Common Problems Requiring Industrial Gearbox Repair

Common Problems Requiring Industrial Gearbox Repair

Industrial gearbox repairs often fall into several categories that result from the failure of one of the components. These are some of the most common failure points for industrial gearboxes:

1. Failure of Sealing Components

Several issues may contribute to the failure of seals. Dirt and debris that get into the lubricant can damage the seals by creating minute tears. These tears will lead to lubrication loss, causing additional damage to the gears and seals. When lubrication leaks from a gearbox, the internal operating temperature rises from friction-generated heat. This excessive heat can break down the seal materials, leading to extra wear.

Having the incorrect size of seals installed on the gearbox or incorrectly installed seals may create leaks which contribute to the failure of the seals and gearbox damage. Regular gearbox maintenance with frequent seal replacements can mitigate damage from dirt and debris. Only permitting qualified, experienced technicians to replace seals can prevent the improper installation of these components. Operating gearboxes in clean environments can also reduce the amount of contamination to the seals.

2. Failure of Gears

The gears themselves also need regular inspections and replacements because a gear failure can stop the gearbox’s operation or severely reduce its efficiency. As with seals, gears typically have a failure from debris or dirt entering the system. This material can get between moving parts, which causes wear on the gears and eventual failure.

In some instances, the debris results from another mechanical problem inside the gearbox, which sends shavings of metal components throughout the unit. Replacing seals regularly and scheduling frequent inspections and gearbox service can prevent this type of gear damage. Overheating can wear down gears or damage lubricant in the gearbox, causing failure of the unit. Overloading the gearbox can also lead to overheating. Avoid excessive loads to protect the operation of the gearbox.

Poor alignment of the gears typically does not happen during normal use, but following service or repairs by an unqualified person. Never allow anyone without knowledge of industrial gearbox repair to service the unit to avoid issues caused by poor maintenance.

3. Failure of Bearings

Approximately 50% of gearbox problems stem from bearing failures. Reasons for bearing failures include improper lubrication and overloading the bearings. Excessive force on the bearings can occur from too high of a load exerted on the shaft. The bearings take much of this extra load, contributing to damage from overuse.

During repairs, technicians will inspect the bearing races ball paths for signs of this type of excessive force. If found, they will replace the bearings. To avoid this type of problem, operators should only use gearboxes within load limits.

Lubrication problems can also damage the bearings. Too little lubrication can cause a buildup of friction heat from the metal bearings running along the metal track. Over time, this metal-on-metal contact will wear out the bearing race, leading to complete failure. Having too much lubrication also causes issues with the bearings through thermal damage caused by fluid friction.

During maintenance, checking the bearings for the proper amount of lubrication can prevent damage to the bearings. Only allow qualified technicians to repair and maintain bearings to ensure the longevity of these parts by avoiding friction damage.