CN114525165B - 一种用于盾构机齿轮传动***的润滑油组合物 - Google Patents
一种用于盾构机齿轮传动***的润滑油组合物 Download PDFInfo
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- CN114525165B CN114525165B CN202011321400.4A CN202011321400A CN114525165B CN 114525165 B CN114525165 B CN 114525165B CN 202011321400 A CN202011321400 A CN 202011321400A CN 114525165 B CN114525165 B CN 114525165B
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Abstract
本发明涉及一种用于盾构机齿轮传动***的润滑油组合物,其包含:组分A,基础油,其含量为90.0~97.75wt%;组分B,含硫极压剂,其含量为0.5~1.5wt%;组分C,节能减磨添加剂,其含量为0.5~2.0wt%;组分D,抗氧剂,其含量为0.5~1.5wt%;组分E,抗磨型分散剂,其含量为0.5~1.0wt%;组分F,高效破乳剂,其含量为0.005~0.1wt%;组分G,抗泡剂,其含量为0.003~0.10wt%。本发明的用于盾构机齿轮传动***的润滑油组合物具有优异的承载能力,良好的轴承保护性能,突出的抗乳化性能,能够满盾构机掘进时低速、重载、大扭矩和有水浸入等复杂工况的润滑需求。
Description
技术领域
本发明属于润滑油技术领域,尤其涉及一种用于盾构机齿轮传动***的润滑油组合物。
背景技术
盾构机的全称为盾构隧道掘进机(Tunnel Boring Machine),作为一种隧道掘进的专用工程机械,可广泛用于地铁、铁路、公路、市政、水电等隧道工程。
盾构机刀盘驱动***(简称主驱动)是盾构机的心脏,是其动力输出的中心,直接起到动力转换和输出的作用,同时还起着支撑盾构刀盘并使之回转破岩的作用。由于盾构掘进过程中维修十分困难和复杂,要求对盾构机主驱动***及其配件的可靠性和稳定性等要求极高。在工作过程中,驱动电机经行星齿轮减速机减速后,驱动与其对应的小齿轮,各小齿轮又与大齿圈啮合传动,提供刀盘驱动扭矩以及承担掘进过程中的负载。刀盘驱动流程图参见图1。
刀盘驱动***是盾构机完成掘进功能的重要组成部分,而减速机则是刀盘主驱***的核心部件,其正常运转与否直接关系着盾构施工的成本和效率。盾构机在掘进过程中,刀盘驱动***载荷多变,刀盘侧要承受0.3-0.5Mpa的压力,单台减速机的工作扭矩能达到6000kN.m以上,刀盘主驱动的总推动力达到30000KN以上,其齿轮传动***是典型的低速大扭矩、工况恶劣(渗漏砂石和水)、工作强度高、冲击负荷大等工况。这种条件下,齿轮往往会产生疲劳现象,特别是当润滑不良时,更会加剧齿轮的擦伤、磨损、点蚀乃至剥落,造成减速机的损坏。这就要求油品具有良好的黏温性能、优异的极压抗磨性、轴承保护性、氧化安定性和抗乳化性。
由于盾构机齿轮箱润滑油的以上特殊性能要求,技术难度较大,加之目前盾构机主要OEM均为国外企业,其配套齿轮箱润滑油往往也被国外公司所垄断,国内公司尚鲜有应用案例。
发明内容
针对上述现有技术的问题,本发明提供的盾构机齿轮箱润滑油具有优异的承载能力,良好的轴承保护性能,突出的抗乳化性能,能够满足盾构机掘进时低速、重载、大扭矩和有水浸入等复杂工况的润滑需求,降低在高负荷下齿轮和轴承的磨损,保障盾构机传动***的可靠、稳定和长期运行。
为实现上述目的,本发明提供一种用于盾构机齿轮传动***的润滑油组合物,包含:
组分A,基础油,其含量为90.0~97.75wt%;
组分B,含硫极压剂,其含量为0.5~1.5wt%;
组分C,节能减磨添加剂,其含量为0.5~2.0wt%;
组分D,抗氧剂,其含量为0.5~1.5wt%;
组分E,抗磨型分散剂,其含量为0.5~1.0wt%;
组分F,高效破乳剂,其含量为0.005~0.1wt%;
组分G,抗泡剂,其含量为0.003~0.10wt%。
本发明所述的用于盾构机齿轮传动***的润滑油组合物,其中优选的是,所述基础油选自Ⅰ类基础油、Ⅱ类基础油、Ⅲ类基础油、聚a-烯烃合成油、双酯类合成油、饱和多元醇酯类合成油、加氢精制矿物油、深度精制光亮油中的至少一种。
本发明所述的用于盾构机齿轮传动***的润滑油组合物,其中优选的是,
所述含硫极压剂选自硫化异丁烯、烷基多硫化物和二烷基二硫代氨基甲酸酯中的至少一种;
所述节能减磨添加剂选自硼化硫代磷酸酯铵盐、磷酸酯芳胺盐、磷酸酯脂肪胺盐、磷酸/亚磷酸混合胺盐中的至少一种;
所述抗氧剂选自2、6-二叔丁基对甲酚、烷基二苯胺缩合物、甲基苯***酯、噻二唑的烷基聚羧酸酯衍生物中的至少一种;
所述抗磨型分散剂选自硼化硫化烷基酚盐、磷化聚异丁烯丁二酰亚胺、硼化聚异丁烯丁二酰亚胺、硼磷化聚异丁烯丁二酰亚胺中的至少一种;
所述高效破乳剂为聚乙烯亚胺类化合物、烷氧基化聚乙烯亚胺化合物、环氧丙烷与环氧乙烷的聚合物中的一种;
所述抗泡剂选自聚甲基硅油、聚甲基丙烯酸酯、聚硅氧烷、改性聚甲基丙烯酸酯、全氟聚醚缩合物中的至少一种。
本发明所述的用于盾构机齿轮传动***的润滑油组合物,其中优选的是,所述含硫极压剂选自硫化异丁烯、叔丁基多硫化物、二叔丁基多硫化物、二异辛基二硫代氨基甲酸酯、二正丁基二硫代氨基甲酸酯中的至少一种,其含量为0.6~1.2wt%。
本发明所述的用于盾构机齿轮传动***的润滑油组合物,其中优选的是,所述节能减磨添加剂选自硼化硫代磷酸酯十二铵盐、硼化硫代磷酸酯十八铵盐、磷酸酯十二胺盐、磷酸酯十八铵盐、磷酸酯芳胺盐、磷酸/亚磷酸混合十二胺盐和磷酸/亚磷酸混合十八胺盐中的至少一种。
本发明所述的用于盾构机齿轮传动***的润滑油组合物,其中优选的是,所述节能减磨添加剂的含量为0.8~1.5wt%。
本发明所述的用于盾构机齿轮传动***的润滑油组合物,其中优选的是,所述抗氧剂包含2、6-二叔丁基对甲酚,还包含二异辛基二苯胺缩合物、丁基辛基二苯胺缩合物、丁基壬基二苯胺缩合物和甲基苯***酯中的一种,所述抗氧剂的含量为0.5~1.25wt%。
本发明所述的用于盾构机齿轮传动***的润滑油组合物,其中优选的是,所述组分E的含量为0.5~0.8wt%。
本发明所述的用于盾构机齿轮传动***的润滑油组合物,其中优选的是,所述组分F的含量为0.005~0.08wt%。
本发明所述的用于盾构机齿轮传动***的润滑油组合物,其中优选的是,所述抗泡剂为分子量1000-10000的聚甲基硅油和聚甲基丙烯酸酯的混合物,或者分子量30000-60000的聚硅氧烷和改性聚甲基丙烯酸酯的混合物;所述抗泡剂的含量为0.003~0.08wt%。
本发明提供的用于盾构机齿轮传动***的润滑油组合物可以按照以下方法制备:根据组合物的黏度等级,将所述基础油(组分A)按比例加入带搅拌器的不锈钢调合釜内,然后按比例将含硫极压剂(组分B)、节能减磨添加剂(组分C)、抗氧剂(组分D)、抗磨型分散剂(组分E)、高效破乳剂(组分F)、抗泡剂(组分G)依次加入到调合釜中,升温至50~65℃下搅拌3-4小时,至混合物全部溶解并均匀透明即可。
为了筛选基础油和添加剂组分及润滑油组合物,本发明在实验室采用了各种试验方法进行模拟评定。评定方法包括润滑油极压性能测定法(GB/T 3142)、润滑油抗磨性能测定法(NB/SH/T 0189)、润滑油抗泡性能测定法(GB/T 12579或ASTM D892)、润滑油承载能力测定法(梯姆肯法)(GB/T 11144或SH/T0532)、石油和合成液水分离性测定法(GB/T 7305或ASTM D1401)、润滑油氧化安定性测定法(旋转氧弹法)(SH/T 0193),烘箱氧化法。
为了评价润滑油组合物性能,采用极压润滑油氧化性能测定法(SH/T 0123),FZG齿轮机试验(法ASTM D5182或DIN 51354),润滑油承载能力测定法(梯姆肯法)(GB/T 11144或SH/T0532),FE-8轴承磨损试验法(DIN51819-3),润滑油摩擦系数测定法(四球法)(SH/T0762)进行测试。其中,FE8滚子轴承测试(FE8 DIN 51819-3)轴承在边界润滑条件的磨损,测试条件为:轴承转速7.5RPM,试验时间80h,试验温度80℃,载荷100kN。测试试验前后轴承的滚子和保持架失重情况,反映油品对轴承保护性能。
本发明把润滑油组合物的承载能力、轴承保护性能、抗氧化性和抗乳化性能作为研究重点,以期达到本发明的润滑油组合物满足盾构机齿轮传动***的润滑要求,解决了轴承或齿轮在苛刻有水浸入工况下因启动或工作扭矩太大容易损坏的问题,从而使减速机的使用寿命延长。
本发明提供的盾构机齿轮箱润滑油组合物,用于盾构机齿轮传动***,包括刀盘驱动用减速机和拼装机回转支撑用减速机的润滑,具有良好的黏温性能、优异的极压抗磨性、轴承保护性、氧化安定性和抗乳化性,FZG承载级达14级以上,FE-8轴承磨损试验的滚子失重小于2mg,可满足盾构机在掘进过程中齿轮减速机承受的高载荷和大扭矩工况下的润滑要求,减少噪音,延长轴承和齿轮箱的安全使用寿命。
另外,该产品生产成本低,承载能力和抗磨性能突出,应用于盾构机行业可产生很好的经济效益与社会效益。并且,该润滑油组合物调配方便,性能优良,盾构机行业近年呈现出井喷式的发展态势,与之配套的润滑油有广阔的推广应用前景。
附图说明
图1为现有技术中的刀盘驱动流程图。
图2本发明实施例1-3的各组合物的摩擦系数对比图。
具体实施方式
以下对本发明的实施例作详细说明:本实施例在以本发明技术方案为前提下进行实施,给出了详细的实施方式和过程,但本发明的保护范围不限于下述的实施例,下列实施例中未注明具体条件的实验方法,通常按照常规条件。
以下实施例涉及的评价方法
润滑油极压性能测定法(GB/T 3142)、润滑油抗磨性能测定法(NB/SH/T 0189)、润滑油抗泡性能测定法(GB/T 12579或ASTM D892)、润滑油承载能力测定法(梯姆肯法)(GB/T11144或SH/T0532)、石油和合成液水分离性测定法(GB/T 7305或ASTM D1401)、润滑油氧化安定性测定法(旋转氧弹法)(SH/T 0193),烘箱氧化法。
极压润滑油氧化性能测定法(SH/T 0123),FZG齿轮机试验(法ASTM D5182或DIN51354),润滑油承载能力测定法(梯姆肯法)(GB/T 11144或SH/T0532),FE-8轴承磨损试验法(DIN51819-3),润滑油摩擦系数测定法(四球法)(SH/T 0762)。
其中,FE8滚子轴承测试(FE8 DIN 51819-3)轴承在边界润滑条件的磨损,测试条件为:轴承转速7.5RPM,试验时间80h,试验温度80℃,载荷100kN。测试试验前后轴承的滚子和保持架失重情况,反映油品对轴承保护性能。
实施例1-1
润滑油组合物(I),包括:36.86wt%的聚α-烯烃PAO40,40.74wt%的聚α-烯烃PAO100和19.40wt%饱和季戊四醇酯组成的基础油(组分A),0.80wt%的高压硫化异丁烯(组分B),0.80wt%硼化硫代磷酸酯十二铵盐(组分C),0.5wt%的2、6-二叔丁基对甲酚和0.25wt%的甲基苯***酯溶液(组分D);0.60wt%的硼化聚异丁烯丁二酰亚胺(组分E);0.01wt%的烷氧基化聚乙烯亚胺化合物(组分F);0.02wt%分子量为60000的硅氧烷和0.02wt%改性丙烯酸酯均聚物的混合物(组分G),以上各组分之和为100%wt%。
将组分A按比例加入带搅拌器的不锈钢调合釜内,然后按比例将含硫极压剂(组分B)、节能减磨添加剂(组分C)、抗氧剂(组分D)、抗磨型分散剂(组分E)、高效破乳剂(组分F)、抗泡剂(组分G)依次加入到调合釜中,升温至60℃下搅拌3小时,至混合物全部溶解并均匀透明即可得到润滑油组合物(Ⅰ)。
润滑油组合物(Ⅰ)主要性能见表1。
实施例1-2
润滑油组合物(Ⅱ)除组分(B)0.80wt%的高压硫化异丁烯调整成0.60wt%的高压硫化异丁烯外,其余均同润滑油组合物(Ⅰ)。润滑油组合物(Ⅱ)主要性能见表1。
实施例1-3
润滑油组合物(Ⅲ)除组分(C)0.80wt%硼化硫代磷酸酯十二铵盐被0.80wt%硼化硫代磷酸酯十八铵盐替代外,其余均同润滑油组合物(Ⅱ)。润滑油组合物(Ⅲ)主要性能见表1。
表1组合物的主要性质
表1和图2结果表明,(1)减磨剂相同的情况下,含硫极压剂的含量越高,油品的极压性能越好,但对油品抗腐蚀和减摩性能不利,极压和腐蚀、极压和减摩是一对矛盾,需要在配方中进行平衡;(2)节能减磨剂与极压剂的比例很关键,直接影响油品的减磨性能;(3)含硫极压剂含量相同的情况下,节能减磨剂的种类对油膜强度影响较大;硼化硫代磷酸酯十八铵盐的油膜强度高于硼化硫代磷酸酯十二铵盐,这是由于烷基链的长短对硼化硫代磷酸酯的性能影响显著,随烷基增大,硫代磷酸酯结构稳定性变好,能够到有效降低摩擦,增大油膜强度。
实施例2-1
润滑油组合物(IV),包括:72.93wt%的HVIS150BS光亮油和24.31wt%精制矿物油500N(性质见表2)(组分A),0.60wt%的高压硫化异丁烯和0.20wt%的二正丁基二硫代氨基甲酸酯(组分B),0.40wt%磷酸酯十八铵盐和0.40wt%硼化硫代磷酸酯十八铵盐(组分C),0.30wt%的2、6-二叔丁基对甲酚和0.30wt%的噻二唑的烷基聚羧酸酯衍生物(组分D);0.55wt%的硼化硫化烷基酚钙(组分E);0.005wt%的烷氧基化聚乙烯亚胺化合物(组分F);0.005wt%的全氟聚醚缩合物(组分G),以上各组分之和为100%wt%。
将组分A按比例加入带搅拌器的不锈钢调合釜内,然后按比例将含硫极压剂(组分B)、节能减磨添加剂(组分C)、抗氧剂(组分D)、抗磨型分散剂(组分E)、高效破乳剂(组分F)、抗泡剂(组分G)依次加入到调合釜中,升温至60℃下搅拌3小时,至混合物全部溶解并均匀透明即可得到润滑油组合物(IV)。
润滑油组合物(IV)的主要性能见表3。
实施例2-2
润滑油组合物(V)除组分(E)0.55wt%的硼化硫化烷基酚钙被0.55wt%的硼化聚异丁烯丁二酰亚胺替代外,其余均同组合物(IV)。润滑油组合物(V)的主要性能见表3。
实施例2-3
润滑油组合物(VI)除组分(E)0.55wt%的硼化硫化烷基酚钙被0.55wt%的硼磷化聚异丁烯丁二酰亚胺替代外,其余均同组合物(IV)。润滑油组合物(VI)的主要性能见表3。
表2基础油500N的主要性质
表3组合物的试验结果
由表3可知,(1)不同类型的抗磨型分散剂对油品的抗氧化能有较大影响,硼化硫化烷基酚钙的抗氧化性能好于硼磷化聚异丁烯丁二酰亚胺和硼化聚异丁烯丁二酰亚胺;(2)不同类型的抗磨型分散剂对油品的抗乳化性也有较大影响,硼磷化聚异丁烯丁二酰亚胺的抗乳化性能优于硼化硫化烷基酚钙和硼化硫化烷基酚钙。所以配方中,抗磨型分散剂的类型和加量比较重要,需要平衡其对油品抗氧化和抗乳化性能的影响。
实施例3
润滑油组合物(Ⅶ),它包括:69.50wt%茂金属催化的高粘度指数聚α-烯烃MPAO65(见表4),7.70wt%的聚α-烯烃PAO10,和19.35wt%的己二酸酯(组分A),0.75wt%的高压硫化异丁烯和0.25wt%的二正丁基二硫代氨基甲酸酯(组分B),0.45wt%磷酸酯十八铵盐,0.25wt%磷酸酯芳铵盐,0.45wt%硼化硫代磷酸酯十八铵盐(组分C),0.50wt%的2、6-二叔丁基对甲酚和0.25wt%的丁基辛基二苯胺缩合物(组分D);0.5wt%的硼磷化聚异丁烯丁二酰亚胺(组分E);0.01wt%的烷氧基化聚乙烯亚胺化合物(组分F);0.015wt%的3000分子量的聚甲基硅油和0.025wt%全氟聚醚缩合物(组分G),以上各组分之和为100%wt%。
将组分A按比例加入带搅拌器的不锈钢调合釜内,然后按比例将含硫极压剂(组分B)、节能减磨添加剂(组分C)、抗氧剂(组分D)、抗磨型分散剂(组分E)、高效破乳剂(组分F)、抗泡剂(组分G)依次加入到调合釜中,升温至60℃下搅拌3小时,至混合物全部溶解并均匀透明即可得到润滑油组合物(IV)。
润滑油组合物(Ⅶ)的主要性能见表5。
表4 mPAO65基础油的实测值
表5组合物(Ⅶ)的评价结果
表5可以看出,研制油组合物(Ⅶ)的FZG承载级大于14级,FZG FE-8轴承磨损试验的滚柱磨损小于1毫克,具有良好的黏温性能、优异的极压抗磨性、轴承保护性、氧化安定性和抗乳化性。
当然,本发明还可有其它多种实施例,在不背离本发明精神及其实质的情况下,熟悉本领域的技术人员可根据本发明作出各种相应的改变和变形,但这些相应的改变和变形都应属于本发明的保护范围。
Claims (8)
1.一种用于盾构机齿轮传动***的润滑油组合物,其特征在于,由以下组分组成:
组分A,基础油,其含量为90.0~97.75wt%;
组分B,含硫极压剂,其含量为0.5~1.5wt%;
组分C,节能减磨添加剂,其含量为0.5~2.0wt%;
组分D,抗氧剂,其含量为0.5~1.5wt%;
组分E,抗磨型分散剂,其含量为0.5~1.0wt%;
组分F,高效破乳剂,其含量为0.005~0.1wt%;
组分G,抗泡剂,其含量为0.003~0.10wt%;
所述含硫极压剂选自硫化异丁烯、叔丁基多硫化物、二叔丁基多硫化物、二异辛基二硫代氨基甲酸酯和二正丁基二硫代氨基甲酸酯中的至少一种;
所述节能减磨添加剂包括硼化硫代磷酸酯十二铵盐、硼化硫代磷酸酯十八铵盐,还包括磷酸酯十二胺盐、磷酸酯十八铵盐、磷酸酯芳胺盐、磷酸/亚磷酸混合十二胺盐和磷酸/亚磷酸混合十八胺盐中的至少一种;
所述抗氧剂包含2、6-二叔丁基对甲酚,还包含二异辛基二苯胺缩合物、丁基辛基二苯胺缩合物、丁基壬基二苯胺缩合物和甲基苯***酯中的一种;
所述抗磨型分散剂选自硼化硫化烷基酚盐、磷化聚异丁烯丁二酰亚胺、硼化聚异丁烯丁二酰亚胺和硼磷化聚异丁烯丁二酰亚胺中的至少一种;
所述高效破乳剂为聚乙烯亚胺类化合物、烷氧基化聚乙烯亚胺化合物、环氧丙烷与环氧乙烷的聚合物中的一种;
所述抗泡剂选自聚甲基硅油、聚甲基丙烯酸酯、聚硅氧烷、改性聚甲基丙烯酸酯和全氟聚醚缩合物中的至少一种。
2.根据权利要求1所述的用于盾构机齿轮传动***的润滑油组合物,其特征在于,所述基础油选自Ⅰ类基础油、Ⅱ类基础油、Ⅲ类基础油、聚a-烯烃合成油、双酯类合成油、饱和多元醇酯类合成油中的至少一种。
3.根据权利要求1所述的用于盾构机齿轮传动***的润滑油组合物,其特征在于,所述含硫极压剂含量为0.6~1.2wt%。
4.根据权利要求1所述的用于盾构机齿轮传动***的润滑油组合物,其特征在于,所述节能减磨添加剂的含量为0.8~1.5wt%。
5.根据权利要求1所述的用于盾构机齿轮传动***的润滑油组合物,其特征在于,所述抗氧剂的含量为0.5~1.25wt%。
6.根据权利要求1所述的用于盾构机齿轮传动***的润滑油组合物,其特征在于,所述组分E的含量为0.5~0.8wt%。
7.根据权利要求1所述的用于盾构机齿轮传动***的润滑油组合物,其特征在于,所述组分F的含量为0.005~0.08wt%。
8.根据权利要求1所述的用于盾构机齿轮传动***的润滑油组合物,其特征在于,所述抗泡剂为分子量1000-10000的聚甲基硅油和聚甲基丙烯酸酯的混合物,或者分子量30000-60000的聚硅氧烷和改性聚甲基丙烯酸酯的混合物;所述抗泡剂的含量为0.003~0.08wt%。
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