How to solve the problem of high oil temperature in the gearbox of WPS60-20-A gearbox caused by excessive load

The WPS60-20-A gearbox has high oil temperature due to excessive load, which can be systematically solved through the following steps:

1、 Core solutions

1. Adjust the load immediately

Check if the motor current exceeds 110% of the rated value. If it is overloaded, optimize the production process or reduce the load.

Avoid frequent starting and stopping (≤ 5 times per hour) to reduce impact loads.

2. Strengthen the cooling system

Water cooling upgrade: If the ambient temperature is high or continuously at full load, the water cooling system (cooling power ≥ 20kW) can be upgraded to stabilize the oil temperature below 55 ℃ through industrial cooling water (inlet water temperature ≤ 32 ℃).

Air cooling assistance: Check whether the fan blades are deformed or stuck, ensure that the protective cover is not blocked, and reversing will cause a decrease in heat dissipation efficiency of more than 50%.

3. Optimize lubrication management

Check whether the lubricating oil level is above the centerline mark, whether the oil quality is turbid or expired, and replace the appropriate model in a timely manner.

Replace lubricating oil every 2000 hours under heavy load conditions and monitor gear wear status through oil spectrum analysis.

2、 Long term maintenance strategy

1. Regularly inspect the heat dissipation components

Check the ash accumulation on the fins of the cooler every month (thickness ≤ 1mm), and annually acid wash the water cooling system to remove scale.

Perform oil analysis every quarter to monitor the content of metal abrasive particles and changes in oil viscosity.

2. Structural design optimization

The box is made of QT600-3 ductile iron (thermal conductivity of 50W/(m · K)), with spiral heat dissipation fins added to the outer wall, expanding the heat dissipation area by 2-3 times.

An axial oil passage is opened on the inner wall of the box, which is linked with the fuel injection system to directly remove the heat from the box when the lubricating oil flows through the inner wall of the box.

3、 Precautions

1. Safe operation: Before troubleshooting, the machine must be shut down, powered off, and tagged. Wait for it to cool down to room temperature, and it is strictly prohibited to disassemble components under high temperature conditions.

2. Tool preparation: infrared thermometer, oil viscosity meter, vibrometer, etc.

3. Data recording: Record environmental temperature, operating load, peak oil temperature, etc. in advance.

Through the above measures, the problem of high oil temperature caused by excessive load in the WPS60-20-A reducer can be effectively solved, ensuring stable operation of the equipment.