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| Analyze gearbox failure |
- Gear reducers fail for a reason. Ideally, they are properly sized and maintained and live a long life, only failing as a result of having reached their expected life span. Unfortunately, many times this is not the case. Unpredictable overloading, worn accessory components, and changes in the application often present undesirable conditions for gear drives.
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The weak link of a gearbox is almost always the gearing, the bearings, or the shafting. Experience shows that often, it is the gearing that fails. Therefore, when a gearbox fails prematurely, look for the condition of the gearing.
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If the gearing is damaged or has broken teeth, it is a safe deduction that the unit has been subjected to loading beyond the mechanical limits of the gearbox. This is of course, assuming the unit was properly lubricated. Replacement with another identical gearbox is likely to produce similar results if the load requirements are not lessened or the drive modified to within the mechanical limits of the gearbox.
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Perhaps more is being asked of the drive in the form of more production and consequent load increases. Perhaps something has failed elsewhere in the drive train which causes more drag and requires the gearbox to work harder.
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