Learn how preventative Gearbox Maintenance can save you in the long run.

IndustrialGearbox Maintenance

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In general the gearbox or speed and torque change devise is as important as any other vital part of machinery as its malfunction would affect the entire process in which it is employed.

In many cases the cost of the drive train is small in comparisons to the rest of the driven machinery and tends to be neglected, as it does not normally “scream” for regular attention. Unfortunately the saying of “a stitch in time saves nine: is rarely more applicable than in industrial gearboxes.

In a 3 stage speed reducer with surface hardened & ground gears as a very rough estimate bearings make up approx 5 % to 10 % of the costs, the gears approx 45 % to 55 %, housing, covers, low speed shaft, and other non-wearing hardware 35 % to 40 %.

Apart from accidents or abuse the main wearing parts are normally the bearings and the uncorrected wear of a bearing which may be only 1 % of the costs can be the cause of progressive damage to the rest of the rotating parts.

Preventative maintenance done on a scientific basis will help you to avoid unexpected & unscheduled production losses and breakdowns. In general properly planned preventative gearbox maintenance will cost between 10 % and 50 % of breakdown maintenance. Training of staff at all levels will even reduce your maintenance cost if you work on a breakdown repair basis; hence the importance of a training course such as this.

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Industrial Gearbox Maintenance

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This 3 day course is designed to provide engineers and superintendents, with a practical working knowledge of Gears and Gearbox Maintenance. The course is intended to provide the understanding to adopt best practices in maintaining geared systems, identify potential problems, and ensure proper repair procedures and quality measures.

Fundamentals Of Gears: Law of gearing, Gear design, Gear-tooth systems, Types of gears. Methods of calculation and integrated design, gear machining, accuracies, corrections, and noise reduction. Methods of increasing load rating.

Materials and surface engineering:

Metallurgy, Choice of Steels, Heat Treatment and Surface Engineering

Gearbox elements: Design and practical considerations of Bearings, Shafts, Seals, and Couplings.

Factors that influence life of these gearbox elements.

Gearbox applications:

Service factors, Load conditions, Typical specification, Drive installations

Maintenance Principles:

Preventative maintenance, Lubrication, Inspections, Filters

Health Determination: Vibration analysis, Lubrication condition monitoring, Thermography

Overhaul Principles: Replacement

Components, Assembly, Horizontal shafts split through the bores, Assembly - vertical shafts horizontal split, Bearing and Oil seal fitting, clearance setting, Testing Running-in, Monitoring

Failure Analysis: History, Evidence, Specifications & Design Criteria, Operating environment including actual operating requirements , Material and lubrication considerations, Relevance of various factors, Significance of root cause analysis

Dates:29 Mar - 31 Mar 201703 May - 05 May 201702 Aug - 04 Aug 2017

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Learn the fundamentals and practical skills

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The course covers the understanding of industrial gears of various types with a review of the underlying principle as well as a brief look at materials machine health determination and the important actions to get the best life and long-term low running costs.

Fundamentals• Involute tooth profile• Conjugate action • Involute • Contact ratio • Helical gearing • Bevel and spiral bevel • Worm gears and variations• Other Shafts at 90° non-intersecting • Methods of calculation • The aim for an integrated design • Gear machining accuracies • Methods of increasing load rating • Corrections • Noise reduction

Materials and Surface Engineering• Metallurgy • Iron and Carbon • Classification of steels • Heat Treatment of Steel • Surface Engineering

Bearings• Bearing Types • Bearing Loading • Load Criteria • Bearing Life Formula • Life adjustment factor • Bearing life • Some aspects of practical experience

Shafts• Internal shaft • Gear fits • Overhung gears • High speed shaft extensions • Low speed shaft extensions • Keyed shaft connections • Shaft mounted gear units

Seals• Seal Types • Material Selection • Operating conditions for lip seals

Gearbox Applications• Horizontal shafts • Vertical shafts • Service Factors • Load conditions • Load conditions on gear teeth • Typical Specification • Drive installations • Rigid Couplings

External Attachments

Lubrication

Maintenance Principles• Maintenance planning • Lubricant rationalization • Planning a methodical lubrication

system

Health Determination• Vibration analysis • Lubrication condition monitoring • Thermography

Couplings• Torsional Flexibility • Angular/ Radial flexibility • Alignment • Over hung loads • Coupling alignment • Flexible couplings • Pin and bush couplings • Steel grid couplings • ‘Tyre’ type couplings • Rubber block type couplings • Gear couplings • Membrane couplings

Overhaul Principles• Replacement Components • Assembly - Horizontal shafts split

through the bores • Assembly - vertical shafts horizontal

split • Oil seal fitting • Bearing clearance setting • Testing Running • Monitoring

Failure Analysis• Introduction • Basic understanding of gear

technology • Basic understanding of environment • Systematic investigation • Gear failure • Causes of Gear failure • Significance of root cause analysis

Course Outline

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Yellotec offers a full complement of training courses in Condition Monitoring disciplines as well product and Reliability Engineering specific courses. Courses offered are either presented under license from International Certification Bodies or are in accordance with ISO requirements.

All our public training courses can also be conducted as an in-house private courses. If you have 10 or more people attending, consider the benefits of an in-house session conducted in the privacy and conveniences of your facilities or a meeting site of your choice. Please contact us so that we can understand your requirements, explore the benefits and make it happen.

Training Opportunities

Private Courses

All Courses Offered By Yellotec

Infrared Thermography (IRT) IRT Basics, Level 1, Level 2 and Level 3

Vibration Analysis (Mobius)Category 1, 2 and 3

Field Lubricant AnalysisNoria Level 1, 2 and 3

Machinery LubricationNoria Level 1 and 2

Oil Analysis SeriesLevel 1, 2 and 3

Shaft AlignmentLevel 1

UltrasoundLevel 1 and 2

Gearbox Maintenance

Failure Analysis

Condition Monitoring for Engineers

Plant Management – Dr. Mike Vorster

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Registration Form

Please register each delegate by completing the details below and return by fax to 011 656 9112, or e-mail to training@yellotec.com. The company details are intended for accounting purposes and must reflect the details required for the completion and delivery of tax invoice.

1. All course fees are payable upon confirmation of booking and an invoice will be sent as per the details indicated above. Bookings cannot be secured until payment of invoice or valid purchase order is received.

2. Only cancellations received in writing 10 days before the start of the course will be refunded in full.3. There will be no charge if a substitute person wishes to replace the original delegate.4. Yellotec reserves the right to cancel any course at any time without liability. In these circumstances, delegates will

be offered an alternative date, or a full refund.5. All Halaal requirements will be charged at an extra cost.6. Delegate no shows, partial attendance or late cancellations will be liable for full cost.

Course Details Course

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Do you have Halaal requirements? Yes No

PUB-10-0004-05-Gearbox Maintenance Brochure

33 Taljaard RoadBartlettBoksburg

PO Box 31448Kyalami1685

www.yellotec.com[t] +27 (0) 11 656 9111[f] +27 (0) 11 656 9112training@yellotec.com

Reg. No: 2013/231556/07VAT No.: 4020210219

Yellotec is a products, service and training provider in the following specialist fields:

1. Complete solutions for the implementation and management of Condition Based Maintenance.

2. Remote Diagnosis of Vibration Analysis.3. Full on-site CBM services, ranging from single

individuals to complete department.4. Oil Analysis Laboratory Services.5. Vibration Analysis Services.

6. Thermographic Analysis Services.7. Laser Alignment & Balancing Services.8. Training in all specialist areas of Condition Based

Maintenance9. Direct agents for Flir Systems (Sweden) and

Prüftechnik(Germany).

Co. Name: Yellow Technical Services (Pty) Ltd.Trading as: Yellotec