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Repair of gearboxes

One of the key problems is effective operation of power transmission systems, the elements of which are gears.

A universal and frequently asked question, which the company managers attempt to answer, is as follows: Should the old equipment be repaired or should the new one be purchased?

PATENTUS S.A. is helping to give a reliable answer to this question.

 

  

Gear assembly Gear hobbing machine GLEASON-PFAUTER

 

Patentus S.A. offers a solution consisting in the execution of a gear repair which restores its technical condition to the new gear level. The costs of the repair performed this way are at the level of 30–70% of a new gear purchase price. The cost of repair depends on the scope of the executed works. Patentus S.A. grants the guarantee from 3 to 12 months for the repair. The guarantee period is determined individually in each case, and it depends on the scope of the works executed and the conditions in which the power transmission system works. 

 

 

Production of the gearbox body  Slotting Machine GLEASON-PFAUTER

 

 

 

When is it worthwhile or necessary to purchase a new gear to replace the old and worn-out one?

Purchase should always be considered:
 

  1. in the case of low-power gear motors, which are manufactured in large batches – they are relatively cheap to buy and spare parts are calculated by the manufacturer so to discourage the user from repairs;
     
  2. when we want to increase the efficiency of a system, technology or a transport system, which is connected with the necessity to increase the drive and electrical motor power, and the structure of the existing gear reducer does not allow this;
     
  3. when the degree of the gear wear and tear is so advanced that it prevents economically justified repair works;
     
  4. if the old type gear can be replaced with a lighter, smaller, having less environmental impact and easier to operate one, without expensive technical modifications of connecting with the driven machine.

 

Gear assembly

When and what types of gears are worth repairing by a company specializing in such services?

Repair should always be considered:

  1. When the repair price is competitive with respect to the price of a new gear.
     
  2. When original spare parts offered by the gear manufacturer are very expensive – this is common practice as the manufacturers of machines and equipment worldwide apply very high profit margins for spare parts.
     
  3. In the case of large-dimension gears, having high power and high turning moments.
     
  4. In the case of high-speed gears with high nominal power.
     
  5. In the case of special gears with the structure individually adjusted to the user`s needs.
     
  6. In the case of gears manufactured as single units or in small batches.
     
  7. When development conditions and work system hinder the selection of a new spare part.
     
  8. When a company performing the repair grants a reliable guarantee for the executed works.
     
  9. When human resources and technical resources as well as experience in the scope of gears limit the risk.
     
  10. When the company deals with professional diagnostics of gears and has the gear service.

 

Thermovision image of gearbox body Results of gearbox vibration measurement

The customer service procedure

  1. Preparation of the offer for the performance of the repair of the gear delivered to the premises of Patentus S.A.
    a.    Washing, removal of old oil, disassembly of the gear;
    b.    Assessment of the equipment technical condition and the degree of wear and tear of sub-assemblies (body, shafts, gear wheels, fittings, lubrication systems, cooling systems)
    c.    Calculation of the repair estimated costs and the offer for the customer;
    d.    Assembly of the gear to the condition which enables transport.
     
  2. Preparation of the offer for the gear repair service based on the visual inspection in the customer´s premises
    a.    Arrival of Patentus S.A. service staff to the customers premises;
    b.    Gear visual inspection and preparation of photo documentation;
    c.    Assessment of the technical condition of the equipment and the degree of wear and tear of sub-assemblies (body, shafts, gear wheels, fittings, lubrication systems, cooling systems, etc.);
    d.    Calculation of the repair estimated costs and the offer for the customer.
    Notice: The gear should be prepared for visual inspection: washed and disassembled into sub-assemblies.

    The costs and the price of works included in item A and B are defined individually and will be settled within the total repair price provided that the customer accepts the offer and orders the gear repair service.

     

  3.  Repair.
    a.    Precise washing of the gear and sub-assembly casing, sand-blasting or blast cleaning of the body;
    b.    Pre-repair inspection of the gear; preparation of repair documentation (structural and process documentation);
    c.    The body regeneration; planning of the surface division, machining of bearing mounting if the measurements and the technical condition assessment prove the necessity of such a repair;
    d.    The performance or regeneration of turning parts (shafts, sleeves, gear wheels, pinions);
    e.    Completing new commercial parts (bearings, sealing rings, clamping rings, back-footings, vents, couplings, pumps, heat exchangers, nozzles, sensors);
    f.    The gear assembly;
    g.    Tests and diagnostics at the test station under full or partial load (the temperature, vibrations, noise);
    h.    Painting, packing, dispatch to the customer.
     
  4. Supplementary services.
    a.    Additionally, we offer the participation of our service staff at the installation and start-up of the gear.
    b.    We manufacture spare parts as per the provided documentation or based on the reverse engineering (restoration of worn and torn details provided as a model).

 

 

Resources which we

  1. Experienced personnel who make use of over 30-year experience in designing, production, tests and repairs of general gears and special power transmissions.
     
  2. The engineering office within the Research and Development Department equipped with engineering work graphic support computer systems – CAD 2D, 3D, belonging to Autocad and Inventor group, and reference specialist Swiss software Kissoft/Kisssys used for calculation of geometric parameters, strength and process parameters of gear wheels.
     
  3. The process department and production preparation department equipped with Autocad and ERP PROalfa systems.
     
  4. The quality control department equipped with measuring machines: Zeiss Acura, Wenzel LH 2600 Hybrid, equipment for metallographic tests, stationary and mobile spectrometers for testing steel chemical composition, magnetic station for the inspection of micro-cracks at the gear wheel surface.


   

Metrological lab no 1 Metrological lab no 2

 

5. Production Department

 

a. SECO/Warwick heat treatment, including furnaces: vacuum chamber furnace CM D12, sealed for tempering and annealing, atmospheric PEGat1000 and PEG700, quenching tank, chamber washing devices.

 

 

  

 

Vacuum heat treatment SECO/WARWICK Furnace for annealing SECO/WARWICK

 

 

b. Devices for improving the durability of drive elements (fig.13)

 

 

   


c. Machining centers: Gleason Pfauter Titan 1200G, Gleason Pfauter P800/1200S H3, Gleason Pfauter Titan 1200H, Welter KF630 CNC

 

 

   

Gear Grinding Machine GLEASON-PFAUTER Bevel Gear Milling Machine AMK 630

 


d. Boring machines: Wotan, Juaristi, Union

 

 

  

CNC boring machine WOTAN CNC boring machine JUARISTI

 
e. Vertical and horizontal  processing center  CNC,  conventional and CNC lathe, universal machin centers for machining and finishing

 

 

  

 

CNC lathe TBI Vertical lathe TOSHULIN

 


f.  Internal grinders, centre-type grinders, flat surface grinders. 

6.    Gear installation department: bridge crane 12 t; heaters: AG Heater 1200 and Heater 300, liquid nitrogen cooling vacuum flasks, assembly press with the load of 30 t.

 

 

  

 

The gearbox bodies prepared for installation

Heater


 

7.    The  plant with the area of 2 x 3000 m2 [1 m2 = 1.196 yards] located in Pszczyna, in Śląskie province.
 

8.     Tests at the test house 630 kW.

Certyficates:

 

  • EN ISO 9001
  • PN-EN ISO 3834-2
  • DIN-18800
  • UD-09-102
  • PN-87/M-69008