I. Core Functions and Design Features of Atlas Copco Gearsets
Power Transmission: Transmits the torque output by the motor to the air compressor main unit (such as screw rotors, piston crankshafts), driving the compression components to operate.
Speed Matching: Adjusts through gear ratio to make the main unit reach the optimal operating speed (such as screw air compressors usually require a higher speed to enhance compression efficiency).
Structural Characteristics:
High Precision Interlock: Uses hard toothed gears (surface quenching or carburizing treatment), with tooth shape accuracy reaching ISO 5 level or above, reducing transmission noise (typically ≤ 85 dB) and energy loss.
Integrated Lubrication: Most are connected to the air compressor lubrication system, continuously lubricating the gear meshing area and removing friction heat.
Compact Design: Integrates well with the main unit and motor, saving installation space, suitable for both fixed and mobile air compressors.
II. Common Types and Application Models of Atlas Copco Gearsets
According to the structure and power range of the air compressor, Atlas Copco gearsets are mainly divided into the following types:
1. Screw Air Compressor Gearsets
Single-stage speed-increasing gearsets: Commonly found in small and medium-sized injection screw air compressors (such as GA series, G11-G160), increasing the motor speed (typically 1500 r/min) to the rotor speed required (3000-6000 r/min), with speed ratios mostly ranging from 2:1 to 4:1.
Characteristics: The inclined gears mesh smoothly and have strong bearing capacity, suitable for continuous operation conditions.
Two-stage gearsets: Used for large screw air compressors (such as GA160 and above models) or high-pressure conditions, achieving a larger speed ratio through two stages of gear transmission, while distributing the load and enhancing reliability.
2. Piston-Type Air Compressor Gearsets
Mostly speed-reducing gearsets, combined with the crankshaft connecting rod mechanism, converting the high-speed rotation of the motor into the reciprocating motion of the piston, with speed ratios designed according to the piston stroke (typically 0.1-0.5), commonly found in small piston machines (such as SF series).
3. Specialized Gearsets for Mobile Air Compressors
For mobile conditions (such as XAS series), the gearsets are enhanced with shock-proof design (such as elastic couplings), adapting to bumpy and vibrating environments, while having higher dustproof and waterproof performance (protective grade often IP54).
III. Key Technical Parameters and Materials of Atlas Copco Gearsets
Core Parameters:
Speed Ratio: Ranging from 0.1 to 4, depending on the model, and needs to match with the motor and main unit speed.
Rated Torque: From several hundred N·m to several thousand N·m (such as large models can reach over 5000 N·m), meeting the requirements for starting the main unit and full-load operation.
Maximum Speed: The maximum allowable speed of the gear is usually ≤ 10000 r/min, to avoid excessive centrifugal force causing tooth surface damage.
Material and Processing:
Gear Blank: Uses high-strength alloy structural steel (such as 42CrMo, 20CrMnTi), ensuring overall strength.
Gear Surface Treatment: Carburizing and quenching (hardness up to HRC58-62) or nitriding treatment, enhancing wear resistance and fatigue resistance.
Case: Cast iron (HT250) or aluminum alloy (for lightweight models), with good rigidity and heat dissipation performance.
IV. Common Faults and Maintenance Points of Atlas Copco Gearsets
Typical Fault Causes:
Gear Strange Noise: Mostly caused by tooth surface wear, excessive tooth clearance (over 0.2mm) or misalignment during assembly, resulting in poor meshing.
High Temperature: Insufficient lubrication (low oil level, deteriorated oil quality) or excessive impurities in the gearbox, increasing friction resistance.
Gear Breakage: Long-term overloading operation, material defects or sudden impact loads (such as frequent motor startups) causing.
Maintenance Suggestions: Regularly check the lubricating oil: Follow the manual instructions (typically every 2,000 - 4,000 hours) to replace the special gear oil (such as Atlas Copco original synthetic gear oil), and the oil level should be within the scale range.
Monitor the operating status: Use an infrared thermometer to measure the temperature of the gearbox (normally it should be ≤ 80℃), listen for any abnormal noises, and stop the machine for inspection if any problems are found.
Regular maintenance: Disassemble and inspect the gear tooth surface wear and bearing clearance every 10,000 - 20,000 hours. If necessary, replace the gears or bearings (it is recommended to use original factory parts to ensure the meshing accuracy).
Avoid overloading: Prevent the air compressor from operating continuously under overpressure and overflow conditions, and reduce the load on the gear set.
