CN105838483A - 一种抗磨风电齿轮油及其制备方法 - Google Patents

一种抗磨风电齿轮油及其制备方法 Download PDF

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CN105838483A
CN105838483A CN201610221235.2A CN201610221235A CN105838483A CN 105838483 A CN105838483 A CN 105838483A CN 201610221235 A CN201610221235 A CN 201610221235A CN 105838483 A CN105838483 A CN 105838483A
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黄毅
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Abstract

本发明公开了一种抗磨风电齿轮油及其制备方法，所述抗磨风电齿轮油由下述重量份的原料组成：单烯基丁二酰亚胺0.4‑0.6份、烷基苯磺酸钙0.1‑0.3份、4,4'‑二辛基二苯胺0.05‑0.15份、2,4‑二(十二烷基硫甲基)‑6‑甲基苯酚0.1‑0.3份、抗磨剂0.2‑0.9份、基础油90‑100份。本发明抗磨风电齿轮油，即使在苛刻工况下依然具有很长的使用寿命，适宜在很宽度范围下使用的齿轮箱的润滑要求；同时，添加了具有抗微点蚀性能的极压抗磨添加剂后，能有效避免或抑制点蚀的形成，保证大型重载机械齿轮传动装置的正常运行。

Description

一种抗磨风电齿轮油及其制备方法
技术领域
本发明涉及工业齿轮油领域，特别涉及一种抗磨风电齿轮油。
背景技术
在能源越发紧张稀缺的现今，人们逐渐开始意识到环保、可再生能源的重要性。风能，作为世界上最丰富的清洁的可再生能源，在过去几年发展势头迅猛。中国风能资源丰富，电力需求大，越来越受到各界的重视。要维持电能产量的不断提高，关键是要保持风电机组顺畅运行。齿轮箱是风电机组的核心部件，可以说是齿轮传动型风机的心脏，对整个系统的正常运作至关重要。根据统计，造成风电场停运的主要原因中，齿轮箱的损坏占到35％。因此齿轮箱的设计和制造通常都非常先进，并且造价不菲。齿轮箱是风力发电机上最为昂贵的组件，一旦发生故障，更换齿轮箱要付出高昂的代价。因此对齿轮箱的使用寿命和可靠性有很高的要求。
齿轮箱是风力发电机的主要润滑部位，用油量占风力发电机用油量的3/4左右，同时对润滑油品的性能要求非常高。目前，齿轮箱受润滑不充分、润滑剂过热提前失效等因素造成的故障率非常高。其中，齿轮表面的微点蚀现象与油品的质量有很大关系，微点蚀的出现会严重影响齿轮寿命。因此，风电齿轮箱用油除具有一般齿轮油的优秀性能外，还应具有抗微点蚀性能。选择具有抗微点蚀性能的风电齿轮箱用油可以有效保护齿轮箱，延长齿轮箱的寿命，对保证风电机组高效稳定运行，提高发电效率有着非凡的意义。
美国专利(专利号为US4,417,991)揭示了一种齿轮油组合物，该组合物通过添加石墨来增加油品在使用中的油膜厚度，不仅降低了金属摩擦副的摩擦和磨损，同时可以提高油品的使用效率，但是由于这种抗磨剂是无机小分子化合物，在油品中的溶解性还是值得商榷 的，使其实用性受到很大的制约。因此，急需一种风电机齿轮润滑油，填补国内空白，满足风电设备齿轮润滑的特殊工作要求。
发明内容
针对现有技术的不足，本发明解决的技术问题是提供一种抗磨风电齿轮油及其制备方法。
本发明目的是通过如下技术方案实现的：
一种抗磨风电齿轮油由下述重量份的原料组成：单烯基丁二酰亚胺0.4-0.6份、烷基苯磺酸钙0.1-0.3份、4,4'-二辛基二苯胺0.05-0.15份、2,4-二(十二烷基硫甲基)-6-甲基苯酚0.1-0.3份、抗磨剂0.2-0.9份、基础油90-100份。
所述的基础油由9-癸烯基-油酸酯、1,2,4-苯三甲酸三(2-乙基己基)酯、9-十八烯酸-13-二十二烯酯混合而成，所述9-癸烯基-油酸酯、1,2,4-苯三甲酸三(2-乙基己基)酯、9-十八烯酸-13-二十二烯酯的质量比为(1-3)：(1-3)：(1-3)。
优选地，所述的抗磨剂由40-60wt％N,N-二(2-乙基己基)二硫代氨基甲酸钼和40-60wt％N,N-二(十三)烷基二硫代氨基甲酸钼组成。
本发明还提供了上述抗磨风电齿轮油的制备方法，其特征在于：将单烯基丁二酰亚胺、烷基苯磺酸钙、4,4'-二辛基二苯胺、2,4-二(十二烷基硫甲基)-6-甲基苯酚、抗磨剂、基础油加入调和釜中混合均匀，冷却即得成品。
本发明抗磨风电齿轮油，即使在苛刻工况下依然具有很长的使用寿命，适宜在很宽度范围下使用的齿轮箱的润滑要求；同时，添加了具有抗微点蚀性能的极压抗磨添加剂后，能有效避免或抑制点蚀的形成，保证大型重载机械齿轮传动装置的正常运行。
具体实施方式
下面结合实施例对本发明做进一步的说明，以下所述，仅是对本 发明的较佳实施例而已，并非对本发明做其他形式的限制，任何熟悉本专业的技术人员可能利用上述揭示的技术内容加以变更为同等变化的等效实施例。凡是未脱离本发明方案内容，依据本发明的技术实质对以下实施例所做的任何简单修改或等同变化，均落在本发明的保护范围内。
实施例中各原料介绍：
烷基苯磺酸钙采用专利申请号：200810011923.1中实施例1的方法制备。
单烯基丁二酰亚胺，其结构式如下：
其中，PIB为分子量为1000的聚异丁烯，n＝3。
4,4'-二辛基二苯胺，CAS号：101-67-7。
2,4-二(十二烷基硫甲基)-6-甲基苯酚，CAS号：110675-26-8。
N,N-二(2-乙基己基)二硫代氨基甲酸钼，其结构式如下：其结构式如下：
其中R为2-乙基己基。
N,N-二(十三)烷基二硫代氨基甲酸钼，其结构式如下：其结构式如下：
其中R为直链十三烷基。
9-癸烯基-油酸酯，采用专利申请号：201280008727.3中实施例中制备化合物F：9-癸烯基-油酸酯。
1,2,4-苯三甲酸三(2-乙基己基)酯，CAS号：3319-31-1。
9-十八烯酸-13-二十二烯酯，采用专利申请号：201280008727.3中实施例中制备化合物D：9-十八烯酸-13-二十二烯酯。
实施例1
抗磨风电齿轮油原料(重量份)：单烯基丁二酰亚胺0.5份、烷基苯磺酸钙0.2份、4,4'-二辛基二苯胺0.1份、2,4-二(十二烷基硫甲基)-6-甲基苯酚0.2份、抗磨剂0.5份、基础油93份。
所述的基础油由9-癸烯基-油酸酯、1,2,4-苯三甲酸三(2-乙基己基)酯、9-十八烯酸-13-二十二烯酯按质量比为1:1:1搅拌混合均匀得到。
所述的抗磨剂由50wt％N,N-二(2-乙基己基)二硫代氨基甲酸钼和50wt％N,N-二(十三)烷基二硫代氨基甲酸钼搅拌混合均匀得到。
抗磨风电齿轮油制备：
将基础油总重量二分之一的基础油(即基础油总重量的一半)加入调和釜中，升温至85℃，加入4,4'-二辛基二苯胺、2,4-二(十二烷基硫甲基)-6-甲基苯酚，400转/分搅拌45分钟；加入剩余二分之一基础油，保持温度为60℃，加入单烯基丁二酰亚胺、烷基苯磺酸钙，400转/分搅拌30min后，加入抗磨剂继续400转/分搅拌30min，冷却至25℃。得到实施例1的抗磨风电齿轮油。
实施例2
与实施例1基本相同，区别仅仅在于：所述的基础油由1,2,4-苯 三甲酸三(2-乙基己基)酯、9-十八烯酸-13-二十二烯酯按质量比为1:1搅拌混合均匀得到。得到实施例2的抗磨风电齿轮油。
实施例3
与实施例1基本相同，区别仅仅在于：所述的基础油由9-癸烯基-油酸酯、9-十八烯酸-13-二十二烯酯按质量比为1:1搅拌混合均匀得到。得到实施例3的抗磨风电齿轮油。
实施例4
与实施例1基本相同，区别仅仅在于：所述的基础油由9-癸烯基-油酸酯、1,2,4-苯三甲酸三(2-乙基己基)酯按质量比为1:1搅拌混合均匀得到。得到实施例4的抗磨风电齿轮油。
实施例5
与实施例1基本相同，区别仅仅在于：所述的抗磨剂仅为N,N-二(2-乙基己基)二硫代氨基甲酸钼。得到实施例5的抗磨风电齿轮油。
实施例6
与实施例1基本相同，区别仅仅在于：所述的抗磨剂仅为N,N-二(十三)烷基二硫代氨基甲酸钼。得到实施例6的抗磨风电齿轮油。
测试例1
按GB/T3142标准对实施例1-6的抗磨风电齿轮油进行四球试验机烧结负荷测试，指标为大于或等于2450N；按SH/T0189标准对实施例1-6的抗磨风电齿轮油进行磨斑直径(60min、196N)测试，指标为小于或等于0.35mm，具体结果见表1。
表1：测试结果表
比较实施例1与实施例2-4，实施例1(9-癸烯基-油酸酯、1,2,4-苯三甲酸三(2-乙基己基)酯、9-十八烯酸-13-二十二烯酯复配)烧结负荷、磨斑直径明显优于实施例2-4(9-癸烯基-油酸酯、1,2,4-苯三甲酸三(2-乙基己基)酯、9-十八烯酸-13-二十二烯酯中任意二者复配)。
比较实施例1与实施例5-6，实施例1(N,N-二(2-乙基己基)二硫代氨基甲酸钼和N,N-二(十三)烷基二硫代氨基甲酸钼复配)烧结负荷、磨斑直径明显优于实施例5-6(N,N-二(2-乙基己基)二硫代氨基甲酸钼和N,N-二(十三)烷基二硫代氨基甲酸钼中单一原料)。

Claims (3)

1.一种抗磨风电齿轮油，其特征在于，由下述重量份的原料组成：单烯基丁二酰亚胺0.4-0.6份、烷基苯磺酸钙0.1-0.3份、4,4'-二辛基二苯胺0.05-0.15份、2,4-二(十二烷基硫甲基)-6-甲基苯酚0.1-0.3份、抗磨剂0.2-0.9份、基础油90-100份；
所述的基础油由9-癸烯基-油酸酯、1,2,4-苯三甲酸三(2-乙基己基)酯、9-十八烯酸-13-二十二烯酯混合而成，所述9-癸烯基-油酸酯、1,2,4-苯三甲酸三(2-乙基己基)酯、9-十八烯酸-13-二十二烯酯的质量比为(1-3)：(1-3)：(1-3)。
2.如权利要求1所述的抗磨风电齿轮油，其特征在于：所述的抗磨剂由40-60wt％N,N-二(2-乙基己基)二硫代氨基甲酸钼和40-60wt％N,N-二(十三)烷基二硫代氨基甲酸钼组成。
3.如权利要求1或2所述的抗磨风电齿轮油的制备方法，其特征在于：将单烯基丁二酰亚胺、烷基苯磺酸钙、4,4'-二辛基二苯胺、2,4-二(十二烷基硫甲基)-6-甲基苯酚、抗磨剂、基础油加入调和釜中混合均匀，冷却即得成品。
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