GEARBOX REBUILDING/UPGRADING/REPAIR/BREAKDOWNS

>GEARBOX REBUILDING/UPGRADING/REPAIR/BREAKDOWNS
GEARBOX REBUILDING/UPGRADING/REPAIR/BREAKDOWNS 2018-04-27T13:33:36+00:00

When gearbox failures occur, your plant or parts of your plant are shutdown. Without spares to repair, your disposition has gone from bad to disastrous. With no plan prepared, costly hours of downtime will ensure fully knowledgeable that your local machine shop is not properly equipped or specialized to handle this area; what are you supposed to do in this situation? Clients scramble to find prints, which can take nearly a day or two to find that there isn’t enough information on the drawings to be able to reproduce your broken piece. The client now makes all efforts to contact the manufacturer to later find out they no longer exist or, with luck, are able to find the parts despite the lead times being 6-8 months away.

This is a daily occurrence in the industry and this situation can easily be avoided only by contacting EGI Industries 24/7 global support immediately. The process of contacting EGI Industries is simple and effective; with our experience comes proper planning!

Here is our common scenario:

BREAKDOWN OCCURS: Clients or New clients from around the world contact EGI Industries via phone +1 518 578 1775 or info@egiindustries.com. Your calls are directed to an engineer or principal of the company, assuring your situation begins in the right hands. Our staff will then proceed to gather your detailed information.

OPTION (A) CLIENTS WHO HAVE THE INFORMATION: We can produce a sketch immediately and return it to the client for approval. Following the approval and depending on the size of the gear, gears can be machined, hobbed, heat-treated, ground, and returned within the span of 1-2 weeks.

Scenario based on a 18-30” gear

 DAY 1:
We gather all the necessary information, produce blue print sketches, send back to the client for approval, receive approval, and then locate the correct material for the application. We then cut material to size for machining.

 DAY 2-3:
At this stage we are machining the blank and setting up the gear machine for critical production.

 DAY 4-5:
We proceed to remove the gear from the CNC machines and install the gear on the gear hobber. We then cut the teeth until it is ready for heat-treatment. An adequate amount of material is left on the gears to compensate for deflection during the tempering stage.

 DAY 6:
Heat treatment. This is the stage where our gear enters an oven for 20+ hours to change the entire composition of the steel to make it harder depending on your specific requirements. At this point, we are setting up the gear grinder to grind the gear to the desired specifications.

 DAY 7:
We receive the gear and install it on the gear grinder and grind each tooth to tolerance per AGMA standards.
Many suppliers parsimoniously do not grind gears due to cost and time. Not grinding your gears will lead to premature failure, vibrations, misalignment, and at times, can cause irreparable damages to matting internals. This is a substantial step, that cannot be omitted. This is yet another reason why EGI states to have your best interests in mind; we do not undermine any step so we can ensure your satisfaction and the quality of our rigorous work.

 DAY 8:
Organize for transport back to client. EGI Industries is well situated, being surrounded by airports, sea ports, train tracks and logistic companies, so getting your critical part back to you, quick and efficiently wherever your situation happens to be, in the world in the world.

OPTION (B) CLIENTS NOT HAVING ANY INFORMATION: Don’t panic. More than half of our calls to our emergency call department are from clients & new clients not possessing any information on their gear or gearbox that is broken. We are experienced in dealing with this matter. Here is an example of the best-and proven-scenario.

Scenario Based on a multiple stage Gearbox:

 DAY 1:

We recommend the client to remove the gearbox and ship it overnight to our facility. If the client is unable to remove the gearbox, we instruct them to have their qualified staff remove the top cover and send us the complete set of broken and good internals with bearings fully-assembled. IF the client does not have the qualified staff to do so, EGI will send our certified millwrights and service engineers to the site to do so immediately.  

 DAY 2:
Internals have been removed, packaged and are ready for overnight shipment.

 DAY 3:
We receive the gearbox in our facility, and then proceed remove all internals and decontaminate it. The housing is sent to our inspection department for sandblasting and UT, MPI inspection. The internals will be thoroughly inspected and recorded. Root-cause failure will be determined as well. At this point we can recommend an upgrade to the client to avoid another failure as from happening or proceed per our clients instructions. At this stage material for the new gears is being prepared. The best quality bearings, and seals are being ordered. Machining time and gear-hobbing time is being scheduled.

 DAY 4-5:
At this stage depending on the number of gear blanks required, we progress to set up the blanks on numerous CNC machines for a predetermined completion date.

 DAY 4-5:
We remove the gear from the CNC machines and then install them on the various gear hobbers. We then cut the teeth on each gear until they are ready for heat treatment. An adequate amount of material is left on the gears to compensate for deflection during tempering stage.

 DAY 6:
Heat treatment. This is the stage where our gear enters an oven for 20+ hours to change the entire composition of the steel to make it harder depending on your specific requirements. At this point, we are setting up the gear grinder to grind the gear to the desired specifications.

 DAY 7:
We receive the gear and install it on the gear grinder and grind each tooth to tolerance per AGMA standards.
Many suppliers parsimoniously do not grind gears due to cost and time. Not grinding your gears will lead to premature failure, vibrations, misalignment, and at times, can cause irreparable damages to matting internals. This is a substantial step, that cannot be omitted. This is yet another reason why EGI states to have your best interests in mind; we do not undermine any step so we can ensure your satisfaction and the quality of our rigorous work.

 DAY 8:
We install all new high-quality bearings
including: SKF®, FAG® and Timken® and seals onto the shafts and press-fit them accordingly. We then install all new gear sets into the newly inspected gearbox housing. We close the cover and prepare for bench testing.

 DAY 9:
We fill the gearbox with oil and set up onto our engineered test bench. We run test the gearbox to the specific rpm without any load for 6 hours. During this time, we record and verify all critical parameters. We remove the unit, drain oil, prepare certifications and hand it off to the logistics company to return it to back to the client. At this point, the gearbox is ready for operation. The client can either install the gearbox or have EGI perform this intricate task.