Gearbox is the driving heart of any machine or equipment, and hence the failure of the gearbox is not desirable, as it costs a lot to the organization due to the failure of gearbox. At the point, when a gearbox fails, it can dramatically affect the productivity, sometime it may shut down the entire line, or in some cases, the whole plant, resulting into huge production loss or monetary loss accounted due to downtime. In some applications, where human interference is connected, the gearbox failure can harm the life of humans also. To avoid this, using gearboxes of highly reliable gearbox manufacturer’s like “Top Gear” is of utmost importance. Top Gear Transmissions offer a wide range of Transmission solutions, designed to get things up and running again as quickly as possible and minimize downtime when the worst-case scenario occurs. Top gear’s huge Research of more than 20 years, has enabled the design of reliable gearboxes that put minimal service requirements and serves as failure avoidance.
With some added maintenance tips or safety precautions, the life of the gearbox can be further increased.
Maintenance Tips for increasing the life of the gearbox.
Before Installation & commissioning of gearboxes
1. Check the gearbox is operating within its manufacturer’s specification for both mechanical and thermal ratings. On many occasions, gearboxes are put into an application beyond their design specification and are being driven by an increased input power greater than the maximum recommended.
2. Proper Lubrication System:- Before Installing the gearboxes, it is necessary to fill the gearbox with proper Lubricant, with proper Lubricating quantity as specified by the Gearbox Manufacturer. For Vertical Mounted Gearboxes use of oil cups is very important.
3. Use the correct type of breathers and keep it clean for dirt and debris.
4. Before joining the gearbox and motor, clean the surfaces of mating parts. Properly remove the Rust preventive applied by the gearbox manufacturer.
5. Proper alignment has to be done between the gearbox and motor shaft (either hollow or solid).
6. Before fitting the coupling & shaft diameter, for input and output shaft, ensure the size of coupling as per the drawing. Ensure the bore tolerances of coupling and shaft tolerances, prevent the heavy force fit or press fit.
7. Before connecting the geared motor to the load, just as a safety measure observe the noise, vibration, leakage and temperature of the gearbox. To prevent problems arising due to the above parameters, Top Gear Tests, all the gearboxes for Leakage, Noise, Vibration & temperature, strictly, before dispatching the gearbox to the customer.
8. For foot free(Solid input) gearboxes ensure the use of stoppers for gearbox and motor to prevent the gearbox and motor from changing their original location.
9. For shaft-mounted gearbox ensure the locking of coupling, improper locking may lead to Vibrations
10. Use tyre coupling for foot free gearboxes, As tire couplings are flexible, they can compensate for significant angle errors and have a vibration and impact-damping effect.
After Installation & commissioning of gearboxes
1. Change the lubricant(oil) after specific hours of running, as recommended by the manufacturer. After changing the oil, observe the old oil, as the presence of small metallic particles may represent the wear of internal parts.
2. Regularly check for the leakages at the input and output shaft, joints, and plugs of the gearbox.
3. Observe the gearbox regularly for noise and vibration. Regular vibration analysis of the internal bearings and gears will confirm any significant changes in the internal condition of the gearbox.
4. Always monitor the signs for overheating of the gearbox, signs such as discolored or burnt exterior paint, or dark oil in the sight glass indicates that there is excess heat rise inside the gearbox. If possible, make use of an infrared temperature gun to Monitor the gearbox temperature on a regular basis and to find out, if there are any sudden changes in temperature.
6. Inspect the gearbox for backlash and also for any increase, in the end, play or lift at the input and output shafts. An increase in backlash may lead to gear teeth wear. And the increase in shaft endplay or lift would indicate wear within the rolling elements of the bearings or even wear in the bearing housings.
7. For No load and Load conditions observe the motor current, increase in the motor current than normal current may indicate the jamming of parts which may lead to failure of bearings and other parts.
8.Take the advice from the gearbox Manufacturer: Always consult with your gearbox manufacturer, for any advice or support required in inspecting; maintaining and repairing; or replacing the gearbox, As an expert, Top Gear can guide you and help you to ensure that your gearboxes are working to their maximum operational efficiency.