Industrial Gearbox Maintenance

Transcription

1 Industrial Gearbox Maintenance Learn how preventative Gearbox Maintenance can save you in the long run.

2 Industrial Gearbox Maintenance In general the gearbox or speed and torque change devise is as important as any other vital part of machinery as its malfunction would affect the entire process in which it is employed. In many cases the cost of the drive train is small in comparisons to the rest of the driven machinery and tends to be neglected, as it does not normally scream for regular attention. Unfortunately the saying of a stitch in time saves nine: is rarely more applicable than in industrial gearboxes. In a 3 stage speed reducer with surface hardened & ground gears as a very rough estimate bearings make up approx 5 % to 10 % of the costs, the gears approx 45 % to 55 %, housing, covers, low speed shaft, and other non-wearing hardware 35 % to 40 %. Apart from accidents or abuse the main wearing parts are normally the bearings and the uncorrected wear of a bearing which may be only 1 % of the costs can be the cause of progressive damage to the rest of the rotating parts. Preventative maintenance done on a scientific basis will help you to avoid unexpected & unscheduled production losses and breakdowns. In general properly planned preventative gearbox maintenance will cost between 10 % and 50 % of breakdown maintenance. Training of staff at all levels will even reduce your maintenance cost if you work on a breakdown repair basis; hence the importance of a training course such as this. Industrial Gearbox Maintenance 2

3 Learn the fundamentals and practical skills This 3 day course is designed to provide engineers and superintendents, with a practical working knowledge of Gears and Gearbox Maintenance. The course is intended to provide the understanding to adopt best practices in maintaining geared systems, identify potential problems, and ensure proper repair procedures and quality measures. Fundamentals Of Gears: Law of gearing, Gear design, Gear-tooth systems, Types of gears. Methods of calculation and integrated design, gear machining, accuracies, corrections, and noise reduction. Methods of increasing load rating. Materials and surface engineering: Metallurgy, Choice of Steels, Heat Treatment and Surface Engineering Gearbox elements: Design and practical considerations of Bearings, Shafts, Seals, and Couplings. Factors that influence life of these gearbox elements. Gearbox applications: Service factors, Load conditions, Typical specification, Drive installations Maintenance Principles: Preventative maintenance, Lubrication, Inspections, Filters Health Determination: Vibration analysis, Lubrication condition monitoring, Thermography Overhaul Principles: Replacement Components, Assembly, Horizontal shafts split through the bores, Assembly - vertical shafts horizontal split, Bearing and Oil seal fitting, clearance setting, Testing Running-in, Monitoring Failure Analysis: History, Evidence, Specifications & Design Criteria, Operating environment including actual operating requirements, Material and lubrication considerations, Relevance of various factors, Significance of root cause analysis Dates: 08 Apr - 10 Apr Jun - 19 Jun Sept - 23 Sept 2015 Cost: R (Excludes VAT) Industrial Gearbox Maintenance 3

4 Course Outline The course covers the understanding of industrial gears of various types with a review of the underlying principle as well as a brief look at materials machine health determination and the important actions to get the best life and longterm low running costs. Fundamentals Involute tooth profile Conjugate action Involute Contact ratio Helical gearing Bevel and spiral bevel Worm gears and variations Other Shafts at 90 non-intersecting Methods of calculation The aim for an integrated design Gear machining accuracies Methods of increasing load rating Corrections Noise reduction Materials and Surface Engineering Metallurgy Iron and Carbon Classification of steels Heat Treatment of Steel Surface Engineering Bearings Bearing Types Bearing Loading Load Criteria Bearing Life Formula Life adjustment factor Bearing life Some aspects of practical experience Shafts Internal shaft Gear fits Overhung gears High speed shaft extensions Low speed shaft extensions Keyed shaft connections Shaft mounted gear units Seals Seal Types Material Selection Operating conditions for lip seals Gearbox Applications Horizontal shafts Vertical shafts Service Factors Load conditions Load conditions on gear teeth Typical Specification Drive installations Rigid Couplings External Attachments Lubrication Maintenance Principles Maintenance planning Lubricant rationalization Planning a methodical lubrication system Health Determination Vibration analysis Lubrication condition monitoring Thermography Couplings Torsional Flexibility Angular/ Radial flexibility Alignment Over hung loads Coupling alignment Flexible couplings Pin and bush couplings Steel grid couplings Tyre type couplings Rubber block type couplings Gear couplings Membrane couplings Overhaul Principles Replacement Components Assembly - Horizontal shafts split through the bores Assembly - vertical shafts horizontal split Oil seal fitting Bearing clearance setting Testing Running Monitoring Failure Analysis Introduction Basic understanding of gear technology Basic understanding of environment Systematic investigation Gear failure Causes of Gear failure Significance of root cause analysis Industrial Gearbox Maintenance 4

5 Training Opportunities Yellotec offers a full complement of training courses in Condition Monitoring disciplines as well product and Reliability Engineering specific courses. Courses offered are either presented under license from International Certification Bodies or are in accordance with ISO requirements. Private Courses All our public training courses can also be conducted as an in-house private courses. If you have 10 or more people attending, consider the benefits of an in-house session conducted in the privacy and conveniences of your facilities or a meeting site of your choice. Please contact us so that we can understand your requirements, explore the benefits and make it happen. All Courses Offered By Yellotec Infrared Thermography (IRT) IRT Basics, Level 1, Level 2 and Level 3 Vibration Analysis ISO Level 1, 2 and 3 Field Lubricant Analysis Noria Level 1, 2 and 3 Machinery Lubrication Noria Level 1 and 2 Oil Analysis Series Level 1, 2 and 3 Ultrasound Level 1 and 2 Gearbox Maintenance Failure Analysis Condition Monitoring for Engineers Plant Management Dr. Mike Vorster Industrial Gearbox Maintenance 5

6 Registration Form Please register each delegate by completing the details below and return by fax to , or to The company details are intended for accounting purposes and must reflect the details required for the completion and delivery of tax invoice. Invoice Details Company VAT Number Postal Address Postal Code Person Responsible for Payment Contact Number Fax Number Payment Method Purchase Order Number Cheque Number Electronic Transfer Ref Number Delegate Details Delegate Name Contact Number Fax Number Address Do you have Halaal requirements? Yes No Course Details Course Dates Cost (Excl. VAT) Terms and Conditions 1. All course fees are payable upon confirmation of booking and an invoice will be sent as per the details indicated above. Bookings cannot be secured until payment of invoice or valid purchase order is received. 2. Only cancellations received in writing 10 days before the start of the course will be refunded in full. 3. There will be no charge if a substitute person wishes to replace the original delegate. 4. Yellotec reserves the right to cancel any course at any time without liability. In these circumstances, delegates will be offered an alternative date, or a full refund. 5. All Halaal requirements will be charged at an extra cost. 6. Delegate no shows, partial attendance or late cancellations will be liable for full cost. Industrial Gearbox Maintenance 6

7 Co. Name: Yellow Technical Services (Pty) Ltd. Trading as: Yellotec [t] +27 (0) [f] +27 (0) PO Box Kyalami Taljaard Street Jet Park Boksburg Reg. No: 2013/231556/07 VAT No.: Yellotec is a products, service and training provider in the following specialist fields: 1. Complete solutions for the implementation and management of Condition Based Maintenance. 2. Remote Diagnosis of Vibration Analysis. 3. Full on-site CBM services, ranging from single individuals to complete department. 4. Oil Analysis Laboratory Services. 5. Vibration Analysis Services. 6. Thermographic Analysis Services. 7. Laser Alignment & Balancing Services. 8. Training in all specialist areas of Condition Based Maintenance 9. Direct agents for Flir Systems (Sweden) and Prüftechnik(Germany). PUB Gearbox Maintenance Brochure