Gear Inspections and Audits

Inspections

To gain a fundamental understanding of the evolving operational and production behavior of a piece of machinery as part of an effective Condition Monitoring Program (CMP), a robust data collection process must be established. Global's Gear-Pro™ method compliments any CMP program to ensure the integrity of gearing.

The Gear-Pro™ electronic crack detection method is used for inspecting cleaned pinion and bull gear teeth, especially in the addendum, dedendum and root areas. It is used to provide more comprehensive, accurate data and faster inspection times than current methods used today. This method detects 100% of all surface anomalies. It has the ability to electronically size any cracks found accurately. Specialty probes are used for pinion inspection.

Conventional methods for surface inspection, such as Magnetic Particle Testing, or Dye Penetrant rely heavily on operator interpretation. At the best, these techniques can determine whether a defect exists but are unable to provide information on defect severity. These methods are also very time consuming.

As visual interpretation is usually the method used to analyze any surface breaking anomalies, a cleaned gear is a must. To be noted, the gear teeth do not need to be wiped down by hand to remove residue as in Magnetic Particle, Liquid Penetrant or Ultrasonic. The colours and 3D imaging of the Gear-Pro™ method that help with visualization are absolutely invaluable in such circumstances. All of the data is provided in an electronic report for future review and eliminates the need for paper files.

Thorough inspection of accessible gear train components allows for preparation of comprehensive reports. These comprehensive reports assist you in:

• A Gear Audit that will identify at risk components
• Enhance the repair life cycle
• The ability to accurately forecast demand for parts in the future
• Could help in determining premiums charged by insurance companies
• Controlling down time

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Gear Audits

Global provides complete gear audits on gear sets for numerous types of Mining equipment. Our gear failure analysis team is able to provide comprehensive information on the condition of gearing utilizing our gear audit program that will detect a potential failure before it occurs.

The program provides real-time mapping of the inspected region, facilitating data interpretation. In addition, this method can detect any casting imperfections deep in the gear that have not already propagated to the surface. (Fig. 1) This type of mapping for the gear is vital information for future trending. Our gear failure analysis team provides comprehensive information on the condition of gearing to enhance the repair life cycle of these components.

Gear Engineering

Through our affiliation with Hofmann Engineering, a worldwide gear manufacturing and gear engineering company, Global can provide full gear engineering and audit services, focusing on quality in every aspect.

Call today to schedule a gear audit for your equipment