With the importance of gearboxes in manufacturing and industrial environments, the need to keep the equipment functioning as intended puts an increased significance on maintenance. Equipment down time only adds a loss of production to the costs associated with repairing or replacing damaged equipment or a Falk gearbox.
Routine maintenance should be structured to reduce or eliminate the stress that occurs during operation to keep the Falk gearbox functioning with a minimum of friction, operation-induced heat and the vibration that accelerates wear on the bearings. Here are some maintenance practices for getting the most life out a Falk or bevel gearbox:
Choose the right lubrication. A gearbox relies heavily upon lubrication to keep friction and heat to a minimum. The oil used for lubrication needs to match the needs and requirements for the gearbox to ensure that everything is operating as intended, especially with the sheer load of gears in a bevel gearbox. It is also important to change the oil at regular intervals; as it degrades, the oil becomes contaminated with debris and its flow properties decrease. Implement a schedule for checking and adjusting the oil level, and plan for regular oil changes.
Oil analysis is also a key component of lubrication maintenance. Analyze the oil regularly to establish a baseline. This will help you determine what parts within your Falk gearbox are wearing out, how fast individual items are becoming worn, how well the oil is holding up to current conditions and whether any major Falk gearbox repairs may be required in the near future.
Perform a vibration analysis. Vibration analysis is also important for getting the most life out of a gearbox. Analyze the vibrations and harmonics of your Falk gearbox to detect any change in operation. A change in vibration may help you identify the moving parts or bearings that may be degrading due to the particular vibration signature given off by the worn component. Internal wear can lead to a number of issues such as bearing failure, excessive gear wear or shaft alignment.
If used correctly, vibration analysis can help you make a timely minor repair as opposed to having a major failure. It can help you identify possible alignment issues from wear in your bevel gearbox. Analyzing vibrations can also help you evaluate the oil quality as it degrades and aid in adjusting maintenance intervals to ensure the oil maintenance is performed at the correct intervals.
[Photo by: Michael Caven on Flickr via CC License]
Posted under Tips and Tricks on Monday, March 7th, 2011