Gears are mechanical machines to transmit motion or change the speed. They should be inspected regularly for wear and tear of the parts for their proper working. It is important to maintain the machine parts so as to avoid accidents or damage to machine parts.
Failure of Gearbox causes a complete breakdown of the machinery, which involve both subsequent repair and lost output. Noticing the signs of failing parts early reduces downtime, saving costs and improves machinery health. Some of the most common forms of gearbox failure are inadequate lubrication, contamination, installation errors, overload and handling errors. The major cause is inadequate lubrication caused by under filling, incorrect specification, mixing or incompatibility, incorrect lubrication, deteriorated grease or oil, water contamination and particulate contamination. Inadequate lubrication leads to accelerated wear rates and component failure. Oil acts as a coolant and overheating of oil and parts leads to metal-to-metal contact which leads to the breakdown of the Gearbox. Water contamination destroys the lubricating properties of the oil which causes foaming of the oil. Water in oil can result from either condensation or damaged seals allowing water to enter. Particulate contamination can be from putting dirty oil in, leaving a filling plug open or from wear or failure particles within the gearbox. Particles also accelerate wear and component breakdown.
Overloaded of components caused by exceeding design limits for load, speed or temperature can also damage the gearbox. As the overload increases it shortens the components life. Once the gearbox is overloaded it leads to noise and vibration, increased temperatures, metallic chip debris and reduced equipment performance. Improper handling and installation can also damage the gearbox. This applies in particular to bearings where the cages are particularly prone to careless handling, installation or removal, but can equally apply to misaligned shafts which can then lead to bearing or gear failure
Always check if the gearbox is operating according to the specification of the manufacturer. Often gearboxes operate in a dirty and dusty environment. It is important to see that it is working in a clean environment as dirty and dusty environment could cause an increased operating temperature or even possible contamination of the gearbox. It is necessary that industrial gearboxes be regularly dusted and brushed clean.
Check the seals for any oil leaks at the input and output shaft as leaks indicate that seals have failed which makes dust, debris and water to enter this creates lubrication loss and causes contamination of the gearbox or inadequate lubrication. Check the breathers to see that water, dust and debris do not enter into the gearbox through the breather. They should be kept clean at all times to allow the gearbox to breathe with ease. Lubrication should be as per the manufacturer’s specification for type, grade and quantity.
Overheating of the gear box causes discoloured or burnt exterior paint, or dark oil in the sight glass. Always monitor the gearbox temperature on a regular basis and look out for any sudden changes in temperature using an infrared temperature gun. Look for signs of wear such as pitting and spalling Inspect the contacts between gear teeth for misalignment as this could be indicative of wear in bearings or the bearing housings. Nearly all gearboxes operate in a noisy environment, which means that not all variations or increases in gearbox noise can be recorded. Regular vibration analysis of the internal bearings and gears will confirm any significant changes in the internal condition of the gearbox and help prevent any unplanned loss of production.
Gears are characteristically reliable mechanisms. Unfortunately, however, like all mechanical things, transmissions eventually wear out and ultimately fail to act as efficiently as they were designed to.
If you are in need of industrial gearbox repair, we at American Gears LLC offer complete reconditioning on industrial gearboxes of all OEM brands. We are fully equipped to provide all gearbox services performing a complete evaluation of your gear box. Our in-house design, engineering, and manufacturing services ensure quality workmanship. We provide warranty and guarantee on workmanship and materials. We work on leading brands like Marley, Amarillo, Philadelphia, Lufkin, Rexnord, Falk, SPX, Falk and Siemens and more.
For all your requirements on Gears and Reducers kindly get in touch with us at 713.360.6995 and take some time to visit our website at http://americangearllc.com/.