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ICTD International Centre for Training and Development

Gear Boxes: Selection, Inspection, Maintenance, Troubleshooting & Repair

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Description

Gearboxes are an integral part of today’s industrial machinery. A gearbox is utilized to increase the output torque or change the speed (RPM) of a motor or a turbine. They allow the driver and driven equipment to operate at their most efficient and optimum speeds and torques. Proper selection, troubleshooting and maintenance of gearboxes is essential in order to make sure they can do their job.

This course covers the specification, installation and operation of gears and gearboxes in modern plant. It reviews current design standards and discusses how to specify and how to use a gearbox. Gearbox installation, lubrication, health monitoring and failure interpretation are discussed in detail. Practice exercises, videos, case studies for an engaging and memorable learning experience

Course Objectives

Upon successful completion of this course, the delegates will be able to:

  • Apply safe working practices and understand the principles of preventive and first-line maintenance
  • Correctly diagnose a range of mechanical faults and plan a suitable course of action
  • Understand the principles of power transmission systems; recognize, remove and refit taper-lock bushes, keyed shafts, belts, chains & couplings; install & align shafts; tension drive train components
  • Correctly remove and refit various types of bearings (roller, ball etc.) identify various bearing types, understand their typical applications & recognize common defects
  • Practice methods of removing broken studs
  • Recognize stripped threads and correctly use thread repair equipment
  • Manufacture gaskets and understand how to remove and replace seals and gland packing
  • Understand the operation of various gearboxes, (helical, spur and worm-wheel)
  • Correctly dismantle and replace drive belts
  • Recognize various types of conveyor systems and their main components
  • Identify typical faults and correctly remove, replace and track a conveyor belt.

Course Outline

Day 1

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

Day 2

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

Day 3

Gearbox Applications

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

Maintenance Principles

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

Day 4

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

Day 5

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 Methodology

A variety of methodologies will be used during the course that includes:

  • (30%) Based on Case Studies
  • (30%) Techniques
  • (30%) Role Play
  • (10%) Concepts
  • Pre-test and Post-test
  • Variety of Learning Methods
  • Lectures
  • Case Studies and Self Questionaires
  • Group Work
  • Discussion
  • Presentation

Who should attend

This course is intended for designers, mechanical and maintenance engineers, technicians, operators and managers involved in gearboxes, prime movers and rotary equipment.

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