Different types of Gearboxes fail under different circumstances and different Loading conditions. Gearbox is the equipment that works in different pressures, temperatures and other environments, proper care should be taken of Gearbox to avoid disastrous consequences. It is always not easy to find out the exact cause of the Gearbox damage because it can happen through various ways like improper lubrication, less Gear strength, loading etc. when the Gearbox is malfunctioned or damaged it is necessary to take precautionary actions and prevent future failures.
In this article, we will get the exact idea on how the Gearbox is Damaged and what are the necessary steps that should be taken to reduce further failures.
HOW DOES A GEARBOX GET DAMAGED?
1) LUBRICATION :-
Each Gearbox has recommended oil level as well as a method to lubricate bearings and Gearsets like splash lubrication or pressure lubrication etc. The Volume of lubricant and the properties of lubricant should be considered before choosing whereas inadequate lubrication in Gearbox can generate friction which created Gearbox Failure.
Bearing is sensitive to shock, misalignment and vibration, in most of the Gearbox Bearing is the major factor for the failure in gearbox. Gears are designed for a specific Meshing, Backlash and Torque therefore slight misalignment will result in Gear wear where the teeth do not mesh the way it is designed.
3) INSTALLATION :-
Installation errors can result in instant malfunctioning of the gearbox assembly. Installation and handling errors should be controlled to reduce damage to gearbox in the long run.
Most of the time installation and handling errors results in surface contamination with dust and other particles which generates heat and damage the Gearbox.
4) OVERLOAD :-
Gearboxes and Gears are have a certain amount of load tolerance, if the load is higher than load tolerance it can lead to cracks, tooth breaking, bending fatigue. This is common in conveyor industry to work more on production line to achieve faster results, when the limits of the conveyor are pushed more than a certain load the Gearbox damages.
5) VIBRATION :-
When the speed and the torque increases this also leads to an increase in the vibration and noise. There are various points that should be considered for design stage of Gear systems to avoid this issue such as using high precision gears, ensure correct tooth contact, increase overlap ratio, using high rigidity gears, using vibration damping material etc.
The Two Important factors considered to the damage of Gearbox is Fatigue in Gear wear and tooth surface and Gear Breakage.
GEAR WEAR AND TOOTH SURFACE FATIGUE. :-
This appears in many ways and does not become an obstacle in operations. Tooth surface fatigue occurs when load is applied on tooth surface repeatedly. It may lead to increase in noise and vibration, increase temperature and Backlash. By finding out the causes of itthese damages can be avoided.
GEAR BREAKAGE :-
There are Generally two types of Gear breakage i.e. Overload Breakage and Fatigue Breakage. Overload breakage occurs when heavy loads are applied to the tooth and Fatigue load occurs when load is repeatedly added. This Breakage can be eradicated by increasing the bending strength and increasing the Gear strength.
HOW CAN YOU PROTECT YOUR GEARBOX FROM DAMAGE?
1) TEMPARATURE EFFECT :-
We need to properly check the temperature of the Gearbox in a regular interval to prevent from overheating. Signs of overheating include burned paint on housings or discoloration, smoke, foam in the sight glass, and melted plastic components. Another sign is water that evaporates fast, boils, or crackles when sprayed on your gearbox.
2) LUBRICATION :-
Check proper maintenance audits for your Gearbox, use the appropriate type and amount of Lubrication depending upon the season and temperature. Keeping oil clean is also very important like checking its environmental contaminants like moisture, dust and physical attributes like acidity, viscosity etc.
3) VIBRATION ANALYSIS :-
To prevent any unplanned loss of production regular vibration analysis should be done for Gears and Bearings. Noise is the basic factor to understand the Gearbox damage but many times the Gearbox is stored in a noisy place that’s why vibration analysis is necessary.
4) WEAR AND TEAR SIGNS :-
Gear breaks when they are used for more harder task than they were manufactured for. The breathers should also be regularly checked as this is the place from where dust and moisture enters into Gearbox. The big problem is Gears does not break immediately it’s a slow process and is understood when the Gear cracks completely.
5) Consult an Expert at our SMD Gearbox.
We have experienced technocrats who are in close contact with the customers and suggest an appropriate solution and customized Gearbox to its customers. We can advise and help you to run your Gearbox in full efficiency and increase the productivity of your Machine. So contact us at SMD Gearbox today!