enhanced antioxidant (AO) protection. These conflicting requirements need to be considered and careful additive choices made when formulating industrial gear lubricants.
Power Generation, Oil, Gas, Water
Railway, Transport
Mobile, Agriculture, Construct
Food, Food,Wood, Wood, Paper, Paper, Conveyer ConveyerBelt Belt
Others
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MAJOR OEMS AND THEIR SUPPLIERS
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Original Equipment
Manufacturer
(OEM)
INTRODUCTION Gear manufacturers number in the hundreds. Their range and application are manifold, and many operate in niche areas; there is no intent in this chapter to try and compare performance. The focus here is on those industrial gear, bearing and seal OEMs who are driving fluid technologies. Their locations, product ranges and fluid requirements are briefly outlined.
COMMERCIAL CONTAINER SHIPS
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INDUSTRIAL GEAR MARKET SEGMENTATION Key fluid specifications are shown against the pyramid to highlight where industry and OEM specifications fit into this market segmentation. Sliding contact Specialized/Engineered Gears Rolling contact Standard Gears
Increasing tempurature, Torque, equipment reliability and fluid drain DIN 51517 pt. I AGMA 9005 E02 R&O
WIND TURBINE
INDUSTRIAL GEAR MARKET SEGMENTATION MODEL
5 PREMIUM
Meets basic needs for corrosion inhibition and oxidation stability
ENTRY
Basic EP Performance
AGMA 9005 E02 AIST 224 GB 5903-2011 L-CKB ISO 12925 L-CKB
DIN 51517 Part III Joy B GB 5903-2011 L-CKC ISO 12925 L-CKC
ISO 12925 L-CKD
Siemens (Flender) T 7300 SEW, Hansen (HIT) GB 5903-2011 L-CKD
Siemens (Flender) T 7300 SEW
Gears: Winergy, ZF Wind, Moventas, Bosch Rexroth (ZF) Nanjing Bearings: Schaeffler, SKF Standards: IEC 61400, ANSI/ AGMA/AWEA 6006--A03
Bearing wear protection, extended EP protection, Robust Corrosion, Basic Seals
MAINSTREAM
Additional Attributes such as Clean Gear
Micropitting robust seal and paint compatability, bearing wear protectection, improved efficiency
PREMIUM SYNTHETIC
Retention of foam control, white etching protection
Micropitting, robust seal and coatings compatibility, bearing wear protection, improved efficiency
Non-EP Circulating Gear
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KEY INDUSTRIAL GEAR LUBRICATION TESTS EXPLAINED
Description
of key tests 1. FOAM TESTS The standard foam test measures both the tendency of lubricants to foam as well as the stability of any foam produced; typical test methods include ASTM D892 and ISO 6247. The oil sample is placed in a graduated cylinder and air is blown through a diffuser stone into the sample for five minutes. This procedure is carried out under three different sets of conditions. The first, Sequence I, uses 190ml of fresh oil at 24°C; Sequence II uses 180ml of fresh oil at 94°C and Sequence III uses oil from Sequence II once it has cooled to 24°C. For each Sequence the volume of foam, in ml, after the five minute period of air being blown into the sample is recorded as the tendency. The volume of foam, in ml, still present 10 minutes after the air has been turned off is recorded as the stability of the foam. The tendency and stability are reported as numbers without units separated by a /; e.g. a lubricant with a tendency of 50ml and stability of 10ml would be reported as 50/10. Typically industrial gear specifications allow a maximum foam performance of 100/10 although some are more demanding; requiring a maximum of 50/0.
ASTM D892 FOAM TESTING EQUIPMENT
FLENDER FOAM RIG
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APPENDICES
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Industrial Gear
dictionary
Addendum
The radial distance between the pitch circle and the outside diameter of a gear.
Additive
Any material added to a lubricant to change its properties, characteristics or performance.
Additive Package/Concentrate
Liquid composition containing a mixture of additives, added to a lubricant to improve performance.
Adhesive Wear
Wear that occurs when heavy loads cause microwelding and material removal on the gear teeth.
Antioxidant
A molecule that inhibits the oxidation of other molecules, for example by removing or isolating free radical intermediates.
Anti-wear
Additive that prevents wear by forming a protective (usually phosphorus) layer on the surface, preventing metal-to-metal contact and abrasion.
Apparent Viscosity
Ratio of shear stress to shear rate of a non-Newtonian fluid.
Asperities Microscopic projections on metal surfaces resulting from normal surface finishing processes. Ideally the lubricating film should be thicker than the combined height of the opposing asperities.
Backlash
The amount of space by which the width of a gear tooth space exceeds the thickness of the engaging gear tooth, measured at the pitch circle.
Base Circle/Base Diameter
The diameter of a gear’s base circle or the circle from which the involute tooth profile is developed.
Base Stock
The base fluid, usually a refined petroleum fraction or a selected synthetic material, into which additives are blended to produce finished lubricant.
Bearing Load Ratio
The ratio between the bearing’s basic dynamic load rating, C (in N) and its actual equivalent dynamic load P (in N), reported as C/P.
Bearing Speed
Usually referenced as the maximum speed at which a bearing can operate. Factors such as cage design, metallurgy, lubrication type, bearing load, alignment and seal type can all affect bearing speed.
Boundary lubrication
Lubrication by a liquid under conditions where the solid surfaces are so close together that appreciable contact between opposing asperities is possible.
Brinelling
Material surface failure caused by excessive Hertzian stress causing surface deformation.
Carburizing Case Hardening
A heat treatment process where molten iron absorbs carbon with the intent of making the metal harder. The process of hardening the surface of a metal object while allowing the metal deeper underneath to remain soft, thus forming a thin layer of harder metal (called the “case”) at the surface.
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INDUSTRIAL GEAR
GEAR
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