What’s the Difference Between Worm Gears and Helical Gears?

industrial gearbox repairGears provide the ability to parts to move properly and allow machines to function as needed. As one of the most important parts to motors and machines, it’s important to know which gear is right for the machine you’re using or working on, especially when it comes to industrial gearbox repairs. Two of the most common types of gears in today’s machines are worm gears and helical gears. Let’s take a look at a few key differences between the two.

Worm Gears

Worm gears are generally used in large gear reductions because of the way the gear is designed. A worm gear consists of axes that cross in space, allowing the gear to transmit power at 90° as well as in places high reductions are required. The way the gear is set up allows for the worm to turn the gear, rather than having the gear turn the worm. Due to the shallow angle of the gear, the gear is firmly held in place. Because the worm is interlocked with the gear, the user is able to accurately control the speed of the gear. The design of a worm gear makes it perfect for machines and motors such as conveyor systems, gates, and lifts that may require a brake. There are also different types of worm gears, allowing users to choose the proper gear during onsite machining services.

Helical Gears

Compared to worm gears, helical gears operate much smoother and quieter. This is because the teeth on the gear are actually cut at an angle to the face of the fear. So when the teeth begin to connect, they connect slowly since they’re angled. The design of a helical gear makes it perfect for transmissions that need a lot of thrust. Depending on the angle of the teeth, the gear can support different thrust loads. Because of the complex design and stages within a helical gearbox, helical gears are generally more expensive than worm gears. But overall, helical gears can be used to effectively ensure a motor is running as smoothly as possible.

Worm gears and helical gears are very different in design and use, which is something important to keep in mind when conducting industrial gearbox repair. Knowing the key differences between these two gears should help you choose the right gear for the job.

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Factors to Consider When Selecting a Gearbox

industrial gearbox repairWhen it comes to choosing a new gearbox, customers are faced with several different options. And while it’s always good to have options, buying the wrong gearbox can be problematic. There are already a few problems you should be concerned about with gearboxes, with the four most common warning signs being vibration, fluid leaks, oil contamination, and excessive noise. But with the right gearbox, you can experience smooth functioning. So how exactly do you choose the right gearbox? Let’s take a look at a few factors to consider when selecting and sizing a gearbox.

Shock load: When a gearbox is subjected to high shock or impact loads, it can experience increased wear. If this wear is not accounted for when sizing, the gear could undergo premature failure or an increased need for industrial gearbox repair. High shock loads require an increased service factor, which is the application’s required value over the rated value of the part. When thinking about shock load, conditions like non-uniform loads as well as hours of operation should be considered. If the gearbox can’t handle the load, it’s going to show wear earlier than expected. So make sure the gearbox is equipped to handle the appropriate load.

Mounting: Along with size and capability, it’s also important to consider how the gearbox will be mounted. There are several options for mounting, including mounting feet or tapped holes on the sides of the unit. The housing style, or mounting options, can affect how a gearbox functions or what kind of additional parts are required. Mounting is important to consider because there could be multiple mounting options for one gearbox so you need to ensure you choose a gearbox that can adhere to your mounting needs.

Motor integration: And lastly, it’s crucial to consider how the gearbox will be integrated with the motor. Some manufacturers provide services that integrate a motor onto the gearbox before shipping. But if this is not the case, it’s important to know the specifications and calculations that are needed to ensure the gearbox and motor will fit together. This is especially important when following a gearbox rebuild guide or performing any sort of industrial gearbox repair services. Overall, the chosen gearbox should integrate flawlessly with the motor.

Choosing a gearbox involves making a lot of important decisions. But if you keep these factors in mind and work with a reputable manufacturer, you’re sure to find the right gearbox for your needs.

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Gearbox Problems That Warrant Professional Repair Services

gearbox repair technicianAs a vehicle owner, you never want to experience a concerning smell, movement, or noise when driving your car. Of course, the same is true when dealing with heavy equipment and other types of industrial machinery.

Unfortunately, vehicles are not invincible, and you may find yourself with a gearbox problem. It’s important to know about common problems with gearboxes so you can spot them as they start to develop but before they lead to equipment failure. To minimize accidents, damage, and downtime, let’s take a look at a few common gearbox problems that definitely require prompt intervention.

Shaking movements: Is your vehicle shaking while you operate it? There might be a problem with your gearbox. If you are experiencing a shaking movement, even if it only occurs above a certain speed or operating threshold, it’s a good indicator that there may be something wrong with the gears. In general, your gear should never be shaking or making grinding noises; however, when manual gearboxes shift into gear, they often make grinding noises and shake slightly. Generally, shaking movements mean that you have damaged or worn gears or gear synchronizers. If this is the case, a gearbox repair technician is going to need to take a look at the vehicle. Fortunately, the right onsite machining services can resolve the problem in no time.

Misalignment: All vehicles are subject to misalignment problems, and it is a very common problem with industrial gearboxes. Misalignment is often found in gear and bearing pitting and can lead to the gearbox failing completely. There could be several causes of misalignment, including improper installation, deflection problems, and thermal expansion. Additionally, if the wrong gearbox is installed or gearbox repair services are done incorrectly, misalignment can occur. If you need a new gearbox, you won’t have trouble getting one. In 2010 alone the U.S. exported about $42.7 billion worth of industrial machines, so any gearbox or machines you need to fix your equipment will be available.

Burning smell: It’s safe to say that your vehicle or industrial machine should never produce a burning smell. So when it does, that’s a surefire sign that something is wrong. Oftentimes, a burning smell is the result of overheating transmission fluid. And because transmission fluid is responsible for keeping parts cooled and lubricated, overheating transmission fluid is a serious problem. Overheating fluid can lead to increased friction, corrosive activity, and a build up of debris within the gearbox. This is why it’s important to have a gearbox repair technician take a look at the vehicle before the gearbox breaks down completely.

Knowing something is wrong with your vehicle can be really frustrating. But it’s important to have a gearbox repair technician take a look at your vehicle sooner rather than later to prevent the problem from worsening.

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Gearbox Not Working? Here Are the Best Qualities to Look for in a Technician

If your gearbox isn’t working like it should, there could be any number of problems — calling a gearbox repair technician is the best way to ensure your materigearbox repair technicianals are fixed properly. If you’re looking to hire a gearbox repair technician, consider these factors when you’re picking your team.

Expertise

While you might be able to skimp on quality in some aspects of your life, relying on a professional gearbox repair technician is a necessity. Because you’re working with industrial gearboxes and professional-grade, often dangerous equipment, you don’t want to be liable for anyone’s injuries and you want to make sure the job is done right. Onsite machining is a difficult process and it takes an experienced technician to perform repair and renewal for your gearbox.

Your gearbox may exhibit common symptoms of a larger issue, such as excessive noise, intense vibration, fluid leaks, or contaminants in your oils — if there is a combination of issues, or another problematic symptom occurring, hiring a specialist is mandatory.

Fair Price

While a highly experienced gearbox repair technician is necessary for your gearbox rebuild, many are able to do it for a cheaper price than their competitors. A good technician will give you a quote, whether it be for a renewal or rebuild. Regardless, the process should always start with a “Not to Exceed” quote that gives you a baseline price that cannot be exceeded. However, after the initial assessment, you may have the ability to request additional services to ensure your gearbox is working at peak condition.

Reliability

Don’t be afraid to look at online reviews regarding automatic gearbox repair technicians. Getting your gearbox repaired can be a costly venture, and proper diagnosis and treatment of the issue are essential. Look for technicians who deal with your issues specifically, or find a technician in your area who works on your specialty part. You should always trust your gut when you’re making this kind of decision. Never be afraid to explore all your options if you feel like you’re being swindled or want a second opinion.

While buying your own gearbox rebuild kits might save you a few dollars and work wonders for predictive maintenance, hiring an experienced professional is the only way to ensure your gearbox will work efficiently and effectively.

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Everything You Need to Know About Worm Gearboxes

gearbox repair technicianIndustrial gearboxes are used all around the world in a variety of applications. There are actually multiple different types of industrial gearboxes that serve different purposes. One common type of industrial gearbox is a worm gearbox. This article is going to explore a few main points that should be known about worm gearboxes.

Like other gearboxes, the worm gearbox is named after the components of the box itself. The worm gearbox contains the worm gear — this gear can transmit power at 90° and as well as in places that require high reductions. The individual parts of the worm gear, the worm screw and worm wheel, work together to allow the gearbox to function properly. This design allows for complete control over the direction and speed of the rotation as well as allowing for a higher torque transmission. The worm shaft can be single- or multiple-threaded depending on the use of the gearbox.

There are many benefits that worm gearboxes can offer. For starters, because they have a low output speed, they run fairly quietly. Additionally, they are relatively small and take up minimal space. And at high transmission ratios, these gearboxes are self-locking.

Because worm gearboxes offer so many benefits, they can be found in a variety of applications. This type of gearbox is commonly used in conveyors, small machinery, and even packaging equipment. This compact size comes in handy when designs have limited space for gearboxes. Additionally, the worm gearbox’s non-reversing application makes it ideal in situations that need to prevent equipment from moving backward, like in the operation of gates and conveyor belts. If a system needs to operate in a way that allows equipment to move in two directions, two worm gearboxes can be used: each direction is controlled by one gearbox.

Because worm gearboxes are commonly used with higher grade materials, like steel, it’s important to find a gearbox repair technician who can specialize in worm gearbox repair services.

Gearbox repair and renewal needs to be done accurately and efficiently in order to ensure the gearbox remains in perfect working condition. So if you have a worm gearbox in need or repair or renewal, make sure you find a gearbox repair technician with the necessary knowledge and skills to get the job done right.

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What Is Vibration Analysis and Why Is it Important?

vibration analysisWhen it comes to evaluating the condition of industrial gearboxes, predictive maintenance is key. One method that allows people to avoid problems with their gearboxes is vibration analysis. Vibration maintenance can help users avoid failures and unplanned downtime, reducing costs. But what exactly is vibration analysis? This article is going to provide a brief overview of this gearbox maintenance method.

This process looks for abnormalities and changes in a system. To do this, various vibrations with specified amplitudes, frequencies, and intensities are used to put industrial gearboxes to the test. In doing this, the test can reveal and detect any developing problems and ensure repairs are done correctly.

Before this analysis is done, a baseline must be established. A baseline vibration spectrum is important to be able to identify any abnormalities. It also allows users to tell the differences between normal vibrations that have no effect on the performance of the machinery and dangerous vibrations causing stress to key components.

After a baseline has been established, vibration analyzers will be used to display the vibration spectrum. Today’s processes allow for three axes, vertical, horizontal, and axial, to be shown at the same time, allowing users to see exactly what’s going on in their machinery. It’s important to gather data from all three axes to gather comprehensive data. With data from just one axis, users may not get an accurate reading of the entire machine. If this occurs, a problem could still remain undetected and lead to failure down the line.

Basic principles of predictive maintenance vibration analysis can be applied to a variety of gearbox repair services. During the analysis process, users should watch for high-frequency peaks and match them to the expected frequencies. In doing this, users will be able to determine if a problem is present. This analysis process is crucial in catching problems before they become serious. If problems are detected as soon as they begin, users can reduce downtime needed for repairs as well as significant failures that could lead to even more downtime and expenses.

With machinery manufacturing shipments totaling 7.1%, or $407.4 billion, of all manufacturing shipments as of 2012 , gearbox repair specialists are well experienced in this analysis process. If you’re experiencing any sort of problems with your gearbox, or are looking to avoid problems in the first place, vibration analysis is key. With this process, you’ll be able to detect problems, evaluate performance, and overall ensure your gearbox is in the best shape possible.

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Does a Low Speed Engine Need a Gearbox? (Probably Not)

gearbox repair servicesIt probably isn’t news to anyone that a boat and a car aren’t built the same way. There are many aspects of both that differ greatly from each other, while there are some that are very similar. In a boat, the need for a gearbox comes only when the speed capability of the engine exceeds the speed of the propeller and there needs to be a reduction in revolutions. So which speeds need a gear box?

Low Speed Engines
These engines typically do not need a gearbox because the engine and propeller rotate at a matched speed. In most cases, a propeller shaft connects the propeller to the flywheel with a damper shaft to reduce vibration. There are bearings as well to help keep consistent alignment as well.

Medium to High Speed Engines
Engines with speeds that exceed the rotation speed of the propeller will need to have a gearbox to ensure speeds are matched. The gearbox reduced the rotation speed of the final drive to a speed that the propeller can keep up with. In single engine layouts, the gearbox is usually installed between the engine and the propeller. For multiple engine layouts, things can get a little bit more complicated because the gearbox will need to register inputs from both sources. Adding a gearbox however will increase vibration so dampers are commonly used to help reduce this effect. Gearbox repair services can provide vibration analysis to find a more effective solution if necessary.

Gearboxes are usually supplied by the engine maker but many independent gearbox makers will provide products that may be better suited by customers who request them. There are times, however, in which a gearbox will be in need of repair or renewal and gearbox repair services should be used. Many gearbox makers will provide gearbox repair and renewal services and onsite machining. Gearbox repair services should also be asked if shaft ad bearing replacements are also possible. Four of the most common signs that a gearbox is in need of attention are too much noise, excessive vibration (especially if dampers are being used), leaks from anywhere, and oil contamination. These signs can be indicative of bad seals, electrical fluting, or bearing failure and should be looked at quickly to avoid further damage.

Whether in a car or in a boat — you’ll probably find a gearbox. There might be slight differences but both types should have routine inspections and repairs. Nothing is worse than a fast car or a nice boat that you can’t drive.

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What Happens During a Gearbox Inspection?

onsite machining servicesThe gearbox is one of the most important parts of your vehicle. Without it, you can’t drive your car. So when something starts to go wrong, it’s important to get your gearbox inspected quickly and efficiently. This article is going to provide a brief overview of what happens during a gearbox inspection.

First, let’s discuss a few signs that your car is telling you that you should get your gearbox inspected.

  1. Dragging clutch: If there’s a grinding noise when you’re trying to shift gear, it’s probably because the still-engaged clutch is failing to disengage and is still spinning with the engine. Luckily, this is generally an inexpensive issue to get fixed.
  2. Slipping gears: Your car should be staying in the gear that you put it in until a change is made. If your car is randomly popping out of gear, get your gearbox looked at right away.
  3. Leaking fluids: Fluid is crucial to a properly functioning gearbox, so even if there is a slight leak it’s important to get it taken care of quickly.
  4. “Check engine” light is on: This is one of the easiest ways to tell when you need to take your vehicle in for inspection – your vehicle is telling you to do so! Your “check engine” light may come on for a variety of reasons, so the mechanic will need to utilize onsite machining services and run a diagnostics test to see what code is showing.

So if you are experiencing one of the problems previously discussed or any other problems with your gearbox, it’s time to take your vehicle in for inspection. When you take your vehicle in for gearbox inspection, it’s a fairly simple process. This process is made easy by onsite machining services. Without the technology mechanics have today, it would take much longer to figure out why something isn’t working properly. With machinery manufacturing shipments totaling $407.4 billion in 2012, the amount of mechanical machines in auto shops has only increased since.

Gearbox repair or inspection will begin with paperwork like most vehicle services do. It’s important to fill out any necessary paperwork to ensure you’re paying for the onsite machining services you need and nothing else. Additionally, it’s important to know the mechanic’s gearbox repair cost and policy on tune-ups and re-inspections if needed.

When it’s time to start the inspection, the gearbox first needs to be cleaned. Like most car parts, your gearbox gets dirty with use so it’s important that it is properly cleaned. Additionally, you should ensure that the area the gearbox inspection is going to take place is clean as well. If the gearbox or surrounding area is dirty, there is a chance something important could be missed during the inspection.

And finally, the gearbox is thoroughly inspected by an experienced mechanic. The mechanic will look for signs of corrosion, overheating, oil leaks, and other damages. The foundation fasteners and the cover fasteners of the gearbox will be checked for signs of tightness. Additionally, the input and output shafts will be checked for leaks. Overall, the entire part will be checked for signs of cracking or damage. Any damage that is found will be fixed accordingly.

When looking for someone to conduct your gearbox repair services, it’s important to choose carefully. The gearbox is a vital part of your vehicle and you should ensure you trust only a qualified, experienced technician to do necessary repairs.

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FAQ About Gearbox Repair and Rebuild Services

gearbox repair servicesWhen it comes to gearbox repair and rebuild services, there are a lot of factors that determine the needs of each specific gearbox. However, there are some common factors that many people still have confusion about. To address any questions or concerns you may have regarding gearbox repair services or gearbox rebuilds, we’ve compiled a list of the most commonly asked questions and their answers.

What is usually included in gearbox rebuild services?

An industrial gearbox rebuild involves disassembly, inspecting for the cause of the failure, and cleaning for reassembly. Any parts that are found to be damaged or worn past the acceptable level are replaced and the gearbox is then reassembled. The main goal of gearbox repair services or a complete gearbox rebuild is to identify the root cause of the gearbox failure and address the problem.

What causes gearbox failure?

Unfortunately, there are many causes of gearbox issues and failure. However, overheating is considered one of the main causes as a result of the engine’s cooling system not being fully functional. But no matter the cause, it’s important to be aware of some common warning signs of issues with a gearbox. Warning signs may include excessive noise, oil contamination, fluid leaks, or vibration. These may be a result of leaky seals, electrical fluting, or bearing failure.

What determines the cost of gearbox repair services?

The price of a gearbox repair or rebuild may vary by a couple hundred dollars depending on the shop that is completing the job. Furthermore, the gearbox repair cost will depend on the abilities and skill level of the shop technicians. Additional factors that may impact price could include the type of vehicle as well as any internal hard part damage. However, it’s important to remember that you get what you pay for. This means if you want high-quality service, you may end up paying a little more.

What is the timeframe of a gearbox rebuild?

Your mechanic should be able to give you an average time range for the specific gearbox rebuild you need. However, the average time is only a few days. It’s important to be patient with your gearbox rebuild because there are a lot of necessary steps that need to be taken in order to ensure the rebuild is done correctly. Furthermore, if unforeseen issues arise during the rebuilding process, that may impact the timeframe of your gearbox rebuild.

With now knowing the answers to these questions, you should hopefully feel more confident about investing in gearbox repair or rebuild services. However, it’s important to find a reputable company to complete the job and answer any additional questions you may have.

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A Short Guide to the Long History of the Gear

industrial gearbox repairsOver the last century and beyond, the machining industry has been one of the most important sectors across the globe. In the U.S., machinery manufacturing shipments totaled roughly $407.4 billion in 2012 — and that’s only 7.1% of all the manufacturing shipments that year.

One aspect of this historic industry that often goes unnoticed is the gear.

While the wheel is normally cited as the most important invention in human history, a strong case could be made for the gear. This simple device allows for the building of incredibly complex machines, and this component is at the heart of the world’s most complex machines. From industrial gearbox repairs to keeping machines running efficiently, gears are essential and should be appreciated much more.

Gears have been an integral part of industry success for much longer than just 100 years. In fact, the Antikythera mechanism is estimated to have been created around the late second century BC.

The Antikythera mechanism is ancient Greece’s version of the gear, an analogue computer used to predict astronomical positions and eclipses for astrological and calendar purposes. It was also used to track the ancient Olympic Games throughout each four-year cycle.

The ancient artifact was discovered in 1902 by Valerios Stais, an archaeologist, among wreckage from a wreck off the coast of the Greek island Antikythera. It contained gears and other components, but one gear attached to the device is approximately 5.5 inches and held 223 teeth.

Famous Greek philosopher and scientist Aristotle provided the world with the earliest description of the gear. He wrote that the “direction of rotation is reversed when one gear wheel drives another gear wheel.” That description might seem simplistic now, but 2,400 ago, it was quite revolutionary.

Today, without industrial gearbox repairs and complicated machine intricacies, manufacturing companies wouldn’t be able to succeed. But the gear is still an important part of today’s industrial success and the history of the world.

If you want to learn more about these simple, yet complex historic devices, contact a professional company that is knowledgeable about industrial gearbox repairs and can provide you with a quality gearbox rebuild guide. Visit Northern Engineering today.

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