Any machinery suffers from wear and tear. It is just the nature of using machinery. In industrial settings, that wear and tear is commonplace. The stark reality is even with proper maintenance and high-quality equipment, machine components will eventually break down. Industrial gearbox repair is simply a way of life.
The industrial environment can be incredibly harsh for machinery. Components have to deal with the following:
- Dirt
- High Speeds
- High Temperatures
- Constant Use
The earlier problems are detected, the more likely it is to avoid a costly breakdown with downtime.
How Can I Detect Problems Early?
There are many ways to detect machinery issues before the component breaks down. Typically, if the problem is detected early, it will help to avoid costly repairs and extended periods of downtime.
Some of the most common ways to detect problems early are in the list below:
- Overheating
- Leaks
- Misalignment
- Noise
- Unexpected Loads
With industrial pump repair services, Allied Marine & Industrial uses all five of the following techniques to ensure machinery is operating at peak performance. We rely on them to help narrow down the areas in need of repair or service.
Overheating
Heat is a constant combatant to proper machinery function. While industrial-grade machine components are designed with this in mind, excessive heat is not conducive to their function. The most common causes of excessive heat within the component occur when bearings or gearing assemblies become slightly misaligned. When this happens, gears need to work harder than they should which can cause heat. Another cause is when the gearings or bearings are not lubricated well enough. Whether maintenance was overlooked or the improper lubrication material was used, when mechanisms are not lubricated well enough, they can cause excessive heat. Some signs of overheating are described below:
- Gearbox is Hot to the Touch
- Discolored Areas on the Housing
- Peeling Paint on the Mechanism
- Metal Plastic Components
- Discolored Lubrication Material
Leaks
Lubrication is the key for machinery to operate efficiently. When components are lubricated adequately, their service life is extended considerably. One way parts can become under lubricated is through leaks. When seals or gaskets become damaged, lubrication can be lost. This can not only lower the gearbox’s efficiency, but also damage bearings which can lead to premature catastrophic failure. Another issue when seals are broken or damaged is contaminants can enter the gearbox. This could include particulates or moisture, both of which can damage the machinery too.
Misalignment
Vibration and improper mounting can sometimes cause components to shift their internal positions. Machinery is designed to specifically operate at a particular position, so when this changes, it can cause problems. At Allied Marine & Industrial we see this a lot when we provide steam turbine repair services. When gearboxes are not properly oriented, the potential for contamination can occur. Even the smallest particulates can damage bearings. Also, if gears are out of alignment, teeth can show signs of premature wear.
Misalignment can also occur when the gearbox is mounted too close to a high heat source. This can cause thermal expansion to occur. Also, when first started, gear boxes can suffer from thermal expansion as well.
Noise
Most gearboxes are not silent when operating. However, they should not generate excessive noise either. This is usually a clue that something is not correctly aligned and that failure might occur. When the gears mesh smoothly, there is going to be some noise, however when they become misaligned, it can sound alarming. There should be no squeaking or rattling sounds when the machinery is engaged. Those can be indicative of a problem with the gearbox.
If the gearing mechanism is out of synch, a banging sound can be heard as the machinery changes through gearings. Those components need to be replaced immediately before damage can spread through other areas of the machine.
Unexpected Loads
Gearboxes are designed to meet specific requirements of the application for which they are used. This means when any unexpected or excessive force or torque occurs, the gears and bearings might fail. Careful monitoring of load feeds is needed to make sure the gearbox lasts as long as possible. If not, industrial gearbox repair might be needed.
Installation should also be carefully monitored as well. Failure to properly support all sides of the gearbox, can result in excessive torque and radial stress. It will affect gearbox efficiency and lifespan if not addressed properly.
What Are the Best Prevention Methods for my Gearbox?
Obviously, as with any machinery, the best prevention is proper use and care. Allied Marine & Industrial recommends the following tips:
- Regular Inspection
- Check Alignment
- Check for Excessive Heat
- Clean Gearbox
Most gearboxes come pre-lubricated ready for installation. In most light-duty applications they may never have to be lubricated. If they are placed in a heavy-duty use cycle, they will need to be lubricated and maintenance will need to be performed.
Final Thoughts
Even with the best maintenance schedule and proper care, mechanical components can fail. We have long been considered the best in marine diesel engine turbocharger service, as well as, gearbox assembly service and repair. With Allied Marine & Industrial, your get the best in repair services and supplies. Whether you are in need of a marine turbochargers supplier or simple industrial gearbox repair, we should be your next call. Reach out to us today to find out more information.