Gear Services is a complete specialty machine shop that specializes in the
rebuilding, reconditioning, and remanufacturing Industrial gearboxes used in
various industries across the U.S.
Nov 29, 2020 In a typical transmission service, the fluid is completely flushed (including the torque converter), a filter is changed, the transmission pan is cleaned and a new pan gasket installed. Common Problems. Premature transmission failure due to lack of maintenance, low fluid, dirty filter. Onsite gearbox repair, inspection, alignment and commissioning Our service engineers have besides their tremendous commitment and flexibility, also a great knowledge of gearboxes in their specific environment. Often the environment is the basis for earlier failure. In addition to onsite inspections and assembly, we can execute the following. For the 8-speed automatic transmission, ZF set out to design and develop an entirely new gear set concept. The result is a revolution in transmission design: a transmission concept with 4 gearsets which requires only 5 shift elements – of which only two are open in any given gear. Service & Repair Industrial Gearbox Repair. With our team of experienced engineers and a global network of gearbox service centres, we can ensure that your equipment is repaired in the shortest possible time, keeping downtime to its lowest level.
With strong roots in the gearbox repair business, we are time-tested to provide all of your repair needs. Gear Services can rebuild and recondition your gearbox at a fraction of the cost of buying new and save you downtime, regardless of the make or model– even if obsolete.
We pride ourselves on our quality workmanship, consistency, and fast turnaround time. It is for these reasons that we offer the industry-leading, 36-month gear drive warranty. Every gearbox undergoes the same 9 step process to ensure accuracy and consistency.
Gear Services’ staff utilizes SolidWorks 3D Modeling for the design of all components and all gearbox repairs. We pride ourselves on consistent repairs in a timely manner. We also offer rush repair for Emergency breakdowns with a team of engineers ready 24/7.
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Upon arrival at or facility, your gearbox will go through our quality assurance process.
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Sizing a gearbox (or gearmotor) for an industrial application typically begins with determining the appropriate service factor. In simple terms, the service factor is the ratio of the gearbox rated horsepower (or torque) to the application’s required horsepower (or torque). Service factors are defined by the American Gear Manufacturers Association (AGMA), based on the type of gearbox, the expected service duty, and the type of application. Near death crack cocaine.
While service factors may seem to be very specific, with thousands of combinations of gearbox types and applications each assigned its own numerical value, the criteria used to determine these values are based not on testing and empirical data, but rather on extensive review and analysis of gearbox manufacturers’ experience.
In general, the horsepower (or torque) rating of a gear tooth is based on the durability of the gear surface — its resistance to pitting — or on its bending fatigue. As the service factor of a gearbox is increased, the relationship between the gear teeth life (based on durability of the gear surface) and load is proportional to the increase in service factor, raised to the 8.78 power. In other words, if the service factor is increased by 30 percent (from 1.0 to 1.30, for example), the gear tooth life will increase 10 times (1.308.78 = 10.01).
To determine the gearbox service factor, start by consulting a set of tables or charts provided by the manufacturer, based on the type of gearing (worm, spiral bevel, helical, etc.). These tables list a wide range of applications (conveyors, cranes, winders, saws, blowers, etc.), each with (typically) three levels of service duty the gearbox is expected to see: zero to 3 hours per day; 3 to 10 hours per day; or greater than 10 hours per day. Each of these application-service duty combinations is assigned a recommended service factor.
Remember, the gearbox service factor is much like a safety factor to ensure the gearbox meets the application requirements, taking into account typical operating conditions known to exist for various types of applications. Once the AGMA-recommended service factor is determined, consider other, non-typical, working conditions that can cause additional stress and wear on the gear teeth, bearings, or lubrication. If any of these conditions exist, increase the service factor accordingly to ensure a sufficient safety margin and life of the gearbox.
Some conditions that may require an increase in the service factor are:
- Elevated temperatures
- Extreme shock loads or vibrations
- Non-uniform loads (cutting versus conveying, for example)
- Cyclic loads (frequent starts and stops)
- High peak versus continuous loads
Once the appropriate gearbox service factor is determined, multiply the service factor by the horsepower (or torque) required for the application, and the result is the output horsepower (or torque) required by the gearbox.
How does service class differ from service factor?
In some cases, manufacturers cite gearbox “service classes” rather than service factors. Service classes are designated as I, II, or III, and are generally translated to numerical service factors of 1.0, 1.4, and 2.0, respectively, to be used in gearbox sizing calculations. It’s common that even if a manufacturer publishes service classes for general application types, they also publish the more specific service factors for specific applications as well.
Why don’t some catalogs list gearbox service factors?
Gearbox Service Factor
Using service factor to guide the selection of a gearbox is appropriate for applications driven by traditional AC induction motors. But because gearbox output torque, speed, and inertia are much more critical for the proper operation of a servo system, sizing a so-called “servo-rated” gearbox requires a more detailed and exact method. For gearboxes that are used in servo systems, the primary emphasis in the sizing process is on required torque and inertia match.