GLOBAL BREAKDOWN RESPONSE

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 broken gear or gearbox. 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:

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, Euro Gear will send our certified millwrights and service engineers to the site to do so immediately.

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

3: We receive the gearbox in our facility, and then proceed to 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 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.

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. 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 the tempering stage.

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.

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 Euro Gear 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.

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 then close the cover and prepare for bench testing.

9: We fill the gearbox with oil and set it 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 the oil, prepare the 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 Euro Gear Industries perform this intricate task.