Errors, Problems, and Solutions for Industrial Gearboxes
Our knowledgeable technical staff explains in this blog the industrial gearbox issues that they see and fix most frequently in the new ball bearing workshops.
Read More: Troubleshooting of Industrial Gear Boxes
1. Bearing Issues
The bearings are the main source of issues with industrial gearboxes. Many problems, such as dirt, contamination, leaks, misalignment, vibration, and shock, can occur with this gearbox component.
2. Inaccuracy
A number of difficulties, such as heat expansion, shoddy installation, incorrect mounting, and deflection concerns, can lead to industrial gearbox misalignment. The gear and bearing pitting of the gearbox are the source of the issue.
Occasionally, the industrial gearbox that our clients are utilizing is not the right one for the job. With only your information and our own inspection, we can assist in identifying this. Complete failure is the ultimate result of misalignment.
3. Poor lubricant
They need the right lubrication to work, much like many other mechanical parts. Because gearboxes work under pressure and at high speeds, lubrication is necessary to keep problems and stoppages at bay. The gears can injure themselves if they start to malfunction.
Make sure there are no leaks when lubricating your components. However, if you’re not, the industrial gearbox may produce noise, grinding, or dryness. Additionally, you must lubricate the item with the appropriate lubricant.
4. High Temperature
When in use, your industrial gearbox can be overheating and flaring up. You may then look into what went wrong in more detail by keeping an eye on things on a regular basis. That’s where to check since that’s where the temperature spike will probably happen—between the housing and shaft.
Poor airflow, overtightened bearings, or inadequate lubrication might be the cause of your industrial gearbox’s high temperatures. Simply contact us and we will do our best to assist you if you need it.
5. Vibrations
Your industrial gearbox would probably tremble when it’s operating, much like a motor would. However, there can be a problem if it starts to show up noticeably. Vibrations rise with increasing torque and speed. Failure probability rises with increased vibrations.
Shaft failure can be caused by vibrations, and symptoms include noise, poor performance, and even visible fissures. The industrial gearbox could not be receiving the necessary assistance or it can be overworked.
Noise, performance concerns, and temperature difficulties are allies. These are the warning indicators that will appear before a complete breakdown and let you know something is off.
As you maintain your industrial gearbox, be aware of these warning signs and schedule an early repair. Both money and time will be greatly saved. Should you fail to do so, you could have to get a new industrial gearbox. Request a free collection and quotation by contacting us.
How To Effectively Identify A Faulty Industrial Gearbox
Strong machinery that can withstand high pressures, temperatures, and abrasive conditions is the industrial gearbox. Regrettably, because they last so long, many people take them for granted. Ignoring small worries might lead to big problems. As with other equipment, your industrial gearbox will notify you if there are any issues that need to be fixed.
The scope of the inspection may be limited despite the fact that in many circumstances a comprehensive on-site gearbox check is requested due to issues including cost, time, accessibility, and qualified personnel.
Early issue detection can save time and money in the long run, even if management may find the cost and downtime prohibitive. Even though a thorough inspection can seem excessively burdensome, a straightforward visual inspection of the gear contact patterns via an inspection port could prevent catastrophic failures in the future. If staff members lack experience with internal inspections, an expert might be hired to conduct the inspection and provide training.
The warning signs of a faulty gearbox will be covered in this post. You should be worried if your gearbox exhibits any of these symptoms.
Sound
Sounds can often be heard from a gearbox that isn’t working properly. Parts rattling or grinding against one another might be the source of these noises. With time, gears, shafts, and bearings deteriorate and produce more loud sounds.
If you notice that the noise level in your gearbox is higher than usual, you should inspect it. The type of noise can be used by skilled engineers to identify the problem’s origin.
For example, high-pitched screeches can be produced by broken gear teeth, low-pitched rumbling noises are usually produced by faulty bearings, and banging and clunking noises are sometimes caused by loose motor mounts.
Getting too hot
Is there a significant difference in the housing and shaft temperatures of your industrial gearbox? This may suggest that something isn’t working correctly.
Overheated gearbox symptoms include smoke coming from shafts and seals, burned-in surface discolouration, and plastic part melting.
There might be a problem with the lubrication. By reducing friction and cooling, it should extend the part’s life. If not, there can be an excessive amount of friction and heat coming from overtightened bearings.
Cracks
You should get your gearbox examined straight immediately if you see any cracks or other visible damage. Increases in the torque and speed of the gearbox may generate vibrations, which might be the source of this. Vibrating parts that are loose, broken, or not placed correctly might cause other parts to get damaged or move out of position.
Out of alignment
With time, parts may become misaligned and move out of position. This can be caused by thermal expansion, vibration, and wear and tear. That being said, it’s possible that the issue originated during installation.
There will be problems down the road if the installed gearbox is not up to the task. In a similar vein, improper installation increases the likelihood of a far earlier failure.
Spills of Oil
Check for shaft seals in your gearbox. If you see oil beginning to leak, you have a problem. Water, dirt, and dust can enter when the seals fail and oil pours out.
Even if you are unable to detect a leak, check your oil levels. You might need to search elsewhere for a leak if they are very low. Gasket failure is another common source of leaks.
