Gear Production

APR 2016

Gear Production

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6—GEAR Production Supplement F E A T U R E The fastest, least expensive approach might involve repairing broken gear teeth to the point that they are functional, or repacking bearings that should really be replaced, making clear this is a temporary patch meant to get the customer back in production, with the likelihood of a more severe—and expensive—failure looming on the horizon. CGS creates a detailed report listing all possible solutions, including the preferred method of repair necessary to return the gearbox to premium working condition. The optimal approach could involve replacing loose gears in damaged gear sets or the entire set, along with splines, shafts and bearings. Conventional wisdom might indicate that the best way to avoid gearbox failure is to develop a preventive maintenance plan, either internally or by contracting with a service provider. Regularly scheduled vibration analyses, along with checking shaft alignment and bearing conditions, could help stave off disaster. Should such a failure occur, however, CGS immediately begins working toward a solution, Mr. Terry says. He relates one example of a company that experienced a gearbox breakdown. This shop's frst concern, of course, was getting the gearbox repaired and back in action as soon as possible. Mr. Terry and his crew offered an alternative that involved getting the gearbox back to 50-percent functionality immediately, while at the same time designing and machining an entirely new gear set to be installed on completion. While this did not get the company back to full capacity immediately, it kept the shop working while it waited for the new gearing to arrive. In addition, the new gears CGS delivered were made of a stronger material for a higher power density, which allowed for a redesign to the gearbox so that it could carry a heavier load. Improved grinding techniques also provided the new gears with a better surface fnish. "Instead of being down for 12 weeks with a catastrophic failure, they only lost a couple of days," says Rodger Kahrs, CGS sales and service representative. "And then we went to their site, installed the new gears, ran them at top speed, fully loaded, and checked the support equipment on either side of the gearbox, Here, a slight groove that was worn into the shaft by the seal over time is visible. The repair solution involved adhering a band of a harder material around the shaft at the point of contact. The discoloration around the bearings was caused by saltwater seepage and can be easily removed. The bearings will be tested and, if needed, replaced with reconditioned bearings or new CARB toroidal roller bearings from SKF.

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