In the field of modern engineering machinery manufacturing, reducers are key core components that are directly related to the operating stability, power output efficiency and service life of the equipment. As a world-renowned construction machinery manufacturer, Sany Heavy Industry (SANY) has always focused on improving the performance of core components to meet more demanding working conditions. This article takes the performance optimization of a primary reducer of Sany Heavy Industry as an example, and analyzes in detail how the company achieved significant performance improvement of the reducer through material upgrades, design improvements and manufacturing process optimization.
Optimization background and challenges
In the actual application of construction machinery, reducers need to withstand high-torque and high-load working environments for a long time, which places extremely high requirements on the wear resistance and stability of their gears, bearings and internal lubrication systems. After analyzing customer feedback and equipment operation data, Sany Heavy Industry found that some reducers suffered from rapid wear, excessive temperature and loud noise under high-intensity operation. This phenomenon is mainly concentrated in the transmission systems of heavy-loaded excavators and mining engineering vehicles, directly affecting the continuous operation capacity and maintenance costs of the equipment.
Performance Improvement Measures
In order to improve the durability and reliability of the reducer, the R&D team of Sany Heavy Industry carried out a comprehensive technical upgrade, adopting a systematic improvement plan from material selection, structural optimization to improvement of lubrication solutions.
Material: Sany Heavy Industry has comprehensively upgraded the reducer gear set and adopted high chromium (Cr) alloy steel as the main material. High chromium alloy steel is widely used in transmission parts of heavy-duty equipment due to its excellent wear resistance and impact resistance. At the same time, carburizing and quenching treatment is added to the gear surface to further increase the hardness and effectively extend the service life of the gear.
Structural optimization: Sany Heavy Industry used topological optimization technology to redesign the gear arrangement and box structure inside the reducer. Through finite element analysis (FEA), engineers found a structural form that can reduce the weight of the reducer while still ensuring strength and rigidity. This design not only reduces energy loss, but also reduces the vibration and noise of the overall equipment.
Lubrication system: Traditional reducers mostly use conventional gear oil, which is prone to lubrication failure due to high temperature conditions. Sany Heavy Industry uses high-temperature anti-oxidation synthetic lubricants in its new reducers and adds an oil circulation cooling system to ensure that the equipment can maintain a stable lubrication state even when running at high temperatures for a long time. This improvement effectively reduces the internal friction coefficient, thereby reducing energy loss and component wear.
Practical application effects and performance improvements
After multiple rounds of optimization tests, the improved Sany Heavy Industry reducer was put into use at multiple construction sites and achieved remarkable results. In a field test on a SY485H heavy hydraulic excavator, the new reducer reduced gear wear by about 25% after 800 hours of continuous operation, and the fuel consumption of the equipment also decreased by about 3%, which fully proved the performance of the reducer. Energy efficiency improvement brought about by optimization.
Another example is the use of mining transport vehicles. Since the optimized reducer has higher impact resistance, it can still maintain stable power output even under full load conditions without frequent maintenance. . This not only reduces equipment downtime, but also significantly improves the overall operating efficiency of the mine.
Through this speed reducer performance optimization, Sany Heavy Industry once again demonstrated its technical strength in the field of construction machinery. The systematic improvements in material upgrades, structural innovations and lubrication improvements have significantly improved the stability and durability of the reducer under heavy loads and extreme environments. For end users, this means lower maintenance costs, longer equipment life and higher operating efficiency.
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