High-speed pump speed-increasing transmission system

Abstract

The invention discloses a high-speed pump speed-up transmission system which comprises a power shaft, an intermediate shaft and an impeller shaft, transmission is achieved through a two-stage speed-up gear pair, a gear is made of carburized and quenched steel, the tooth surface hardness ranges from 56 HRC to 62 HRC, the carburizing depth is matched according to modulus, and G1-stage dynamic balance correction is conducted; the gear is in interference fit with the shaft through a woodruff key, the tooth height contact rate is larger than or equal to 60%, and the tooth length contact rate is larger than or equal to 80%; the gear pair is lubricated through spraying of a spraying nozzle, the oil pressure ranges from 0.2 MPa to 0.6 MPa, the oil temperature ranges from 60 DEG C to 80 DEG C, and efficient heat dissipation and oil film stability are achieved in cooperation with cooling water circulation. The service life of the gear is greatly prolonged, the bearing temperature rise is reduced, the comprehensive maintenance cost is reduced, and the operation reliability and energy efficiency of the high-speed pump in the fields of petroleum, chemical engineering and the like are remarkably improved.

Description

Technical Field

[0001] The invention relates to the technical field of high-speed pumps, and in particular to a high-speed pump speed increasing transmission system. Background Art

[0002] With the rapid development of modern industrial technology, high-speed pumps, as key fluid transmission equipment, are widely used in the fields of petroleum, chemical industry, electricity, etc. The performance of its speed-increasing transmission system directly affects the operating efficiency, stability and service life of the equipment. However, the following outstanding problems exist in the prior art: (1) Insufficient stability of the gear system: High-speed gears are prone to noise, tooth surface wear and fracture due to material fatigue, dynamic balance deviation, meshing vibration, etc. under heavy load and high-speed rotation conditions, resulting in reduced transmission efficiency and shortened service life; (2) Low efficiency of the lubrication system: Traditional lubrication methods are prone to oil temperature loss and unstable oil pressure under high-speed conditions, and unreasonable nozzle aperture design often leads to insufficient or excessive lubrication, aggravating bearing temperature rise and vibration; (3) Insufficient processing and assembly accuracy: Gear processing errors and assembly interference deviations will introduce imbalance, further amplifying system vibration and noise.

[0003] Existing solutions mostly target single problems (such as optimizing gear materials or adjusting lubrication parameters), lack the coordinated optimization of gear design and lubrication system, and are difficult to achieve systematic performance improvement. Therefore, there is an urgent need for a high-speed pump speed-increasing transmission system that integrates high-precision gear manufacturing, dynamic balance control, and intelligent lubrication optimization to comprehensively improve equipment reliability, reduce maintenance costs, and meet the needs of industrial efficient transmission. Summary of the invention

[0004] In order to improve the overall performance of a high-speed pump, the present invention provides a high-speed pump speed increasing transmission system.

[0005] The technical solution adopted by the present invention is as follows: a high-speed pump speed-increasing transmission system, comprising a transmission box, in which a power shaft, an intermediate shaft and an impeller shaft are arranged, the power shaft and the intermediate shaft are connected by a first speed-increasing gear pair, and the intermediate shaft and the impeller shaft are connected by a second speed-increasing gear pair; the gears of the first speed-increasing gear pair and the second speed-increasing gear pair are made of carburized and quenched steel, with a tooth surface hardness of 56-62HRC, and the carburizing depth is matched according to the modulus; the gears and shafts of the first speed-increasing gear pair and the second speed-increasing gear pair are interference fit through a semicircular key and are corrected by G1 level dynamic balancing; the gear contact surfaces of the first speed-increasing gear pair and the second speed-increasing gear pair are tested by a color coating method, and the tooth height contact rate is ≥60%, and the tooth length contact rate is ≥80%; the first speed-increasing gear pair and the second speed-increasing gear pair adopt a jet lubrication method, the nozzle aperture is 0.8-1.0mm, the jet pressure is 0.2-0.5MPa, the jet angle is aligned with the entrance of the meshing area, the oil temperature is controlled at 60-80℃, and the oil pressure is stabilized at 0.2-0.6MPa.

[0006] Preferably, when the total transmission power is < 135KW, the first speed increasing gear pair and the second speed increasing gear pair adopt spur gears with a module m = 1.27mm; when the total transmission power > 135KW, the first speed increasing gear pair and the second speed increasing gear pair adopt helical gears with a module m = 1.5875mm.

[0007] Preferably, the gear module of the first speed increasing gear pair and the second speed increasing gear pair is 1.27mm, and the corresponding carburizing depth is 0.4 - 0.7mm; the gear module of the first speed increasing gear pair and the second speed increasing gear pair is 1.5875mm, and the corresponding carburizing depth is 0.8 - 1.2mm.

[0008] Preferably, the power shaft is installed in the transmission box through a low-speed bearing, the intermediate shaft is installed in the transmission box through a medium-speed bearing, the impeller shaft is installed in the transmission box through a high-speed bearing, the low-speed bearing and the medium-speed bearing are rolling bearings, and the high-speed bearing is a sliding bearing.

[0009] Preferably, the low-speed bearing and the medium-speed bearing adopt spray lubrication; the high-speed bearing transports high-pressure lubricating oil to the friction surface through a pre-designed oil hole.

[0010] Preferably, the diameter ratio of the X oil hole to the Y oil hole of the high-speed bearing is 5:2. The X oil hole generates a lubricating film between the high-speed bearing and the impeller shaft, and the Y oil hole generates a lubricating film between the high-speed bearing and the thrust disk.

[0011] Preferably, the transmission box is equipped with a cooling water circulation device, with the inlet pressure / outlet pressure being 0.45MPa / 0.25MPa respectively, and the inlet temperature / outlet temperature being 32°C / 45°C respectively.

[0012] The present invention has the following beneficial effects: 1. Enhanced stability of the gear system: By using high-strength carburized and quenched steel and precise control of the carburizing depth, the tooth surface hardness reaches 56 - 62HRC, improving the pitting resistance and fatigue strength and extending the gear life; 2. Improved assembly accuracy: The gear pair undergoes G1-level dynamic balance correction and is assembled and detected by the coloring method, with the transmission error controlled at the micron level, reducing vibration and noise; 3. Optimized lubrication efficiency and temperature control ability: The precise design of the nozzle aperture of 0.8 - 1.0mm and the injection pressure of 0.2 - 0.5MPa, combined with the oil temperature control and the stable oil pressure range, improve the coverage rate of the lubricating film, reduce the bearing temperature rise, and avoid local overheating and wear; 4. Power adaptability and energy consumption optimization: When the power is < 135 kW, spur gears with a module of 1.27 mm are used; when the power ≥ 135 kW, helical gears with a module of 1.5875 mm are used, taking into account both transmission efficiency and load-bearing capacity to reduce energy consumption; 5. Improvement of operation reliability: The cooling water circulation device collaborates with the lubrication system to stabilize the oil viscosity, improve the heat dissipation efficiency, enhance the continuous operation stability of the equipment, reduce the frequency of shutdown for maintenance, and lower the comprehensive operation and maintenance cost. Brief Description of the Drawings

[0013] Figure 1 It is a schematic diagram of an embodiment of the present invention.

[0014] Gearbox 1, power shaft 2, intermediate shaft 3, impeller shaft 4, first speed increasing gear pair 5, second speed increasing gear pair 6, low-speed bearing 7, medium-speed bearing 8, high-speed bearing 9. Detailed Embodiment

[0015] The present invention will be further described below in conjunction with the embodiments and the drawings.

[0016] In the embodiment, as Figure 1As shown in the figure, a speed increasing drive system of an RCP-V1 type high-speed pump includes a transmission case 1. Inside the transmission case 1, there are a power shaft 2, an intermediate shaft 3 and an impeller shaft 4. The power shaft 2 and the intermediate shaft 3 are drivingly connected through a first speed increasing gear pair 5, and the intermediate shaft 3 and the impeller shaft 4 are drivingly connected through a second speed increasing gear pair 6. The gears of the first speed increasing gear pair 5 and the second speed increasing gear pair 6 are made of carburized and quenched steel, with a tooth surface hardness of 56 - 62 HRC, and the carburizing depth is matched according to the module. The gears of the first speed increasing gear pair 5 and the second speed increasing gear pair 6 and the shaft are interference-fitted through a woodruff key and are dynamically balanced and corrected to grade G1 according to ISO 1940-1 "Mechanical Vibration - Requirements for the Balance Quality of Rotors". The dynamic balance weight removal method is drilling, and the weight removal position is on the side of the gear, 20 mm away from the tooth root of the gear. The contact surface of the gears of the first speed increasing gear pair 5 and the second speed increasing gear pair 6 is detected by the coloring method, with a tooth height contact ratio ≥ 60% and a tooth length contact ratio ≥ 80%. The first speed increasing gear pair 5 and the second speed increasing gear pair 6 adopt the jet lubrication method, with a nozzle aperture of 0.8 - 1.0 mm, a jet pressure of 0.2 - 0.5 MPa, the jet angle aiming at the entrance of the meshing area, the oil temperature controlled at 60 - 80 °C, and the oil pressure stabilized at 0.2 - 0.6 MPa. In this embodiment, through carburized and quenched steel (20CrMnTi) and a carburizing depth (0.4 - 1.2 mm) matched with the module, the tooth surface hardness reaches 56 - 62 HRC, the pitting resistance of the gear is increased by 40%, and the service life is extended to more than 50,000 hours. The grade G1 dynamic balance correction (residual unbalance ≤ 0.367 g·mm / kg) combined with the tooth surface contact ratio detection (tooth height ≥ 60%, tooth length ≥ 80%) reduces the vibration noise from 85 dB to below 72 dB, and the transmission error is controlled at the micron level. The nozzles of the jet lubrication of the gear pair adopt single oil holes or multiple oil holes, with the aperture selected as 0.8 - 1.0 mm, and the oil pressure maintained at 0.2 - 0.6 MPa, forming a stable oil film, increasing the lubrication coverage rate by 30% and reducing the bearing temperature rise by 15%.

[0017] In the embodiment, when the total transmission power < 135 KW, the first speed increasing gear pair 5 and the second speed increasing gear pair 6 adopt spur gears with a module m = 1.27 mm; when the total transmission power > 135 KW, the first speed increasing gear pair 5 and the second speed increasing gear pair 6 adopt helical gears with a module m = 1.5875 mm. By optimizing the selection of the module, the transmission efficiency and load-bearing capacity are optimized, and the energy consumption is reduced. The design of the helix angle of the helical gear at 10 - 20° reduces the axial force, reduces the gear meshing vibration, and improves the stability under high-speed conditions.

[0018] In the embodiment, referring to Table 1, different module values correspond to different carburizing depths, specifically: the gear module of the first speed increasing gear pair 5 and the second speed increasing gear pair 6 is 1.27 mm, and the corresponding carburizing depth is 0.4 - 0.7 mm; the gear module of the first speed increasing gear pair 5 and the second speed increasing gear pair 6 is 1.5875 mm, and the corresponding carburizing depth is 0.8 - 1.2 mm. This embodiment ensures the best match between the tooth surface hardened layer and the core toughness, improving the fatigue resistance strength. At the same time, precise carburizing control avoids heat treatment deformation, reduces the subsequent grinding amount, and improves the processing efficiency.

[0019] Table 1 Selection of Heat Treatment Carburizing Depth

[0020] In the embodiment, as Figure 1 shown, the power shaft 2 is installed in the transmission case 1 through the low-speed bearing 7, the intermediate shaft 3 is installed in the transmission case 1 through the medium-speed bearing 8, the impeller shaft 4 is installed in the transmission case 1 through the high-speed bearing 9. The low-speed bearing 7 and the medium-speed bearing 8 are rolling bearings, and the high-speed bearing 9 is a sliding bearing. The low-speed / medium-speed bearings adopt rolling bearings (with low friction coefficient), and the high-speed bearing adopts a sliding bearing (with strong load-bearing capacity), taking into account both efficiency and service life, and reducing the comprehensive wear rate. The graded bearing design adapts to the lubrication requirements of different speed segments and reduces the material fatigue caused by the temperature rise difference.

[0021] In the embodiment, as Figure 1 shown, the low-speed bearing 7 and the medium-speed bearing 8 adopt the jet lubrication method; the high-speed bearing 9 transports high-pressure lubricating oil to the friction surface through pre-designed oil holes. The low-speed / medium-speed bearings are independently jet lubricated with an oil pressure of 0.2 - 0.5 MPa, avoiding interference with the gear lubrication system and improving the oil distribution accuracy. The high-speed sliding bearing directly supplies oil through the oil holes, shortening the lubrication path, increasing the oil film formation speed, and reducing the friction power consumption.

[0022] In the embodiment, as Figure 1 shown, the diameter ratio of the X oil hole and the Y oil hole of the high-speed bearing 9 is 5:2 (5 mm and 2 mm respectively). The X oil hole generates a lubricating film between the high-speed bearing 9 and the impeller shaft 4, and the Y oil hole generates a lubricating film between the high-speed bearing 9 and the thrust disk. The precise ratio design of the X oil hole and the Y oil hole optimizes the oil film distribution on the radial and thrust surfaces, reducing the friction coefficient; the precise oil hole size avoids over-lubrication or under-lubrication and extends the bearing life.

[0023] In the embodiment, as Figure 1As shown, the transmission case 1 is equipped with a cooling water circulation quantity device, with the inlet pressure / outlet pressure being 0.45 MPa / 0.25 MPa respectively, and the inlet temperature / outlet temperature being 32°C / 45°C respectively. The cooling water circulation device cooperates with the oil temperature control to improve the heat dissipation efficiency and reduce the oil oxidation rate. Through the linkage control of temperature and pressure, the dynamic balance failure caused by thermal deformation is prevented, and the continuous operation stability of the equipment is improved.

[0024] Obviously, the above embodiments of the present invention are merely examples for illustrating the present invention, rather than limiting the implementation manners of the present invention. Other obvious changes or variations derived from the essential spirit of the present invention still fall within the protection scope of the present invention.

Claims

1. A high-speed pump speed-increasing transmission system, characterized in that: The invention comprises a transmission box (1), wherein a power shaft (2), an intermediate shaft (3) and an impeller shaft (4) are arranged in the transmission box (1); the power shaft (2) and the intermediate shaft (3) are transmission-connected via a first speed-increasing gear pair (5), and the intermediate shaft (3) and the impeller shaft (4) are transmission-connected via a second speed-increasing gear pair (6); The gears of the first speed-increasing gear pair (5) and the second speed-increasing gear pair (6) are made of carburized and hardened steel, with a tooth surface hardness of 56-62HRC, and a carburizing depth matched according to the module; The gears and shafts of the first speed-increasing gear pair (5) and the second speed-increasing gear pair (6) are interference-fitted with a semicircular key and are subjected to G1-level dynamic balancing correction; The gear contact surfaces of the first speed-increasing gear pair (5) and the second speed-increasing gear pair (6) are tested by a color coating method, and the tooth height contact rate is ≥60%, and the tooth length contact rate is ≥80%; The first speed-increasing gear pair (5) and the second speed-increasing gear pair (6) are lubricated by jetting, with a nozzle aperture of 0.8-1.0 mm, a jet pressure of 0.2-0.5 MPa, a jet angle aimed at the entrance of the meshing area, an oil temperature controlled at 60-80° C., and an oil pressure stabilized at 0.2-0.6 MPa.

2. The high-speed pump speed-increasing transmission system according to claim 1, characterized in that: When the total transmission power is less than 135 kW, the first speed-increasing gear pair (5) and the second speed-increasing gear pair (6) use spur gears with a module m=1.27 mm; when the total transmission power is greater than 135 kW, the first speed-increasing gear pair (5) and the second speed-increasing gear pair (6) use helical gears with a module m=1.5875 mm.

3. The high-speed pump speed-increasing transmission system according to claim 2, characterized in that: The gear module of the first speed-increasing gear pair (5) and the second speed-increasing gear pair (6) is 1.27 mm, and the corresponding carburizing depth is 0.4-0.7 mm; the gear module of the first speed-increasing gear pair (5) and the second speed-increasing gear pair (6) is 1.5875 mm, and the corresponding carburizing depth is 0.8-1.2 mm.

4. The high-speed pump speed-increasing transmission system according to claim 1, characterized in that: The power shaft (2) is mounted on the transmission box (1) via a low-speed bearing (7), the intermediate shaft (3) is mounted on the transmission box (1) via a medium-speed bearing (8), and the impeller shaft (4) is mounted on the transmission box (1) via a high-speed bearing (9), the low-speed bearing (7) and the medium-speed bearing (8) are rolling bearings, and the high-speed bearing (9) is a sliding bearing.

5. The high-speed pump speed-increasing transmission system according to claim 4, characterized in that: The low-speed bearing (7) and the medium-speed bearing (8) are lubricated by jetting; the high-speed bearing (9) delivers high-pressure lubricating oil to the friction surface through a preset oil hole.

6. The high-speed pump speed-increasing transmission system according to claim 5, characterized in that: The ratio of the diameters of the X oil hole and the Y oil hole of the high-speed bearing (9) is 5:2, the X oil hole generates a lubricating film between the high-speed bearing (9) and the impeller shaft (4), and the Y oil hole generates a lubricating film between the high-speed bearing (9) and the thrust plate.

7. The high-speed pump speed-increasing transmission system according to claim 1, characterized in that: The transmission box (1) is equipped with a cooling water circulation device, the water inlet pressure / water outlet pressure are 0.45 MPa / 0.25 MPa respectively, and the water inlet temperature / water outlet temperature are 32° C. / 45° C. respectively.

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