Gearbox - Theory, Practice and Maintenance

This class will provide the participant with the knowledge needed to properly maintain service, inspect, select and repair a variety of Industrial gearboxes. The course will be and instructor-led, hands-on class that will allow the participant to physically take a part various industrial gearboxes and learn to properly “set” the gears and how to properly “preload” the bearings for maximum life expectancy.

Course Objectives

At the completion of this course the participant will be able to:

• Properly “setup” an industrial gear drive.
• Understand the selection procedures used to select the correct industrial gearbox.
• Troubleshoot industrial gearboxes using failure analysis.
• Select the correct lubrication to ensure maximum life expectancy.
• Correctly remove and replace bearings, seals and gears

Learning Points To Be Delivered Objective

Pre-test

What is a gear? The types of gear.

• Spur gear
• Bevel Gear
• Worm gear
• Helical Gear
• Herringbone gear
• Hypoid gear.

Understanding the gears.

• Nomenclature in respective gear
• Applications of gears
• Velocity ratio

Gear ratio

• Gear trains
• Example problems and questions
• Comparison of gears and their applications
• Gear tooth parameters permissible deviation as per class of accuracy & consequence

Gear trains

• Installation gear box system
• Alignment checks using different methods.
• Study of drive misalignment consequence
• Back lash (use of filler gauge)
• Backlash & axial float adjustment in straight/Spiral Bevel & Helical gears
• Starting of gear box system
• Gearbox parameters checking procedure in normal working condition

Understanding the installation & alignment check.

• Analyzing gear box failure
• Gearbox vibration graph interpretation & permissible deviation
• Maintenance of gear box
• Preventive Maintenance
• Predictive Maintenance
• Proactive Maintenance
• Shut down Maintenance
• Corrective Maintenance

Analyzing the gear box failure & Maintenance of gear box

• Condition monitoring
  • Bearing temp
  • Permissible damage limit
  • Current to check load on the motor
  • Gearbox Bearing condition check & life prediction

Lubrication & Condition monitoring

• Typical case study of GB failure & root cause analysis