ZLYJ Series Plastic Extruder Gearbox Reducer

ZLYJ Series Gearbox for Plastic Extruder

ZLYJ series Extruder Gearboxes is a high-precision gear transmission device with a hard tooth surface and thrust package designed for plastic and rubber screw extruders. The product design refers to various technical specifications specified in JBT8853-2001 Cylindrical Gear Reducer. Its feature is that the gear and shaft parts are high-strength alloy copper. The accuracy of gear machined by carburizing, quenching, and gear grinding process is Gb10095-886. Tooth surface hardness HRC54-62. The front end of the hollow output shaft is equipped with a large-sized thrust bearing to bear the axial thrust when the screw is working. The machine is small, has high bearing capacity, stable transmission, low noise, and high efficiency.

CAD Diagram & Dimensions Table

Table 1 

Introduction for Plastic Extruder Gearbox

In the broad picture of today's global manufacturing industry, the plastic extrusion industry plays a vital role, not only supporting the supply of basic materials in many key fields such as packaging, construction, automobiles, electronics, etc., but also constantly pushing the boundaries of technological innovation. . With the increasing awareness of environmental protection and the growing demand for sustainable development, plastic extrusion technology is rapidly evolving in a more efficient, precise and environmentally friendly direction. This process requires production equipment to have higher performance standards, which can achieve optimal utilization of materials and high-quality output of products while ensuring output.It is against this industry background that the ZLYJ series helical gear reducer stands out with its excellent design and manufacturing technology, and has become a key factor in improving the efficiency and product quality of plastic extrusion production lines. This series of reducers is specially designed to cope with the high torque requirements and long-term continuous operation challenges in the plastic extrusion process. Through precise transmission control and excellent load bearing capacity, it effectively reduces energy loss and improves extrusion speed and stability. properties, thereby ensuring the dimensional accuracy and surface finish of the product. In addition, the ZLYJ series also focuses on reducing maintenance costs and improving the overall life of the equipment, providing strong equipment support for plastic processing companies and helping them maintain a leading position in global competition. Therefore, an in-depth understanding of the working principle, technical advantages and positive impact of the ZLYJ series reducer on the plastic extrusion industry is of great significance for promoting the upgrading and development of the entire industry chain.

Code & Mark of Speed Reducer

In the code of speed reducer.it in cudes model,center distance of output grade,normal transmissionratio,assembling way.

Assembling Way

Suitable Condition

The serial product can be used in reducing driving of single scew rod extruder with thescrew rod diameter of 30~250mm.The input speed of the gearboxes is normally not larger than 1500rpm.The driving ratio is between 6.3 and 20,and that can be selected preterentially in thetable.The driving ratio can be also adjusted as per requirement of customer.The temperature in work environment is -10~45 C.lf the temperature is over the range,itcan also be equipped lubricating heat or colling device as request.

Lubrication Cooling Heating

The gear and bearing adapt the lubricating way of immersing lubricating in oil pool and splashinglubricating. For ZLYJ225 and above specification, the lubrication of bearing of speed reducer ,besidessplashing lubricating, if also increase lubricating system of oil pump to lubricate through forced oilsupply.The brand of lubricating oil is middle polar pressure gear oil N220 or other qualified gear oil with similar viscosity. When ambient temperature is below 0℃. lt is necessary to increase electric heating pipein the oil pool for preheating lubricating oil.When ambient temperature is over 35'℃, manufacture should carry out the calculation of thermalbalance in accordance with the temperature value of customer in order to ascertain whether in creasecooling device.The schematic diagram for oil circuit of forced lubricating is shown in Fig 3:Moved by gears above 450Oil pass of electric contacting point pressure gauge according to the request of the customers

Cooling Methods

Installation & Maintance

• 1、The reducer shall be protected from moisture during transportation and storage. The outsidesurfaces of reducer shall be recoated with anti-rust oil if it has been left uninstalled for 6 months.
• 2、 The reducer shall be instled on a level foundation .When all anchor bolts are evenly tightenedensure that the screw inserted into the output shaft turns freely and regularly, thus to prevent thelifetime of the bearing of output shaft from being shortened due to additional forceapplied to it. Thescrew shall not be installed and dismantled by force.
• 3、 After the reducer is installed , fll the lubricating oil to the center line of oil leveler. The oil level shalbe confirmed on condition that the lubricating oi is evenly distributed in the oil tank ,regulary checkedand, in no event ,below the oil lever. The medium-load industrial gear oil L-CKC220 or L-CKC320 isrecommended. The oil shall be changed after 300~600h for the first time and every 3000h after that.The lubricating oil shall be discharged and replaced only when the reducer is stopped and the oil hasnot cooled yet. The tank shall be flushed with oi of identical quality. The oil of high viscosity which isnot suitable for flushing may be preheated or replaced with oil of low viscosity.
• 4、 For the reducer equipped with oil pump for forced lubrication ,during the early stage of operationthe oil pump may incur insufficient oil feed and loud noise due to the high viscosity of lubricating oil.Which would gradually die away along with the temperature rise of the lubricating oil. For the reducerequipped with motor oil pump, first start up and run the motor oil pump without load for a while to fullylubricate all lubricating points.
• 5、 lf the oil pump incurs loud noise during normal operation, the resistance of oil way may be high.Clean the filter cleaner and its accessories then. For any reducer, if it is started up after being idle forlong time or at low temperature, it shall run without load for a while to fully lubricate all the bearings.
• 6、 lf the oil heats up quickly with a temperature rise over 70 or to over 100 , or deteriorates or anyexceptional noise occurs , stop the machine to find the cause. lf it is due to binding problem of toothflank, solve the cause and replace the lubricating oil before restart.

Fault & Cause & Solution

[ninja_tables id="823693"]

Scope of application

1. The speed of the high-speed shaft shall not be greater than 1500 rpm.2. The peripheral speed of gear transmission shall not be greater than 20m/s.3. The working environment temperature is - 40-45 ℃. If it is lower than 0 ℃, the lubricating oil should be preheated to above 0 ℃ before starting. This reducer can run in both positive and negative directions, but some models have one-way high-speed shafts. The default direction of the oil pump is clockwise rotation facing the output shaft. If the direction changes, please explain it when ordering.

How to select the appropriate model

The mechanical power, axial thrust and thermal power must be checked for the selection of ZLYJ reducer. The detailed steps are as follows:

1. Selection ratio (Table 1 ）Input speed n1=1000pm, output speed n2=70 rpmi=n1/n2=1000/70=14.28, Selection ratio 14
2. Specification of gear selection reducer (Table 1)Select the model according to the input power and output speed provided by the user.Input power P=26KW, 29KW>26KW, and the most economical, select ZLYJ200
3. Assembly type of reducer (Fig. 1)Select the assembly type of the reducer according to the installation mode of the user.
4. Calculated axial thrust Fa=xds PS/(4 x 1000)Screw diameter: ds=75mm    Screw pressure: PS=26MPaThrust Fa=mx75 × 26/(4 × 1000)=114.8KN187KN>114.8KN, ZLYJ200 can withstand this axial thrust
5. Clearance connection size (Figure 1, Table 2)Check the hole diameter, key width, spline parameters and shaft hole depth of hollow output shaft.Check the size of the anchor mounting hole and the size of the thrust package threaded hole
6. Constant cooling mode (Table 3)Small size reducers are generally splash lubricated and naturally cooled.Large reducer adopts forced lubrication and cooler cooling. If the user requires configuration beyond the attached table, it must be stated when ordering.

Model	ZLYJ112	ZLYJ133	ZLYJ146	ZLYJ173	ZLYJ200	ZLYJ225	ZLYJ250
Thrust KN	41	54	60	153	187	250	268
Model	ZLYJ280	ZLYJ315	ZLYJ330	ZLYJ375	ZLYJ420	ZLYJ450
Thrust KN	356	403	448	495	545	590

 

Model	ZLYJ112	ZLYJ133	ZLYJ146	ZLYJ173	ZLYJ200	ZLYJ225	ZLYJ250	ZLYJ280	ZLYJ315	ZLYJ330	ZLYJ375	ZLYJ420	ZLYJ450
Ratio	8	8	10	10	12.5	12.5	16	16	16	16	16	16	16
Screw diameter	35	45.5	55	65	75	90	100	105.110	120	130.150	150.160	165	165
Motor power	5.5-4P	7.5-4P	11-4P	18.5-4P	25-4P	45-4P	45-4P	55-6P	75-6P	132-6P	132-6P	160-6P	200-6P
Input speed	800	800	900	900	1000	1000	1120	960	960	960	960	960	960
Output speed	100	100	90	90	80	80	70	60	60	60	60	60	60
Remarks	Motor and reducer are driven by pulley							The motor and reducer are connected by coupling

 

Application of Extruder Gearbox

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