Falk gearboxes are commonly used to drive mixers for chemical processing. As they age, these gearboxes wear and require increased levels of maintenance. A proper maintenance schedule and procedures will help monitor the overall condition of the drive system and provide information that will help determine the condition of the Falk gearbox. This will then help operators decide whether gearbox repairs – or a replacement – are required.
There are several indications that wear is occurring within a Falk gearbox and that a mixer drive is having problems:
1. Excessive heat. When Falk gearbox components become unusually hot during regular operation – as measured at the bearing races, housing surface or bulk oil temperature – it typically indicates either a change in load or lubricant failure. If left unchecked, excessive heat can lead to gearbox failure.
2. Excessive vibration. A more noticeable indicator of trouble is when the Falk gearbox begins visibly shaking during operation. Such abnormal vibrations often indicate component problems, such as worn bearings; a frequency analysis can help pinpoint specific component problems. If addressed early enough, these types of gearbox repairs can often be made without replacing the entire unit.
3. Excessive noise. If the noise level of a Falk gearbox increases during normal operation – especially if it makes a whining sound – it’s another obvious sign of gear or bearing wear. Again, measuring the level and frequency of the sound can help determine the specific problem area.
4. Lubricant problems. If a Falk gearbox begins leaking oil, it’s a sign of seal failure. These types of gearbox repairs should be taken care of promptly, as oil leaks cause the system to run hotter and may contaminate product. On the other hand, oil breakdown within the unit indicates contamination or excessive heat. An oil analysis is used to determine internal wear levels or contamination from external sources.
5. Frequency of repair. One reason it’s important to keep careful records of all past maintenance problems and gearbox repairs is to be able to spot patterns that may indicate a larger problem. For example, if the frequency of gearbox repairs is increasing, this is a sign of component problems such as worn gears and bearings throughout the system.
The age of the system dictates whether or not repair is preferred over replacement. A drive that is over 15 years old will require extensive maintenance to continue functioning well. A good rule of thumb is that option to replace a drive unit should be seriously considered when the cost of the repair exceeds 50 percent of the cost of replacement.
Drive wear is an inevitable part of long-term mixer usage. With proper maintenance, including keeping accurate records of maintenance and system condition, a Falk gearbox will provide maximum service life, and the decision to repair or replace the unit will be easier to determine.
Contact Mar-Dustrial for more information on mixer drives.
Posted under Machinery Maintenance, Tips and Tricks on Tuesday, November 1st, 2011