There can be a lot of causes for gearbox failures, such as design issues or gearboxe manufacturing effects. These are some of the most common ones. They have gate durability, but still, they are very prone to failures as they require demanding environments to operate in. The deficiencies of the proper lubrication system and high loading can be some of the other reasons. It is important to find out the root of the problem and implement necessary preventive measures to reduce downtime and maintenance costs.
Given below are the top five most common gearbox failures and how to identify them:
- Gear wear
It is a mechanical phenomenon where the surfaces come in contact. As a result, it removes or causes distortion of layers of the gear’s teeth surface material. This continuous friction is caused due to inadequate lubrication. The symptoms are reduced efficiency, increased noise, and overheating.
Preventative measures:
- Use high-quality lubrication from time to time. Choose the lubricant that suits its operational needs the most.
- Make sure you have proper gear alignment, load management, and speed adjustment.
- It is recommended to have a regular lubrication schedule, which will ensure cleanliness as well.
- In order to remove contaminants from the lubricants, use a filtration system.
- Overloading
Usually, the gearboxes are designed to endure a high amount of load tolerance. though in the first place, if the gear assembly is overloaded, then it can suffer from bending fatigue. This can result in tooth breaking or complete failure in case of extreme overloading. It can reduce the impact of wear resistance and have the potential of catastrophic sudden breakdown. due to this cracks or deformation in the gear teeth can be seen.
Preventative measures:
- According to the required load and torque, use the appropriate gearbox.
- Sensors can be used to detect excessive loads and continuous monitoring of the operational conditions will help prevent extreme overload cases.
- Misalignment
It is important to do a proper installation of the gearbox as each of them is designed for specific contact points and meshing curves. The overall alignment is supposed to fit on the torque, backlash, and shaft. Even the slightest misalignment can cause overlapping of the component travel path. This can result in assembly blockage or even permanent failure. It is also caused due to the thermal expansion of the foundation during operation.
Preventative measures:
- During installation, use proper alignment tools.
- Frequent periodic alignment checks are required.
- Design flexible couplings to accommodate thermal expansion.
- Inadequate lubrication
It is mainly caused because of using degraded lubricants or failing to top up oil levels. This can increase the friction in the gearbox operation. As a result, this friction helps generate heat and contact fatigue. It also causes abrasive wear, which can result in premature failure.
Preventative measures:
- It is recommended to check the oil level indicator windows. This is where the manufacturers specify the quantity of lubrication.
- Follow the recommendations provided by the manufacturer for change intervals and lubricant type.
- Bearing failures
It is caused due to the misalignment of the shafts. Some of the other causes are excessive loads or contamination of lubrication in housings. It causes reduced performance and overheating.
Preventative measures:
- During installation and operation, ensure proper alignment of shafts.
- Regular checks and replacement of damaged bearings.
Conclusion
By understanding and working on proper penetrative measures for these common gearbox failures, you can minimize downtime and maximize the lifespan of your gearbox. Consistent monitoring, proper maintenance, and installation are the key points for avoiding costly repairs. In order to prevent mistakes, errors, and failures, you can contact the gearbox manufacturer provider.