Industrial gearboxes are the driving force, powering the production lines of thousands of companies worldwide. Chances are – they are also at the heart of your production line, bringing unparalleled productivity to your operations.
But what happens when one of your industrial gearboxes begins to suffer from wear and tear, ultimately resulting in a malfunction? The answer is simple: your whole production line will go on hiatus. If you find yourself in a situation where your industrial gearbox has malfunctioned, you may not need to rush to buy a new industrial gearbox just yet. Instead, you may want to take a look at industrial machine gearbox repair services.
Industrial gearbox repair services are a much affordable and faster alternative than buying a completely new gearbox. But how exactly can you ensure your industrial gearbox is properly repaired? Read on to learn the ten essential steps of successful industrial gearbox repair procedures.
Why Not Just Buy a New Gearbox?
Repairing a broken gearbox is usually a better option than buying a brand-new gearbox for many reasons:
- Cost Savings- Even in the worst-case scenario, repairing a broken industrial gearbox ends up being 40% cheaper than buying a brand-new gearbox.
- Time Savings- Using emergency industrial gearbox repair services, you can get your old gearbox up and running within 24 hours. On the other hand, buying and installing a brand-new gearbox can lead to production stoppages that last for months.
- Avoiding Compatibility Issues- Gearboxes come in all shapes and sizes, which is why sometimes buying a new gearbox can lead to component compatibility issues on your production site.
- Extended Gearbox Warranty- Most professional gearbox repair companies are certified by several gearbox manufacturers, which enables them to provide you with an extended warranty for your repaired gearbox.
Now that we established why you should think twice before rushing to buy a brand-new industrial gearbox, let’s break down a typical industrial gearbox repair procedure.
Industrial Gearbox Repair Procedure: 10 Essential Steps to Success
Industrial gearbox repair is a streamlined process that involves completely disassembling the broken unit, pinpointing the broken parts, replacing those parts, reassembling the gearbox, and completing several performance tests.
To help you better understand the typical machine gearbox repair workflow, we have created a list of 10 essential steps involved in any industrial gearbox repair procedure, as followed by Houston Pump and Gear engineers.
Step #1: Broken Industrial Gearbox Shipment or Pick Up
You will first need to remove your broken unit from production and send it over to industrial gearbox repair professionals. Some gearbox repair companies even offer gearbox pick-up services, which can take some logistics weight off your shoulders.
BONUS: Looking to avoid halting the production while your gearbox gets repaired? Houston Pump and Gear can exchange your broken gearbox for a working one while we do the repairs. Check out our industrial gearbox exchange program.
Step #2: Industrial Gearbox Primary Examination
Once your unit arrives at the repair facility, our industrial gearbox repair professionals will examine it and determine all the specs of your unit. We will evaluate all the visible damages done to the gearbox and provide a ballpark estimate on the gearbox repair. This estimate will be solely based on our previous experiences working with identical gearboxes and is subject to change.
Step #3: Industrial Gearbox Disassembly
Once we document all the required information about the gearbox make and model, we will disassemble the gearbox and look at all components in greater depth. At this point, we will break down your unit into bearings, bolts, gears, shafts and casing to gather a complete picture of the expected repair.
Step #4: Industrial Gearbox Deep Cleaning
To accurately assess the extent of the damages, our mechanics will use a wide variety of industrial gearbox cleaning solutions to leave all the gearbox components spotless. Why is this step necessary? Due to prolonged usage, many gearbox components will have oils, lubricants, and other consumables stuck to them. These particles often make it hard to understand which details need fixing. Only when your gearbox is cleaned inside-out will we be able to examine each one of the broken parts accurately.
Step #5: Industrial Gearbox Failure Analysis
This is the most important step of any industrial gearbox repair procedure. We will examine each gearbox part to understand which details might be causing issues with your gearbox. Our industrial gearbox repair professionals will then document every broken detail and explain how they have affected the performance of your gearbox.
Step #6: Detailed Industrial Gearbox Repair Estimates & Approval
At this point, we will provide you with a detailed service cost estimate and explain which parts of your broken industrial gearbox should be replaced. You will have a clear picture of what needs to be repaired and how much this should cost. When you are satisfied with the provided estimates – our gearbox repair professionals will proceed to overhaul your gearbox, replacing all the broken parts.
Step #7: Replacement of Broken Industrial Gearbox Parts
Once we agree on the project deliverables, our engineers will order or reverse-engineer and manufacture industrial gearbox replacement parts and replace the broken ones. To be as efficient with your resources as possible, we will try to repair the damaged parts whenever possible.
Depending on the complexity of repairs and the chosen service package, the process can take between 24 hours to a couple of weeks (we offer both emergency and regular gearbox repair).
Step #8: Putting Your Industrial Gearbox Back Together
Once our experts confirm that we have all the working parts in place, we will proceed to reassemble your gearbox, bringing it back to its’ fully functional state.
Step #9: Running Industrial Gearbox Performance Tests
Once we put everything back together, we will ensure that your revamped gearbox is performing in line with your unit’s performance standards. At this point, we will run several tests to evaluate the following key gearbox performance indicators:
- RPM: We will run several no-load spin tests to see if your repaired gearbox is producing the expected output.
- Decibels on Output: We will run sound check tests to evaluate if your rehauled gearbox operates within the optimal noise range.
- Total Vibration on Output: We will also measure the vibrations produced by your gearbox during operation to make sure that it’s safe to operate.
If your gearbox passes all the quality assurance tests – then it is good to go!
Step #10: Applying Protective Paint to Your Repaired Gearbox Unit
Assuming that your gearbox has passed all the performance evaluation tests, we will repaint it with a layer of protective paint, which will ensure the longevity of your gearbox, and provide it with a fresh, new look.
Ready to Move Forward with Your Machine Gearbox Repair?
Houston Pump and Gear has 16+ years of experience repairing broken industrial gearboxes. We have an established fail-safe workflow tested by time, and we work with many industrial gearbox manufacturers, including:
- Flender Gearbox Repair Services
- Falk Gearbox Repair Services
- Western Gearbox Repair Services
- Foote-Jones Gearbox Repair Services