In today’s era Gearbox has became very important equipment for transmitting in various industries like Thermal, Sugar, Agricultural, Automotive, Wind Turbine, Material Handling, Machine tool, Construction, Steel, Pharma, Paper & pulp and many more. Improper assembly of Gearbox and its sub assemblies cause misalignment which leads to failure.
2. Assembly of Industrial Gearboxes is very
important parameter which affects the quality of
the product and may lead to Gearbox Failure.
In today’s era Gearbox has became very
important equipment for transmitting in various
industries like Thermal, Sugar,
Agricultural, Automotive, Wind Turbine, Material
Handling, Machine tool, Construction, Steel,
Pharma, Paper & pulp and many more
3. Improper assembly of Gearbox and its sub
assemblies cause misalignment which leads to
failure.
Parallel, radial and angular misalignments occur
in meshing gears as shown in Fig.
Misalignment in radial direction
Axial or Radial Misalignments
Perpendicular to plane of action
In plane of action
4. The gearbox fails probably due to few internal
misalignments causing overhang-meshing gears,
deflection of pinion or gear shaft supported
between the bearings, poor adjustment of
bearings, bearing wear, poor foundation and
assembly error etc. These reasons Causes the
malfunction of the gearbox. Deflection of shaft
causes imperfect meshing of gears, bearing
overstress, and seal wear etc. The overloaded
contact area results in wear, pitting, scuffing and
breakage of gear’s teeth etc. Gearbox consists of
gear, bearing, and shafts as the primary loading
components, and failure of one component
5. Hence to avoid such internal misalignments it is
very necessary to ensure proper sub-assemblies
of gears, shafts and bearings. As a gearbox
manufacturer it is very important to verify these
things at early stage itself by having stringent
quality checks to prevent any later
consequences.
6. Today Top Gear Transmissions is recognized as
leading Industrial Gearbox manufacturer in
India due to its high quality products. All
gearboxes of Top Gear are Tested for various
parameters including but not limited to as
mentioned below,
Contact pattern
Preloading of Bearings
Noise
Vibration
Temperature
Motor Current
Leakage
7. CONTACT PATTERN
A very important parameter when designing a
gear pair is the maximum surface contact stress
that exists between two gear teeth in mesh, as it
affects surface fatigue (namely, pitting and wear)
along with gear mesh losses. Hence it is very
important to check the contact pattern between
two mating gears.
8. BACKLASH
Backlash is a clearance or lost motion in a
mechanism caused by gaps between the mating
parts. Hence it is one of the important parameter
and needs to be ensured. Very less backlash can
cause noise and wear & tear, whereas more
backlash can result into transmission losses.
Hence depending upon the application the
desired backlash has to be decided and ensured.
9. PRELOADING OF BEARINGS
Along with the elimination of clearances,
preloading bearings also increases the stiffness
of the assembly, improves rotational accuracy
and decreases noise due to vibration or
resonance. Additionally, preloading eliminates
skidding of rolling elements and keeps them in
the proper location in the bearing. Many types of
rolling element bearings require some form of
preload for proper operation, including angular
contact ball bearings, tapered roller bearings and
cylindrical roller bearings.
10. NOISE, TEMPERATURE, &
VIBRATION
To safeguard gearbox against any failure, early
failure diagnosis (or indication) of critical loading
components are essential. Noise, Vibration and
Temperature Testing gives clear idea about the
state of assembled gearbox. Top Gear
Transmissions has its own stringent quality
acceptance criteria for these parameters and all
gearboxes are 100% tested for Noise, Vibration &
Temperature.
11. MOTOR CURRENT
It is very essential to monitor the Motor current
and compare it with standard values. This gives
clear idea about the inside working of gearbox. If
there is any sort of jamming between shafts,
gears etc the current drawn by motor is higher
than the regular standard value.
12. LEAKAGE
Any misalignments’ caused during assembly of
sub components give rise to leakages. Hence
leakage test is performed on each and every
gearbox to detect minute leakages.
Hence in this way if you are a buyer you will get a
clear idea about how good is your gearbox
assembled for which you have to refer the best
manufacturers of gearboxes who perform all such
tests and furnish the test certificates to buyer.
Top Gear Transmissions is amongst one of those
and are recommended by various esteemed
OEM’s and Government organizations as a
reliable source of Industrial Gearbox
Manufacturer in India.
13. GET IN TOUCH
We’re here to listen:
M-71, Addl. M.I.D.C. SATARA. Dist : Satara
Maharashtra, India, Pin : 415 004.
+91-9158009095
sales@topgeartransmission.com
