Why We Need to Focus on Industrial Gearbox Assembly & Installation?
At the present time, industrial gearboxes with high power, high speed, and low noise. have become very important transmission equipment in various industries. such as sugar, wind turbines, crane hosting, construction. Industrial gearbox occupies an important position for the industrial production process. So what inspections should we do on gearbox assembly and installation Before production? its effect will impact on the overall production quality and efficiency. KONIC suggests doing a thorough inspection. if have any flaws, these flows should be promptly and reasonably corrected.
Industrial Gearbox Assembly & Installation Causing Misalignment
Improper of industrial gearbox assembly & installationn and their subassemblies can lead to misalignments. which can lead to failures such as Parallel. radial and angular misalignments can occur in the meshing gears.
- Misalignment in the radial direction
- Misalignment in axial or radial direction
- Perpendicular to the plane of action
- In the plane of action
The gearbox most likely fails due to a few internal misalignments that cause overhang-meshing gears. deflection of the pinion or gear shaft supported between the bearings. poor bearing adjustment, bearing wear, poor foundation, and assembly error, among other things. These factors contribute to the gearbox malfunction. Let’s find out how to check the gearbox assembly properly in this article.
Standard of Industrial Gearboxes Assembly
1. Contact Mode
When designing a pair of gears. a very important parameter is the maximum surface contact stress present. between the teeth of the two mating gears, as it affects surface fatigue .as well as gear meshing losses. So, it is very important to check the contact pattern between the two mating gears.
Backlash is the clearance or loss of motion in a mechanism. caused by the clearance between mating parts. Thus, it is an important parameter that needs to check. Very small backlash can lead to noise and wear. while more backlash can lead to transmission losses. Therefore, depending on the application, the required backlash must be determined and ensured.
3. Bearing Preload
With the elimination of backlash. preloaded bearings also increase the stiffness of the assembly. improving rotational accuracy and reducing noise due to vibration or resonance. Besides, preload eliminates rolling element slippage. and keeps it in the proper position in the bearing. Many types of rolling element bearings require some form of preload to operate properly. including angular contact ball bearings, tapered roller bearings, and cylindrical roller bearings.
4. Noise Temperature Vibration
In order to safeguard the gearbox from any failure. early fault diagnosis of critical load components is essential. Noise, vibration and temperature tests provide the condition of the assembled gearbox. KONIC has its own strict quality acceptance criteria for these parameters. and all gearboxes need tested for 100% noise, vibration and temperature.
5. Motor Current
It is very important to check the motor current and compare it with standard values. This gives a clear picture of the internal workings of the gearbox. If there is any kind of interference between the shafts, gears. the motor current will be higher than the regular standard values.
Any misalignment” leakage caused during the assembly of subcomponents. So, a leak test need performed on every gearbox to detect minor leaks.
Method of Industrial Gearbox Installation
7.Installation of Gearboxes
- The installation of gearboxes can be generally divided into two ways. one is to pour them into concrete using secondary grouting after clear positioning. and the other is to pour a piece of iron plate containing threaded holes. to fix the gearbox in concrete through the threaded holes.
- The second method, the gear contact surface need inspected after finishing the fastening of the foundation bolts. Because of the deflection of the gearbox itself and the corresponding support parts. the gearbox is bound to be deformed, and the contact effect of the gear surface is easily affected. As a result, the clearance at the base bolt position need checked and shims or removed to adjust the bolt contact. This process requires repeated loosening and tightening of the bolts. and since the gearbox itself is strong, the corresponding corrections are usually small. After confirming that the bolts are tight and the teeth are in good mesh. next commissioning work carried out.
8.Initial Inspection and Oiling
Before installing the gearbox, it is usually empty. so it is necessary to inspect the inside of the gearbox and add the appropriate amount of oil. Although the gearbox nameplate has indicated the grade and quantity of lubricant . at face, the initial lubricant should be some what higher than the standard. And the anti-rust oil that comes with the gearbox from the factory can be compatible with the lubricant. so in order to avoid impurities entering the box. no more tank cleaning work and attention to the use of the corresponding filtering device when adding lubricant.
Before starting the gearbox, the inspection must be comprehensive and meticulous. and the main inspection items are as follows:
- Confirm the correct lubricant and oil level in the tank;
- Inject lubricant;
- Confirm the alignment condition of the shaft coupling;
- Check the connection status of the main and auxiliary pipelines;
- Inspect the tightening status of the foot bolts and box bolts;
- Confirm the tooth surface by moving the gearbox.
Start the equipment under no-load condition. first of all, the gear lubricant supply and pressure should be clarified. if the pressure is incorrect, the equipment should be shut down and checked immediately. after that, check the oil temperature, if the oil temperature is too low or too high. focus on controlling the flow of cooling water. to ensure the oil temperature at 120-140 °F. after the oil temperature returns to normal state . After that, need to confirm whether the oil pressure state is normal.
Run the gearbox under light load to confirm the lubrication status. and then focus on monitoring the bearing position. if there is a rapid rise in oil temperature. which means that there may be problems with the bearings. it is also necessary to stop and check, and run the gearbox under full load. to confirm whether there is any abnormal noise, vibration. or abnormal changes in bearing temperature and oil temperature. which should be below 140 °F.
Conclsion for Industrial Gearbox Assembly & Installation
To avoid such quality problems. need to to ensure that the gears, shafts and bearings are properly assembled. As a gearbox manufacturer, it is very important to verify these things at an early stage. through strict quality checks to prevent any later consequences. Konic Gear is considered a trusted manufacturer of industrial gearboxes. due to the high quality of its products. All konic gearboxes are tested on various parameters. allowing our customers to trust us with KONIC gearboxes.
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