Gearboxes are among the most complex and delicate components of a powertrain. This is one of the reasons why there is a multitude of possible defects on gearboxes.
This article wants to shed some light on the most common gearbox defects and their causes, as well as give you some advice how to detect defects early on.
As previously mentioned, gearbox defects can be multifold and complex. Among others, these are the most common:
The solutions for analysis and diagnoses of wear and tear are as varied as the possible defects themselves. Damage on bearings is among the most common defects, it becomes noticeable through symptoms like increased noise, elevated bearing temperature or vibrations in the gearbox early on. Detecting bearing damage early on prevents unplanned machine and production shutdowns and any subsequent damages.
An easy and efficient method to detect wear on bearings early on is the analysis of lubricants and monitoring of oil levels. Too high or too low amounts of oil leads to increased bearing temperatures and subsequent damage. Oil analyses will also reveal metallic shavings in the oil, which could be an indicator for increased wear due to overloading.
Thermographic measurements are also a suitable method to detect unusual temperature developments in the bearing and identify causes of damage at an early stage. Thermography is also an easy method which can be conducted without disassembling the gearbox, providing you with important findings about the cause of possible damages in a fast and cost-efficient way.
Wear of gear wheels, seals or tubings are also easily discovered by performing an endoscopy of the gearbox. Here, too, disassembly of the gearbox is not necessary and any damage can be detected quickly and easily.
Wear on rotating parts is almost inevitable, but there are some ways to prevent and keep it off for as long as possible. The most crucial aspect is the correct design and installation of the gearbox according to its load. Our experts often encounter gearboxes which are misaligned, causing vibrations detrimental to the material. Not only the alignment of the gearbox is important, but also the alignment of the whole powertrain. Vibrations are only minimized in order to prevent gearbox damages if all components are properly aligned. Vibration measurements are suitable to identify critical components from the outset and straighten them out precisely and proactively.
Another recommended procedure is a torque analysis for your gearbox to check how much torque is present during the operation of your machine and if all components are designed according to the actual load. Torque measurements are one of the most efficient solutions when you want to improve the life span of your powertrain components.
Have your gearbox and if possible, the whole powertrain, checked by experts on a regular basis. It is important to look for any signs of wear like formation of cracks, leakages or damage. Analysing lubricants, thermographic or vibration measurements can also hint at wear at an early stage and provide you with the opportunity to take repair measures before an unplanned machine shutdown occurs.
Vibration monitoring and its benefits