Fatigue reliabilitybased inspection and maintenance planning of gearbox components in wind turbine drivetrains article pdf available in energy procedia 53. Low noise levels, speed to market, costeffectiveness and durability play a significant role in the success of a gearbox design. A gearboxs lubrication and oil should be your first stop. When your gearbox is in need of emergency repair our engineering team are rapidly accessible and work with you to minimise costs and get your gearbox up and running in the shortest possible time. Predictive maintenance is the complement of preventive maintenance. It is assumed that the pinion shaft has been fitted to the maincase, and that the crownwheel bearing shims have been determined and fitted.
Gearbox assembly manual dear friend of fast boats, you have bought a gearbox kit. On the other hand, inspections cause undesirable downtime and. The shaft ends and other machined surfaces outside the gearboxes are. Circular pitch p is the distance along the pitch circle or pitch line between corresponding profiles of adjacent teeth. The information is illustrated through the spur gear tooth because it is the simplest and hence most comprehensible. Transmission system chief function of the device is to receive power at one torque and angular velocity and to deliver it at another torque and the corresponding angular velocity. Estimate gearbox housing and shaft temperatures using water spray. Gearbox topic of interest maintenance power climber. Rossi gearbox repair, service and support gbs gearbox services international is the fastest, full service, worldwide specialist in gearbox repair of rossi gearboxes. Operating and maintenance instructions planetary gearboxes series esp datum. Hence it becomes necessary to reduce the speed of the motor. Installation and maintenance instructions nord gear. Traditionally, preventive maintenance for gearboxes has consisted of regularly checking their oil levels and replenishing as needed.
For that reason, many predictive maintenance pdm programs also use thermography to detect when a gearbox is running. Kumera drives oy fi11100 riihimaki, finland gearboxes. This book is intended to be a quick reference information, see operator manual for model if more information is needed. Or each gear reducer must be retained in place relative to the drive shaft. Available both nationwide and internationally, gearbox training can be carried out either at our own works or onsite at the customers premises.
Therefore one assembly known as gearbox will be used in between motor and output machine. Keeping in line with its strategy of gearing the future elecon presents the eon series answer to industry needs. Elecon worm reduction gear units are supplied in completely condition without oil. National renewable energy laboratory national wind technology center. Through the utilization of various nondestructive testing and measuring techniques, predictive maintenance determines equipment status before a breakdown occurs. Kumera powerplaza is the online market place for kumera mechanical transmission products and associated spare parts. Gearboxes planetary and spur designs from anaheim automation. Forgoing routine maintenance on any gearbox could spell disaster for the entire. Lubrication helps reduce friction on moving parts so gear changes occur smoothly. When gearboxes and ancillary equipment fails, the greatest concern is getting it running again, but spare parts. It is structured in major sections covering key gearbox assembly groups, coupling and mounting, as well as general maintenance aids. Industrial gearbox service manual is designed as a practical guide to provide information covering key gearbox assembly groups. Regular gearbox inspection is recommended as part of a proactive maintenance programme.
Proper maintenance should focus on keeping the gearbox in normal running condition. With this kit you are able to assemble a clutch and gearbox unit, this will be called cgu further on. Though parts like the gearbox rarely present any major problems to the mechanic, it does not mean that it needs no inspection. The worm gearbox configuration allows the worm to turn the gear with ease. Focal points are to give basic maintenance information with which they can identify the cause of the fault. Mar 14, 17 industrial mechanical parts comments off on how to maintain an industrial gearbox gearboxes are an essential part of so many pieces of machinery.
The gearbox should be stored in a dry area to reduce chances of nonworking components. This schedule is essentially a combination of the individual preventative maintenance cards. Gear nomenclature and tooth proportions information about gear nomenclature and tooth proportions is given in this chapter. Industrial gearbox services overview normal receiving hours are monday through friday from 6. Sep 18, 2014 industrial gearbox maintenance and repairs 1. On the other hand, inspections cause undesirable downtime and breaks in shift work or production lines. Preventive industrial gearbox maintenance will help you avoid a breakdown in production and keep your business up and running. But the prime mover say motor runs at fixed rpm, say 1440,2800 etc. Our primary specialties are construction and maintenance in large industrial plants and facilities. Oil quality, color and consistency should be checked at. This can save you money and reduce the probability of downtime. In many industries, the gearbox, which is the equipment that transmits mechanical power, is an essential piece of equipment. Taking the latest innovations of our gearbox service experts, our goal is to get, often mission critical, gearboxes back into production at the shortest timespan possible. Operating and maintenance instructions planetary gearboxes.
Industrial gearbox service centers industrial gearboxes service finland. An annual maintenance schedule for the plant that is broken down weekbyweek to show required preventative maintenance tasks to be performed. The gearbox service manual is designed as a practical guide to provide essential information in a logical and systematic manner. Worm gears worm gears are able to withstand high shock loads, low in noise level and maintenance free but are less efficient than other gear types. Installation, lubrication and maintenance of industrial. Structure and features 4 types 5 standard reduction ratio ip 6 recommended lubrication oils 6 selection of. To provide for disconnecting the engine from the driving wheels.
The gearboxes maintenance free are lubricated with synthetic oil the others with. Industrial gearbox maintenance and repairs to prolong the operating life of industrial gearboxes, regular inspections and maintenance are essential. Drives using gears should be called gear drives because a gear drive may not have a box enclosure. By routinely analyzing particulate content and concentration in the oil, engineers are able to monitor the condition of an operating gearbox and circumvent damage that may be beyond. Industrial gearboxes have a variety of lifespans, but you can ensure that yours will last as long as it should by performing regular inspections and maintenance. Maintenance professionals have several important tools at their disposal for diagnosing gearbox lubrication problems, the most prevalent of which is oil analysis. Serving an entire spectrum of mechanical drive applications from food, energy, mining and metal. If you want to keep your gearbox functioning at its optimal performance, then regular maintenance should be done. All the gearboxes and electrical motors are painted grey ral 9022 with. The eon series has been developed keeping in mind the industry requirements. Industrial gearbox maintenance 3 this 3 day course is designed to provide engineers and superintendents, with a practical working knowledge of gears and gearbox maintenance. Jan 01, 2009 the lifeblood of any gearbox is the oil in it that lubricates the gears. The course is intended to provide the understanding to adopt best practices in maintaining geared systems, identify potential problems, and ensure proper repair. For bonfigliolis a series of helicalbevel gearboxes, the oil type and running temperature both play a significant part in determining oil change intervals.
If the gearbox cannot dissipate the heat by natural cooling then a cooling fan is installed on the input shaft or a heat exchanger is used as an oil cooler. Gearboxes with inline step gearbox and hollow input shaft for fitting flange mounted im b14 im3681 electric motor or for complementing other flanged iec. Mar 03, 2014 gear box industrial applications 3 introduction. See approved lubricants leaflet for futher details. Worm gears can be used in right angle configuration. Let us know if any special arrangements are required or if you need assistance with shipping the unit to our facility. Bearing solutions for all industrial gearbox types not all gearbox types can be treated the same. We know that youre looking for maximum process availability and dont want to run the risk of unplanned downtime.
Worm gears worm gears are able to withstand high shock loads, low in noise level and maintenancefree but are less efficient than other gear types. We can create custom engineered transmission solutions of any size and con. Our specialist gearbox maintenance training provides the end user with the practical skills and principles required to carry out mechanical maintenance and inspections of their specific gear unit. Regularly check for unusual noises coming from your industrial gearbox. Regular maintenance of your industrial gearbox is the best way to determine what repairs it may need. Oil quality, color and consistency should be checked at every service. Repairing an existing gearbox to a good as new standard can cost 40% less than a replacement unit and can even reduce turnaround time from an average.
Detailed damage analysis in dialog with the operator. Upon arrival at our facility, the gearbox and any additional components will be photographed and inventoried. Either way nord recommends the use of shaft shoulders, locking collars or fixing. Installation, lubrication and maintenance of industrial gear. Fundamentals, selection, installation and maintenance of. Despite how ubiquitous gearboxes may be, its easy to overlook their repair needs.
This cgu is based on the in germany well known mathogearbox, so it could be defined as well engineered. Use parts breakdown for gearbox as reference to part assembly order. When designing a gearbox or reducer, many factors need to be considered to meet application and commercial requirements. Both proactive maintenance when something is wrong and preventative maintenance are important in keeping your gearbox. Gear box service arnold engineering arnold engineering. Gearbox maintenance tips diagnosing gearbox problems with gearmax when you approach brad foote gearing with a malfunctioning gearbox, the first step is identifying the problem. May 12, 2016 conduct vibration tests on your industrial gearbox.
This maintenance test will show any changes in movement or misalignment of the gears. Movement can happen, for example, if there are cracks in the element. All torque transmissions industrial gearmotor maintenance. The gearbox design and testing will dictate which method of cooling is used. Find model type in index or find gearbox assembly number in list. Unexpected problems can be inconvenient and repairs can be expensive. In gearboxes, maintenance scheduling revolves around ensuring lubrication quality and levels are maintained. Industrial gearbox repair, rebuild and reconditioning services. Gear box industrial applications linkedin slideshare.
Thanks to the use of gearboxes, a small rotation force torque can be used to produce a much greater rotation force, and a slow rate of revolution can be speeded up. With predictive devices currently available, it is incumbent upon. Routine gearbox maintenance routine gearbox maintenance should include, but not be limited to the following simple procedures. Using the auditory or tactile cues discussed previously, an engineer may be able to solve the problem with just a phone call. It is also assumed that the correct barrel spacer has been ascertained and fitted to give correct fork setting. Also, gearboxes often are in inaccessible or unsafe locations that make oillevel checking and oil sampling difficult. Gearboxes listed in this manual show the steps to assemble the gearbox as. However, with regular in situ gearbox inspections by trained experts, we can identify any issues before a problem occurs. A gear is a cylindrical part having cut teeth on its periphery, which mesh with another toother part gear in order to transmit torque. The shaft ends are coated with anticorrossive agents which are to be removed only by suitable solvents. These gearbox maintenance measures are time consuming and expensive and require shutting down the equipment.
This wear is reduced to a minimum by the lubricant used, which increases the lifetime of all parts of the gearbox. Pdf fatigue reliabilitybased inspection and maintenance. Maintenance a complete change of oil is recommended after the first 2,500 hours of operation or 6. Do a vibration test if the work environment is too noisy.
If the oil level in a gearbox gets too low or loses its ability to lubricate, the gearbox will overheat and eventually fail. The lifeblood of any gearbox is the oil in it that lubricates the gears. Survey the gearbox housing temperature by touching it with the palm of your hand and using temperaturesensitive paint, crayons and labels, or a digital thermometer probe. It tells the operators what tasks must be performed each week of the month. Here are a few easytodo maintenance tips, which will help keep your industrial gearbox in good working condition. The gearbox weight is recorded on the packaging and on a label attached to. Thats why we offer a full asset management service, which looks after your gearbox through a planned, regular maintenance programme. Check the gearbox housing temperature using an infrared thermometer or infrared imaging camera. When you purchase an industrial gearbox, you are making an investment. Gearbox typical failure modes, detection and mitigation. Gearbox typical failure modes, detection and mitigation methods. Oil changes should occur at intervals no longer than one year.
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