Industrial gearboxes are not only complex but require very expert hands when it comes to overhaul. There are general rules and procedures which should be applied to get the best results. The only thing to be ensured is that Gearbox repair and service chosen should be expert. If the service has industrial experience then it is a big plus. Dealing with industrial gearboxes is not a child’s play so make sure to check on all the eligibility before handing the equipment. A glimpse of overall process in this regard is as under:
- Stripping the equipment
The top three concepts that are taken care of in this phase are backlash measurement, end float and general condition noting. Stripping means detaching any external parts fitted to gearbox. Once the unit is delivered to the overhauling premises it is identified, photographed and inspected. A complete report detailing the parts condition is made.
- Dimensional measurement
Overhaul is a concept which comes into play when the unit undergoes wear and tear. Complete and accurate measurement is therefore necessary. It also ensures that the manufacturer’s dimensions are also calculated against the unit. There are various concepts that are checked in this regard. Some questions answered are as follows:
- Are the bores concrete and the parallelism condition?
- What is bore positioning? Measurement of it horizontally and vertically.
- Joint face flatness condition
- What is the bore shape?
- The process begins
Now the actual part begins. Some of the steps that are taken in this regard are as follows:
> Removal of gear and bearing
It is done with specialized equipment. Presses of various tonnages are required to perform the task. It is a delicate process which can be made safe and secure if right type of machinery is used.
In this phase various procedures are applied to check the gearbox condition. Specially made and high power equipment is used. Right process application means that the cracks are detected. It ensures that if the crack has a long history and had remained undetectable then this issue never happens.
Again in this part through high beam laser the gearbox is aligned. The damaged parts brought back to the original shape after proper testing. If required seal experts are also consulted so that equipment life is enhanced and oil leakage never happens. If required the damaged parts are also metal sprayed.
- Checking and reassembly
The shafts are reassembled and checked for performance. Backlash and end float are completely checked to avoid future performance issues. The gearbox is then reassembled and all the results are recorded in report.
- Load testing
Different data points are checked and the values are noted. Partial load testing is also done to note the temperature of bearings. Other testing mechanics are also practiced to ensure that the final delivery made is flawless. Vibration analysis data can also be recorded which is made a part of final report.
Once the gearbox is ready its outer surface is painted and the equipment is dispatched where it came from. It is duty of the dispatcher to take care of processes like protection and wrapping.