Special quenching oil and method for ultra-large-modulus, large-size and ultra-thick gear ring

Abstract

The invention belongs to the field of heat treatment, and particularly relates to quenching oil special for an ultra-large-modulus, large-size and ultra-thick gear ring and a method. 5%-15% of a cooling accelerant; 1.0%-4.0% of a high-temperature antioxidant; 0.5%-2.0% of a dispersing agent; 0.1%-1.0% of a surfactant; 0.1%-0.5% of a metal deactivator; 0.01%-0.1% of a defoaming agent; wherein the cooling accelerant is a blend selected from a styrene-maleic anhydride copolymer ester and polyalkyl methacrylate, and the cooling speed of the cooling accelerant at the 300 DEG C stage is not lower than 5.0 DEG C / s. The method is used for solving the industrial problems of insufficient quenching hardness and shallow hardening layer of the tooth root part of the existing ultra-multi-modulus large gear ring, and the problems of rapid oxidation and aging of quenching oil caused by huge workpieces, high oil temperature and long period.

Description

Technical Field

[0001] This invention belongs to the field of heat treatment, specifically a quenching oil and method for ultra-large module, large size and ultra-thick gear rings. Background Technology

[0002] Quenching is one of the most important processes in heat treatment. Quenching involves heating steel above its critical point, holding it at that temperature for a certain time, and then rapidly cooling it in a quenching medium to obtain a martensitic structure. The purpose of quenching is to increase the hardness and wear resistance of steel, giving parts good overall mechanical properties. Commonly used quenching media include brine, water, mineral oil, and air.

[0003] Due to their large module, large size, and large thickness, ultra-large module, large size, and large thickness, excessively high temperature or excessively slow cooling rate during the quenching process of these gears can lead to poor quenching results, insufficient hardening at the tooth root, and shallow hardened layer, thus affecting the quality of the gears. Therefore, it is essential to strictly control the temperature and cooling rate to ensure the quality of quenching for these types of gears.

[0004] Currently, gear quenching oils consist of base oil, refrigerant, antioxidant, brightener, and surfactant. The refrigerant, represented by polyisobutylene (CN105950844A), primarily relies on high-temperature viscosity enhancement to suppress vapor film formation. However, its effect is passive and physical. When quenching ultra-thick gear rings, heat transfer from the core to the surface takes time. If the surface vapor film stage is too long, the temperature at the tooth root will drop too slowly in the initial cooling phase, falling into the "nose" region of the supercooled austenite transformation curve, resulting in pearlite or bainite transformation instead of martensite formation. Ultimately, this leads to a shallow hardened layer at the tooth root, insufficient hardness, and an inability to withstand enormous bending stress, making it the weakest link in the entire gear. Summary of the Invention

[0005] The technical problems to be solved by this invention are: the industry problem of insufficient hardness and shallow hardened layer at the root of the tooth of the existing high-module large gear ring, as well as the problem of rapid oxidation and aging of quenching oil caused by the large size of the workpiece, high oil temperature and long cycle.

[0006] To solve the above-mentioned technical problems, the inventors, through practice and summarization, derived the technical solution of this invention, which adopts the following technical solution:

[0007] A special quenching oil for ultra-large module, large size, and ultra-thick gear rings, comprising:

[0008] Base oil: 75% ~ 90%;

[0009] Cooling agent: 5% ~ 15%;

[0010] High-temperature antioxidant: 1.0% ~ 4.0%;

[0011] Dispersant: 0.5% ~ 2.0%;

[0012] Surfactant: 0.1% ~ 1.0%;

[0013] Metal passivating agent: 0.1% ~ 0.5%;

[0014] Defoamer: 0.01% ~ 0.1%;

[0015] The cooling agent is a blend selected from styrene-maleic anhydride copolymer ester and polyalkyl methacrylate, and the cooling rate of the cooling agent at 300℃ is not less than 5.0℃ / second.

[0016] In a preferred embodiment, the weight ratio of the polyalkyl methacrylate and the styrene-maleic anhydride copolymer ester is (2~4):(3~5):(1~3).

[0017] In a preferred embodiment, the base oil is a hydrotreated paraffinic mineral oil with a kinematic viscosity of 18-28 cSt at 40°C and a flash point of not less than 200°C.

[0018] The dispersant is polyisobutylene succinimide;

[0019] The surfactant is sorbitan monooleate or alkylphenol polyoxyethylene ether;

[0020] The high-temperature antioxidant is a compound of at least two selected from alkylated diphenylamine, octyl / butyl diphenylamine and hindered phenolic esters, with a weight ratio of (3:1) to (1:2).

[0021] A method for preparing a quenching oil specifically for ultra-large module, large size, and ultra-thick gear rings, comprising the following steps:

[0022] a) Base oil pretreatment:

[0023] The base oil is pumped into a reactor, heated to 65-75°C, and stirred and dehydrated under a vacuum of -0.05-0.08 MPa for 30-60 minutes.

[0024] b) Phased mixing and addition:

[0025] Phase 1:

[0026] While maintaining the temperature and vacuum of step a), add the high-temperature antioxidant, metal passivator and dispersant in sequence, and stir at 300-500 rpm for 45-60 minutes until completely dissolved;

[0027] Phase Two:

[0028] The temperature of the reactor is lowered to 50-60°C, the surfactant and coolant are added, and the mixture is stirred at 500-800 rpm for 60-90 minutes under normal pressure to form a homogeneous and transparent system.

[0029] c) Homogenization and filtration:

[0030] The mixture obtained in step b) is subjected to homogenization in a homogenizer at a pressure of 15 ~ 25 MPa, and then filtered through a 5μm precision filter to obtain a mixed oil.

[0031] d) Defoaming and settling:

[0032] Add the defoamer to the filtered mixed oil, stir at 200-300 rpm for 20-30 minutes, and let it stand for aging for more than 24 hours to obtain the special quenching oil.

[0033] In a preferred embodiment, a base frame is installed on the top of the reactor, a drive motor is installed on the base frame, a gear component one is installed at the output end of the drive motor, a gear component two is meshed on the upper side of the gear component one and a gear component three is meshed on the lower side, and gear components two and three are respectively rotatably mounted on the base frame;

[0034] A stirring shaft is rotatably installed inside the reactor. One end of the stirring shaft passes through gear component two and gear component three, and a transmission gear ring is installed in the area between gear component two and gear component three. Both ends of the transmission gear ring are provided with transmission surfaces, which mesh with gear component two and gear component three respectively. The other end of the stirring shaft is inserted into the reactor and a stirrer is installed. There are two sets of stirrers, and a transmission area is installed on the stirring shaft in the area between them.

[0035] The upper position control component and the lower position control component are installed on the top of the inner side of the reactor. The upper position control component is adjustable in height relative to the reactor.

[0036] A sliding ring is vertically sliding between the upper position control component and the lower position control component. The sliding ring is connected to a partition plate via a hanger rod. The partition plate and the transmission area form a vertical transmission connection.

[0037] A reflux pipe is installed on the side of the reactor, which is used to connect the upper and lower spaces of the partition plate;

[0038] A rotating seat one is installed inside the reactor, and a rotating seat two is installed on the lower position control component. An axial adjustment component is provided on the rotating seat one and the rotating seat two. The axial adjustment component is used to adjust the axial displacement of the stirring shaft.

[0039] The reactor is equipped with a vacuum pump, a pressure sensor, a temperature sensor, a liquid level sensor, and a heating jacket. The vacuum pump is connected to the inside of the reactor through a pipeline. The pressure sensor, temperature sensor, and liquid level sensor are distributed on the reactor and are used to detect the pressure, temperature, and liquid level of the material inside the reactor, respectively. The heating jacket provides heat energy to the environment inside the reactor.

[0040] In a preferred embodiment, the upper position control component includes an upper ring plate, and an adjusting screw and a vertical guide rod are installed on the top of the upper ring plate. The adjusting screw is used to adjust the vertical height position of the upper ring plate.

[0041] The lower position control component includes a lower ring plate, which is fixed to the inner wall of the reactor.

[0042] An elastic element is provided on the opposite side of the lower ring plate and the upper ring plate. The elastic element is used to move the ring.

[0043] An axial hole is provided on the upper ring plate, and an axial guide rod is inserted into the axial hole. The axial guide rod is fixed to the top of the moving ring.

[0044] In a preferred embodiment, the axial adjustment component includes a mounting hole on the side of the rotating seat, in which a spring body and a constraint body are installed. Two sets of position rings are provided on the outer side of the stirring shaft, with two position rings in each set. The position rings and the constraint body are mutually adapted, and the distance between the two position rings is equal to the difference between the distance between the two gear components and the length of the transmission gear ring.

[0045] In a preferred embodiment, the stirrer includes an upper mounting plate and a lower mounting plate, a mounting sleeve is installed between the upper mounting plate and the lower mounting plate, a plurality of one-way ratchet teeth are installed inside the mounting sleeve and stirring blades are installed on the outside, a ratchet wheel is installed on the stirring shaft, and the ratchet wheel is arranged inside the mounting sleeve and meshes with the one-way ratchet teeth.

[0046] Only one of the two agitators operates simultaneously with the agitator shaft during operation.

[0047] In a preferred embodiment, a plurality of defoaming needles are evenly distributed on the upper surface of the partition plate;

[0048] The partition plate includes an upper rotating plate and a lower fixed plate. A connecting body is provided on the upper rotating plate, and an arc-shaped groove is provided on the lower fixed plate. The connecting body is engaged with the arc-shaped groove by a spring. A traction rope is connected to the upper rotating plate, and a guide ear is provided on the lower fixed plate. Both the upper rotating plate and the lower fixed plate are provided with release holes that can be aligned by rotating a certain angle. One end of the traction rope passes through the guide ear and is connected to a winding device. The winding device is installed on the top of the reactor.

[0049] In a preferred embodiment, the preparation steps are as follows:

[0050] a) Base oil pretreatment:

[0051] Step a1: The base oil is pumped into the reactor. When the base oil is pumped in, the winding device is pulled by the traction rope to rotate the upper rotating plate relative to the lower fixed plate by a certain angle. At this time, the upper and lower positions of the release hole coincide. After the coincidence, the base oil enters and reaches the area below the partition plate until the set liquid level is reached. At this time, part of the base oil fills the area above the partition plate and replaces the air in the return pipe.

[0052] Step a2: The heating jacket heats the base oil inside the reactor to 65 ~ 75°C. At the same time, the vacuum pump evacuates the reactor to a vacuum level of -0.05 ~ -0.08 MPa.

[0053] Step a3, stirring and dehydration:

[0054] The drive motor starts, causing gear one to rotate. Gear one drives gear two and gear three to rotate simultaneously. The transmission gear ring meshes with gear two. During rotation, the stirring shaft rotates, which in turn drives the agitator below to rotate. At the same time, the partition plate moves upward, and the moving ring moves upward. Under the action of the elastic element on the upper ring, the stirring shaft is axially adjusted until the transmission gear ring and gear three mesh, completing the reverse rotation. At this time, the agitator above rotates, and the partition plate moves downward. Under the action of the elastic element on the lower ring, the stirring shaft is axially adjusted until the transmission gear ring and gear two mesh again. This cycle repeats for 30 to 60 minutes for stirring and dehydration.

[0055] b) Phased mixing and addition:

[0056] Phase 1:

[0057] Maintaining the temperature and vacuum of step a2, the winding device actively releases the traction rope, and the upper plate resets under the action of the spring to close the release hole. The separator separates the oil into upper and lower layers. Then, the high-temperature antioxidant, metal passivator and dispersant are added to the upper layer in sequence. While maintaining the action of step a3, stir for 45 to 60 minutes until completely dissolved.

[0058] Phase Two:

[0059] Reduce the temperature of the reactor to 50-60°C, add the surfactant and coolant to the upper layer of oil, maintain the action of step a3, and stir for 60-90 minutes to form a homogeneous and transparent system;

[0060] c) Homogenization and filtration:

[0061] The upper rotating plate is pulled by the winding device to rotate relative to the lower fixed plate by a certain angle, the release hole is opened, and the bottom of the reactor is led out to the homogenizer through the oil drain pipe. It is then subjected to circulating homogenization under a pressure of 15 ~ 25 MPa, and then filtered through a precision filter to obtain mixed oil.

[0062] d) Defoaming and settling:

[0063] The filtered mixed oil is introduced into a separate mixing vessel, and the defoamer is added. After stirring at 200-300 rpm for 20-30 minutes, it is left to stand and age for more than 24 hours to obtain the special quenching oil.

[0064] Compared with the prior art, the present invention has the following beneficial effects:

[0065] Improvements to the composition of quenching oil:

[0066] 1. To address the poor heat dissipation conditions and slow cooling rate caused by the formation of a vapor film at the tooth root, this invention uses specific polymers such as styrene-maleic anhydride copolymer esters as a cooling agent, achieving a high cooling rate of no less than 5.0℃ / second at 300℃. The use of a blend of polyalkyl methacrylate and styrene-maleic anhydride copolymer esters exhibits high-temperature film-breaking characteristics. Utilizing molecular chain properties, oil solubility is improved, ensuring the polymer can stably dissolve in the base oil. Simultaneously, highly polar ester and carboxyl groups are introduced, which is crucial for the cooling effect. When a high-temperature workpiece (such as a gear ring above 700℃) is immersed in quenching oil, the oil around the workpiece instantly vaporizes, forming a stable vapor film. At this point, the polar ends adsorb at the vapor-liquid interface on the workpiece surface, reducing the surface tension of the oil and interfering with the stability of the vapor film, making it easier to rupture and disintegrate prematurely. This allows the workpiece to enter the extremely rapid boiling stage of cooling more quickly, which is the most critical step in solving the fin root quenching problem. During the boiling stage, the polymer chains adsorbed on the workpiece surface may act as "nuclei," promoting the generation and rapid detachment of bubbles, thus maintaining extremely high heat transfer efficiency. When the workpiece temperature drops below the boiling point of the oil, it will re-dissolve uniformly in the oil without excessively increasing the low-temperature viscosity, ensuring good fluidity at low temperatures and preventing deformation and cracking of the workpiece due to uneven cooling. Polyalkyl methacrylate itself is a viscosity index improver, but when added to quenching oil, it exhibits a cooling effect. This may be because at room temperature, the coiling of molecular chains has little effect on the viscosity of the oil, but at high temperatures, the molecular chains unfold and increase in volume, leading to a significant increase in local viscosity of the oil around the workpiece. The temporarily increased viscosity at high temperatures makes it difficult for vapor bubbles to form, merge, and stabilize, thereby inhibiting the persistence of the vapor film and promoting its premature rupture. This allows control over the size and detachment frequency of bubbles, making boiling cooling more intense and uniform, avoiding local overcooling or undercooling. This case also includes surfactants, which can overcome the drawbacks of the additives. The combination of the two with styrene-maleic anhydride copolymer will yield even better results.

[0067] 2. This invention employs a specific compound system of alkylated diphenylamine and hindered phenolic esters, and strictly limits the compounding ratio. It utilizes the synergistic effect of antioxidants with different mechanisms (primary antioxidant and secondary antioxidant) to solve the problem of severe oxidation caused by long quenching time and high oil temperature of large parts.

[0068] 3. This invention introduces a dispersant (polyisobutylene succinimide) and a specific surfactant (such as sorbitan monooleate). The former ensures the long-term stability of the polymeric refrigerant in the oil and prevents precipitation; the latter, by reducing surface tension, enhances the wetting and penetration ability of the quenching oil into complex tooth profiles, especially the narrow space at the tooth root, working together with the refrigerant to solve the problem of tooth root quenching.

[0069] Targeted improvements in the preparation process:

[0070] 4. This invention employs a staged mixing process, adding additives to each component in two stages under different temperatures, vacuum levels, and stirring speeds. In the first stage, antioxidants are added at higher temperatures and vacuum levels to facilitate degassing and dissolution. In the second stage, refrigerants and surfactants are added at lower temperatures and with high-speed stirring / shearing to prevent polymer degradation due to high-temperature shearing and to ensure thorough dispersion. This process is not common knowledge in the field but a specialized method designed to protect the activity of specific components and achieve the desired final performance.

[0071] 5. Subsequent homogenization and high-speed shearing in this invention: A homogenizer and a high-speed shear emulsifier are used to ensure that the formed polymer micelles or dispersion system is sufficiently stable and uniform, and to avoid performance fluctuations during use.

[0072] 6. In this invention, after homogenization, filtration is performed to remove internal minute impurities, and a defoamer is added for subsequent mixing. If the defoamer is added before filtration, it will be intercepted by the filter, resulting in a "waste of adding" problem.

[0073] 7. During additive mixing, the present invention uses a drive motor to rotate the stirring shaft through a transmission structure to mix the internal raw materials. At the same time, it drives the partition plate to move vertically. The stirring shaft can switch between forward and reverse rotation at the upper and lower extreme positions, thereby completing the reciprocating switching of the partition plate's up and down running state. Through the up and down movement of the partition plate, the upper and lower layers of oil are circulated and pumped out, realizing the mixing method of upper layer liquid inlet and upper layer mixing, and lower layer liquid inlet and lower layer mixing. This can overcome the problem that the traditional refrigerant in this case is prone to high bottom concentration during mixing and stirring, which leads to subsequent homogenization loss and quenching oil quality problems. Attached Figure Description

[0074] Figure 1 These are the performance indicators of the product of this invention.

[0075] Figure 2 The quenching oil cooling curve of this invention.

[0076] Figure 3 This is a diagram showing the internal structure of the reactor used in the preparation of the quenching oil of this invention.

[0077] Figure 4 for Figure 3 A magnified view of a portion of point A in the middle.

[0078] Figure 5 for Figure 3 A magnified view of a section at point B.

[0079] Figure 6 This is a diagram showing the connection relationship between the stirrer and the stirring shaft of the present invention.

[0080] Figure 7 This is a horizontal cross-sectional view of the connection node between the stirrer and the stirring shaft of the present invention.

[0081] Figure 8 This is a schematic diagram of the structure of the moving ring and partition plate assembly of the present invention.

[0082] Figure 9 This is a top view of the partition plate of the present invention.

[0083] Figure 10 This is a schematic diagram of the structure of the discharge port of the reactor of the present invention.

[0084] In the diagram: 100, Reactor; 101, Vacuum Pump; 102, Pressure Sensor; 103, Heating Jacket; 104, Temperature Sensor; 105, Liquid Level Sensor; 110, Base Frame; 111, Drive Motor; 112, Gear Component 1; 113, Gear Component 3; 114, Gear Component 2; 120, Stirring Shaft; 121, Transmission Gear Ring; 122, Positioning Ring; 123, Upper Mounting Plate; 124, Lower Mounting Plate; 125, Mounting Sleeve; 126, Ratchet; 127, One-Way Ratchet; 128, Stirring Blade; 130, Rotary Seat 1; 1 40. Upper position control component; 141. Adjusting screw; 142. Vertical guide rod; 143. Elastic component; 144. Axial guide rod; 150. Lower position control component; 160. Moving ring; 161. Divider plate; 1611. Upper rotating plate; 1612. Lower fixed plate; 1613. Connector; 1614. Spring component; 1615. Traction rope; 1616. Release hole; 1617. Guide ear; 1618. Winder; 170. Return pipe; 180. Rotating seat II; 190. Axial adjustment component; 191. Spring body; 192. Constraint body. Detailed Implementation

[0085] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0086] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0087] Example 1

[0088] A special quenching oil for ultra-large module, large size, and ultra-thick gear rings, comprising:

[0089] Base oil: 75% ~ 90%;

[0090] Cooling agent: 5% ~ 15%;

[0091] High-temperature antioxidant: 1.0% ~ 4.0%;

[0092] Dispersant: 0.5% ~ 2.0%;

[0093] Surfactant: 0.1% ~ 1.0%;

[0094] Metal passivating agent: 0.1% ~ 0.5%;

[0095] Defoamer: 0.01% ~ 0.1%;

[0096] The cooling agent is a blend selected from styrene-maleic anhydride copolymer ester and polyalkyl methacrylate, and the cooling rate of the cooling agent at 300℃ is not less than 5.0℃ / second.

[0097] In a preferred embodiment, the weight ratio of the polyalkyl methacrylate and the styrene-maleic anhydride copolymer ester is (2~4):(3~5):(1~3).

[0098] In a preferred embodiment, the base oil is a hydrotreated paraffinic mineral oil with a kinematic viscosity of 18-28 cSt at 40°C and a flash point of not less than 200°C.

[0099] The dispersant is polyisobutylene succinimide;

[0100] The surfactant is sorbitan monooleate or alkylphenol polyoxyethylene ether;

[0101] The high-temperature antioxidant is a compound of at least two selected from alkylated diphenylamine, octyl / butyl diphenylamine and hindered phenolic esters, with a weight ratio of (3:1) to (1:2).

[0102] A method for preparing a quenching oil specifically for ultra-large module, large size, and ultra-thick gear rings, comprising the following steps:

[0103] a) Base oil pretreatment:

[0104] The base oil is pumped into a reactor, heated to 65-75°C, and stirred and dehydrated under a vacuum of -0.05-0.08 MPa for 30-60 minutes.

[0105] b) Phased mixing and addition:

[0106] Phase 1:

[0107] While maintaining the temperature and vacuum of step a), add the high-temperature antioxidant, metal passivator and dispersant in sequence, and stir at 300-500 rpm for 45-60 minutes until completely dissolved;

[0108] Phase Two:

[0109] The temperature of the reactor is lowered to 50-60°C, the surfactant and coolant are added, and the mixture is stirred at 500-800 rpm for 60-90 minutes under normal pressure to form a homogeneous and transparent system.

[0110] c) Homogenization and filtration:

[0111] The mixture obtained in step b) is subjected to homogenization in a homogenizer at a pressure of 15 ~ 25 MPa, and then filtered through a 5μm precision filter to obtain a mixed oil.

[0112] d) Defoaming and settling:

[0113] Add the defoamer to the filtered mixed oil, stir at 200-300 rpm for 20-30 minutes, and let it stand for aging for more than 24 hours to obtain the special quenching oil.

[0114] Example 2

[0115] like Figures 2 to 9As shown, the above embodiment also discloses a special reactor for realizing the above quenching oil preparation process: the top of the reactor 100 is equipped with a base frame 110, a drive motor 111 is installed on the base frame 110, a gear component 112 is installed at the output end of the drive motor 111, a gear component 114 is meshed on the upper side of the gear component 112 and a gear component 113 is meshed on the lower side, and the gear component 114 and the gear component 113 are respectively rotatably mounted on the base frame 110;

[0116] A stirring shaft 120 is rotatably installed inside the reactor 100. One end of the stirring shaft 120 passes through gear component 2 114 and gear component 3 113, and a transmission gear ring 121 is installed in the area between gear component 2 114 and gear component 3 113. Both ends of the transmission gear ring 121 are provided with transmission surfaces, which are respectively meshed with gear component 2 114 and gear component 3 113. The other end of the stirring shaft 120 is inserted into the reactor 100 and a stirrer is installed. Two sets of stirrers are provided, and a transmission area is installed on the stirring shaft 120 in the area between them.

[0117] The upper position control component 140 and the lower position control component 150 are provided on the top inner side of the reactor 100. The upper position control component 140 is adjustable in height relative to the reactor 100.

[0118] A moving ring 160 is vertically slidingly engaged between the upper position control component 140 and the lower position control component 150. The moving ring 160 is connected to a partition plate 161 via a hanger rod. The partition plate 161 and the transmission area form a vertical transmission engagement.

[0119] A reflux pipe 170 is provided on the side of the reactor 100. The reflux pipe 170 is used to connect the upper and lower spaces of the partition plate 161. The top inlet and bottom inlet of the reflux pipe 170 can be distributed in a vortex shape. That is, the oil entering the upper and lower spaces of the partition plate 161 is deviated from the direction of the stirring shaft 120 and runs in the opposite direction to the rotation of the stirrer and the stirring shaft. This can better flush the refrigerant in the bottom part of the oil layer and drive it to be fully mixed with the stirrer. In particular, the bottom inlet and outlet of the reflux pipe 170 are oriented towards the oil drain pipe, which is more conducive to the accumulation of refrigerant at the bottom.

[0120] A rotating seat 130 is installed inside the reactor 100, and a rotating seat 2 180 is installed on the lower position control component 150. An axial adjustment component 190 is provided on the rotating seat 130 and the rotating seat 2 180. The axial adjustment component 190 is used to adjust the axial displacement of the stirring shaft 120.

[0121] The reactor 100 is equipped with a vacuum pump 101, a pressure sensor 102, a temperature sensor 104, a liquid level sensor 105, and a heating jacket 103. The vacuum pump 101 is connected to the reactor 100 through a pipe. The pressure sensor 102, temperature sensor 104, and liquid level sensor 105 are distributed on the reactor 100 and are used to detect the pressure, temperature, and liquid level of the material inside the reactor, respectively. The heating jacket 103 provides heat energy to the environment inside the reactor.

[0122] The upper position control component 140 includes an upper ring plate, and an adjusting screw 141 and a vertical guide rod 142 are installed on the top of the upper ring plate. The adjusting screw 141 is used to adjust the vertical height position of the upper ring plate.

[0123] The lower position control component 150 includes a lower ring plate, which is fixed to the inner wall of the reactor 100;

[0124] An elastic element 143 is provided on one side opposite to the lower ring plate and the upper ring plate. The elastic element 143 is used to move the ring 160. The specific structure here is that the ring plate is provided with a mounting groove, and the elastic element 143 is a rod that slides in the groove and a spring that is arranged in the groove.

[0125] The stroke of the upper ring plate partition plate 161 can be adjusted by rotating the adjusting screw 141 to achieve different degrees of mixing and stirring.

[0126] An axial hole is provided on the upper ring plate, and an axial guide rod 144 is inserted into the axial hole. The axial guide rod 144 is fixed to the top of the moving ring 160 and guides the moving ring 160 vertically to complete the up and down movement of the partition plate 161.

[0127] The axial adjustment component 190 includes a mounting hole on the side of the rotating seat, in which a spring body 191 and a constraint body 192 are installed. Two sets of position rings 122 are provided on the outer side of the stirring shaft 120, with two position rings in each set. The position rings 122 and the constraint bodies 192 are mutually adapted, and the distance between the two position rings 122 is equal to the difference between the distance between the two gear components and the length of the transmission gear ring 121.

[0128] When the moving ring is obstructed from moving up or down and the elastic element 143 is compressed, the moving ring will be subjected to a reverse force, which will force the partition plate and the stirring shaft to change position along the axial direction, and switch the constraint body 192 between the two position rings 122. After the switch, the transmission gear ring and another gear are engaged, and the reverse rotation is completed (the reverse here is a relative concept of direction of rotation), which also completes the switching of the up and down running direction of the partition plate.

[0129] The stirrer includes an upper mounting plate 123 and a lower mounting plate 124. A mounting sleeve 125 is installed between the upper mounting plate 123 and the lower mounting plate 124. Multiple one-way ratchet teeth 127 are installed inside the mounting sleeve 125, and stirring blades 128 are installed on the outside. A ratchet wheel 126 is installed on the stirring shaft 120. The ratchet wheel 126 is arranged inside the mounting sleeve 125 and meshes with the one-way ratchet teeth 127.

[0130] When the two agitators are rotating, only one of them will operate together with the agitator shaft 120.

[0131] This allows the following process to occur: when the separator plate moves downward, the lower agitator rotates relative to the stirring shaft, and the separator plate squeezes the lower layer of oil into the upper space, flushing the bottom area of ​​the upper space. At the same time, the upper agitator rotates with the stirring shaft, mixing the oil in the upper space. When the separator plate moves upward, the upper agitator rotates relative to the stirring shaft, and the separator plate draws the upper layer of oil into the lower space, flushing the bottom area of ​​the lower space. At the same time, the upper agitator rotates with the stirring shaft, mixing the oil in the upper space. This cycle repeats until the oil is evenly mixed.

[0132] To achieve selective separation and communication between the upper and lower oil layers, and to ensure the lower oil layer is relatively enclosed and can be pumped out in conjunction with the up-and-down movement of the separator plate, the separator plate 161 includes an upper rotating plate 1611 and a lower fixed plate 1612. The upper rotating plate 1611 is provided with a connecting body 1613, and the lower fixed plate 1612 is provided with an arc-shaped groove. The connecting body 1613 is engaged with the arc-shaped groove by a spring member 1614. A traction rope 1615 is connected to the upper rotating plate 1611, and a guide ear 1617 is provided on the lower fixed plate 1612. Both the upper rotating plate 1611 and the lower fixed plate 1612 are provided with release holes 1616 that can be aligned by rotating a certain angle. One end of the traction rope 1615 passes through the guide ear 1617 and is connected to a winding device 1618. The winding device 1618 is installed on the top of the reactor 100 and is an electric reel or electric drum. The release and tightening of the traction rope are accomplished through a system module.

[0133] The reactor 100 has a discharge pipe at its bottom, with an inner outlet pipe 107 slidingly fitted inside. A sealing plate 106 is installed at the top of the inner outlet pipe 107, and a discharge port is located on the top side of the inner outlet pipe 107. The bottom portion of the inner outlet pipe 107 is exposed outside the discharge pipe and is fitted with a connecting plate 109. A telescopic component 108, which is either a cylinder or an electromagnetic telescopic rod, is installed at the bottom of the reactor 100. The movable end of the telescopic component 108 is connected to the connecting plate 109. By controlling the extension and retraction of the movable end of the telescopic component 108, the inner outlet pipe 107 moves up and down, allowing the internal oil to be discharged from the discharge port into the homogenizer. This design avoids the problem of refrigerant residue accumulating and clogging in the discharge pipe of traditional reactors.

[0134] The preparation steps using the above-described reactor are as follows:

[0135] a) Base oil pretreatment:

[0136] Step a1: The base oil is pumped into the reactor 100. When the base oil is pumped in, the rewinder 1618 is pulled by the traction rope 1615 to drive the upper rotating plate 1611 to rotate relative to the lower fixed plate 1612 at a certain angle. At this time, the upper and lower positions of the release hole 1616 coincide. After the coincidence, the base oil enters and reaches the area below the partition plate 161 until the set liquid level is reached. At this time, part of the base oil fills the area above the partition plate 161 and replaces the air in the return pipe 170.

[0137] In step a2, the heating jacket 103 heats the base oil inside the reactor 100 to 65 ~ 75°C. At the same time, the vacuum pump 101 evacuates the reactor to a vacuum level of -0.05 ~ -0.08 MPa.

[0138] Step a3, stirring and dehydration:

[0139] The drive motor 111 starts, driving gear 112 to rotate. Gear 112 drives gear 114 and gear 113 to rotate simultaneously. The transmission gear ring 121 meshes with gear 114. During rotation, the stirring shaft 120 rotates. The stirring shaft 120 drives the lower stirrer to rotate. At the same time, the partition plate 161 moves upward. The moving ring 160 moves upward and, under the action of the elastic element 143 on the upper ring, adjusts the stirring shaft 120 axially until the transmission gear ring 121 and gear 113 mesh, completing the reverse rotation. At this time, the upper stirrer rotates, and the partition plate 161 moves downward. Under the action of the elastic element 143 on the lower ring, the stirring shaft 120 is adjusted axially until the transmission gear ring 121 and gear 114 re-mesh. The cycle repeats, stirring and dehydrating for 30 to 60 minutes.

[0140] b) Phased mixing and addition:

[0141] Phase 1:

[0142] Maintaining the temperature and vacuum level of step a2, the winding device 1618 actively releases the traction rope 1615, and the upper rotating plate 1611 resets under the action of the spring 1614, closing the release hole 1616. The separator 161 separates the oil into an upper layer and a lower layer. Then, the high-temperature antioxidant, metal passivator and dispersant are added to the upper layer in sequence. While maintaining the action of step a3, the mixture is stirred for 45 to 60 minutes until it is completely dissolved.

[0143] Phase Two:

[0144] Reduce the temperature of reactor 100 to 50-60°C, add the surfactant and coolant to the upper layer of oil, maintain the action of step a3, and stir for 60-90 minutes to form a homogeneous and transparent system;

[0145] c) Homogenization and filtration:

[0146] The upper rotating plate 1611 is pulled by the winding device 1618 to rotate relative to the lower fixed plate 1612 by a certain angle, the release hole 1616 is opened, and the bottom of the reactor 100 is led out to the homogenizer through the oil drain pipe. It is then subjected to circulating homogenization under a pressure of 15 ~ 25 MPa, and then filtered through a precision filter to obtain mixed oil.

[0147] d) Defoaming and settling:

[0148] The filtered mixed oil is introduced into a separate mixing vessel, and the defoamer is added. After stirring at 200-300 rpm for 20-30 minutes, it is left to stand and age for more than 24 hours to obtain the special quenching oil.

[0149] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. The substitutions may be replacements of some structures, devices, or method steps, or they may be complete technical solutions. Equivalent substitutions or modifications made to the technical solutions and inventive concepts of the present invention should all be covered within the scope of protection of the present invention.

Claims

1. A special quenching oil for ultra-large module, large size, and ultra-thick gear rings, characterized in that, include: Base oil: 75% ~ 90%; Cooling agent: 5% ~ 15%; High-temperature antioxidant: 1.0% ~ 4.0%; Dispersant: 0.5% ~ 2.0%; Surfactant: 0.1% ~ 1.0%; Metal passivating agent: 0.1% ~ 0.5%; Defoamer: 0.01% ~ 0.1%; The cooling agent is a blend selected from styrene-maleic anhydride copolymer ester and polyalkyl methacrylate, and the cooling rate of the cooling agent at 300℃ is not less than 5.0℃ / second.

2. The quenching oil for ultra-large module, large size, and ultra-thick gear rings according to claim 1, characterized in that, The weight ratio of the polyalkyl methacrylate and the styrene-maleic anhydride copolymer ester is (2~4): (3~5): (1~3).

3. The quenching oil for ultra-large module, large size, and ultra-thick gear rings according to claim 1, characterized in that, The base oil is a hydrotreated paraffinic mineral oil with a kinematic viscosity of 18-28 cSt at 40°C and a flash point of not less than 200°C. The dispersant is polyisobutylene succinimide; The surfactant is sorbitan monooleate or alkylphenol polyoxyethylene ether; The high-temperature antioxidant is a compound of at least two selected from alkylated diphenylamine, octyl / butyl diphenylamine and hindered phenolic esters, with a weight ratio of (3:1) to (1:2).

4. A method for preparing a special quenching oil for ultra-large module, large size, and ultra-thick gear rings as described in any one of claims 1-3, characterized in that, The steps are as follows: a) Base oil pretreatment: The base oil is pumped into a reactor, heated to 65-75°C, and stirred and dehydrated under a vacuum of -0.05-0.08 MPa for 30-60 minutes. b) Phased mixing and addition: Phase 1: While maintaining the temperature and vacuum of step a), add the high-temperature antioxidant, metal passivator and dispersant in sequence, and stir at 300-500 rpm for 45-60 minutes until completely dissolved; Phase Two: The temperature of the reactor is lowered to 50-60°C, the surfactant and coolant are added, and the mixture is stirred at 500-800 rpm for 60-90 minutes under normal pressure to form a homogeneous and transparent system. c) Homogenization and filtration: The mixture obtained in step b) is subjected to homogenization in a homogenizer at a pressure of 15-25 MPa, and then filtered through a precision filter to obtain a mixed oil. d) Defoaming and settling: Add the defoamer to the filtered mixed oil, stir at 200-300 rpm for 20-30 minutes, and let it stand for aging for more than 24 hours to obtain the special quenching oil.

5. The preparation method of a special quenching oil for ultra-large module, large size, and ultra-thick gear rings according to claim 4, characterized in that, The reactor (100) is equipped with a base frame (110) on top. A drive motor (111) is installed on the base frame (110). A gear component (112) is installed at the output end of the drive motor (111). A gear component (114) meshes with the upper side of the gear component (112) and a gear component (113) meshes with the lower side. The gear component (114) and the gear component (113) are respectively rotatably mounted on the base frame (110). A stirring shaft (120) is rotatably installed inside the reactor (100). One end of the stirring shaft (120) passes through gear component two (114) and gear component three (113), and a transmission gear ring (121) is installed in the area between gear component two (114) and gear component three (113). Both ends of the transmission gear ring (121) are provided with transmission surfaces, which mesh with gear component two (114) and gear component three (113) respectively. The other end of the stirring shaft (120) passes through the reactor (100) and is equipped with a stirrer. There are two sets of stirrers, and a transmission area is installed on the stirring shaft (120) in the area between them. The upper position control component (140) and the lower position control component (150) are provided on the top inner side of the reactor (100). The upper position control component (140) is adjustable in the upper and lower positions relative to the reactor (100). A sliding ring (160) is vertically sliding between the upper position control component (140) and the lower position control component (150). The sliding ring (160) is connected to a partition plate (161) via a hanger rod. The partition plate (161) and the transmission area form a vertical transmission fit. A reflux pipe (170) is provided on the side of the reactor (100), and the reflux pipe (170) is used to connect the upper and lower spaces of the partition plate (161); A rotating seat one (130) is installed inside the reactor (100), and a rotating seat two (180) is installed on the lower position control component (150). An axial adjustment component (190) is provided on the rotating seat one (130) and the rotating seat two (180). The axial adjustment component (190) is used to adjust the axial displacement of the stirring shaft (120). The reactor (100) is equipped with a vacuum pump (101), a pressure sensor (102), a temperature sensor (104), a liquid level sensor (105), and a heating jacket (103). The vacuum pump (101) is connected to the reactor (100) through a pipe. The pressure sensor (102), temperature sensor (104), and liquid level sensor (105) are distributed on the reactor (100) and are used to detect the pressure, temperature, and liquid level of the material inside the reactor, respectively. The heating jacket (103) provides heat energy to the environment inside the reactor.

6. The method for preparing a special quenching oil for ultra-large module, large size, and ultra-thick gear rings according to claim 5, characterized in that, The upper position control component (140) includes an upper ring plate, and an adjusting screw (141) and a vertical guide rod (142) are installed on the top of the upper ring plate. The adjusting screw (141) is used to adjust the vertical height position of the upper ring plate. The lower position control component (150) includes a lower ring plate, which is fixed to the inner wall of the reactor (100); An elastic element (143) is provided on the opposite side of the lower ring plate and the upper ring plate. The elastic element (143) is used to move the ring (160). An axial hole is provided on the upper ring plate, and an axial guide rod (144) is inserted into the axial hole. The axial guide rod (144) is fixed to the top of the moving ring (160).

7. The preparation method of a special quenching oil for ultra-large module, large size, and ultra-thick gear rings according to claim 6, characterized in that, The axial adjustment component (190) includes a mounting hole on the side of the rotating seat, in which a spring body (191) and a constraint body (192) are installed. Two sets of position rings (122) are provided on the outer side of the stirring shaft (120). Each set of position rings (122) has two rings. The position rings (122) and the constraint body (192) are adapted to each other. The distance between the two position rings (122) is equal to the difference between the distance between the two gear components and the length of the transmission gear ring (121).

8. The method for preparing a special quenching oil for ultra-large module, large size, and ultra-thick gear rings according to claim 7, characterized in that, The agitator includes an upper mounting plate (123) and a lower mounting plate (124). A mounting sleeve (125) is installed between the upper mounting plate (123) and the lower mounting plate (124). Multiple one-way ratchet teeth (127) are installed inside the mounting sleeve (125), and stirring blades (128) are installed on the outside. A ratchet wheel (126) is installed on the stirring shaft (120). The ratchet wheel (126) is arranged inside the mounting sleeve (125) and meshes with the one-way ratchet teeth (127). Only one of the two agitators operates together with the agitator shaft (120) when the shaft (120) is rotating.

9. A method for preparing a special quenching oil for ultra-large module, large size, and ultra-thick gear rings according to claim 8, characterized in that, The partition plate (161) includes an upper rotating plate (1611) and a lower fixed plate (1612). A connecting body (1613) is provided on the upper rotating plate (1611), and an arc-shaped groove is provided on the lower fixed plate (1612). The connecting body (1613) is engaged with the arc-shaped groove by a spring (1614). A traction rope (1615) is connected to the upper rotating plate (1611), and a guide ear (1617) is provided on the lower fixed plate (1612). Both the upper rotating plate (1611) and the lower fixed plate (1612) are provided with release holes (1616) that can be aligned by rotating a certain angle. One end of the traction rope (1615) passes through the guide ear (1617) and is connected to a winding device (1618). The winding device (1618) is installed on the top of the reactor (100).

10. A method for preparing a special quenching oil for ultra-large module, large size, and ultra-thick gear rings according to claim 9, characterized in that, The preparation steps are as follows: a) Base oil pretreatment: Step a1: The base oil is pumped into the reactor (100). When the base oil is pumped in, the rewinder (1618) is pulled by the traction rope (1615) to rotate the upper rotating plate (1611) relative to the lower fixed plate (1612) by a certain angle. At this time, the upper and lower positions of the release hole (1616) coincide. After the coincidence, the base oil enters and goes to the area below the partition plate (161) until the set liquid level is reached. At this time, part of the base oil fills the area above the partition plate (161) and replaces the air in the return pipe (170). Step a2: The heating jacket (103) heats the base oil inside the reactor (100) to 65 ~ 75°C. At the same time, the vacuum pump (101) evacuates the reactor to a vacuum level of -0.05 ~ -0.08 MPa. Step a3, stirring and dehydration: The drive motor (111) starts, driving gear component one (112) to rotate. Gear component one (112) drives gear component two (114) and gear component three (113) to rotate simultaneously. The transmission gear ring (121) and gear component two (114) mesh. During the rotation, the stirring shaft (120) rotates. The stirring shaft (120) drives the lower stirrer to rotate, and at the same time drives the partition plate (161) to move upward. The moving ring (160) moves upward and, under the action of the elastic element (143) on the upper ring, adjusts the stirring shaft (120) axially to the point where the transmission gear ring (121) and gear component three (113) mesh, completing the reverse rotation. At this time, the upper stirrer rotates, and at the same time, the partition plate (161) moves downward. Under the action of the elastic element (143) on the lower ring, the stirring shaft (120) is adjusted axially to the point where the transmission gear ring (121) and gear component two (114) re-mesh. The cycle repeats, stirring and dehydrating for 30 to 60 minutes. b) Phased mixing and addition: Phase 1: While maintaining the temperature and vacuum of step a2, the winding device (1618) actively releases the traction rope (1615), and the upper rotating plate (1611) resets under the action of the spring (1614) to close the release hole (1616). The separator (161) separates the oil into an upper layer and a lower layer. Then, the high-temperature antioxidant, metal passivator and dispersant are added to the upper layer in sequence. While maintaining the action of step a3, the mixture is stirred for 45 to 60 minutes until it is completely dissolved. Phase Two: The temperature of the reactor (100) is reduced to 50-60°C. The surfactant and coolant are added to the upper layer of oil. The action of step a3 is maintained and the mixture is stirred for 60-90 minutes to form a homogeneous and transparent system. c) Homogenization and filtration: The upper rotating plate (1611) is pulled by the winding device (1618) and rotated relative to the lower fixed plate (1612) by a certain angle. The release hole (1616) is opened, and the bottom of the reactor (100) is led out to the homogenizer through the oil drain pipe. It is then subjected to circulating homogenization under a pressure of 15 ~ 25 MPa, and then filtered through a precision filter to obtain mixed oil. d) Defoaming and settling: The filtered mixed oil is introduced into a separate mixing vessel, and the defoamer is added. After stirring at 200-300 rpm for 20-30 minutes, it is left to stand and age for more than 24 hours to obtain the special quenching oil.

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