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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Impellers 101: Understanding the Importance of Impeller Design

gearbox repair and renewalWhen you’re thinking about gearbox repair and renewal, it’s important to understand all of the components surrounding the engine. The impeller design in your vehicle is a critical component of ensuring the efficiency and functionality of your vehicle.

What is an impeller?
Impellers are rotating devices that are designed to change the flow or pressure of liquids, gases, and vapors. They consist of various vanes, or blades, which are arranged around a central shaft. When the device rotates, it sucks in fluids or gases and forces them out the opposite side.

While impellers may seem very similar to propellers, they are used to move different types of objects. A propeller typically refers to a device that moves an object to which it is attached, like a propeller on a boat. On the other hand, impellers are designed to move the substance passing through it without moving the attached object.

Types of impeller designs
Since the impeller is a critical component of your vehicle, the design of the impeller is the most significant factor in determining performance of the car. There are three basic types of impellers:

  1. Open impeller: This impeller design has the vanes free on both sides. Because open impellers are structurally weak, they are generally used in small pumps.
  2. Semi-open impeller: This impeller design consists of free vanes on one side and enclosed vanes on the other. this design offers higher efficiency and strength. Because of this, they are often used in medium-diameter pumps.
  3. Closed impeller: In this impeller design, the vanes are located between the two discs and are usually used in large pumps.

Aside from the overall impeller design, there are also design options for the impeller blades. The blades can be backward-curved, radial, or forward curved. The design of the impeller and its blades is very important to understand, as the design can impact the functionality of your vehicle.

When considering industrial gearbox repair and renewal, it’s important to remember that your a gearbox is a huge factor in the overall functioning of a vehicle or machine. With that in mind, it’s important to look out for warning signs of gearbox problems like vibration, excessive noise, oil contamination, and fluid leaks. Typically, these may be a result of bearing failure, electrical fluting, or leaky seals, but you should always ask experiences gearbox repair specialists to determine the cause of any issues you may be experiencing.

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Should Your Rebuild or Replace Your Vehicle’s Gearbox?

gearbox rebuildThe transmission, or gearbox, is one of the most important parts in a vehicle. It changes the gear ratio, allowing the wheels to move at different levels and powers. A gearbox rebuild can restore a vehicle to its maximum operating function. Here are a few signs that could mean you need to repair or replace your transmission:

  • You can smell burning transmission fluid
  • Your transmission fluid is leaking
  • The check engine light comes on
  • Your vehicle is making strange noises
  • It’s difficult to shift or stay in gear

Rebuilding a transmission, or gearbox, can be an expensive task. But even though it may be expensive, it’s cheaper than buying an entirely new one. By catching the transmission problems early enough, you can give your vehicle a new life. If you’re on the fence about deciding to repair or replace your gearbox, consider these few benefits of transmission repairs.

With either a manual or automatic gearbox repair, you’ll have your vehicle back quicker. While a rebuild may only take a few days, getting a replacement usually takes at least a week.

As previously stated, a rebuild is going to save you money. Typically, the gearbox repair cost is about half of what a replacement would cost you. Rebuilds require less materials and time, reducing the cost significantly.

A gearbox rebuild is also more environmentally friendly than a replacement. A rebuild requires fixing what you have, while a replacement requires getting rid of the total old gearbox. Recycling gearbox parts reduces the wasting of undamaged parts. With 90% recycled content, steel is the most recycled material in the world. You’ll also reduce the usage of natural resources that would have to be used to create the new parts.

A damaged transmission can cause your vehicle to not run properly, making it unsafe. An industrial gear drives repair and renewal will:

  • Give you better control of your drive wheels
  • Give you back usage of any gears you were unable to use before
  • Stop leaking transmission fluid
  • Allow for easier shifting into gears

It’s also important to consider the quality of a gearbox rebuild. During a rebuild, each part is removed and inspected for possible damage. It is then easy to replace unreliable parts. With a replacement transmission, there’s no way to really tell the quality of each and every part.

In knowing all of these benefits of a gearbox rebuild, you will be able to make an informed decision about whether to replace or repair your transmission.

 

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4 Huge Benefits of Onsite Machining

onsite machiningIt can only take a small mechanical issue to cause a large problem for your business, especially if your machinery is on the larger end of the spectrum. With onsite machining services, you are able to correct your problems quickly and economically.

In this post, we will dig into some of the many ways onsite machining can help your business recover after a mechanical failure.

Onsite Analytical Assessment Capability
If you are operating a large ship, tractor, or other major machinery, it can be difficult to pinpoint the exact cause of the problem. While in the cases of some medium sized machinery it might be conceivable to ship the whole apparatus to a mechanic, it is not a practical way to approach the problem.

With onsite machining services, you are able to have an expert visit your site in person in order to perform diagnostics like predictive maintenance vibration analysis and see what sort of system repair and renewals are required.

Fewer Logistical Complications
Even if you can identify the cause of you mechanical problems and are able to isolate them, it can still be a headache to try to ship the equipment to be repaired. With onsite machining, you can have a technician repair the issues on the premises, saving you the trouble of shipping.

No Expensive Shipping Costs
Did you know that machinery manufacturing shipments cost a total of $407.4 in the year 2012 alone? It shouldn’t be hard to understand why. Afterall, it takes a lot of power to haul big pieces of machinery from one location to another. With onsite machining, you are able to avoid this costly process by having the mechanic come directly to you.

Faster Turnaround
One of the best benefits of onsite machining is that once the equipment has been repaired, you can immediately resume running your machine. This will help you avoid downtime that can be devastating to your business’s bottom line.

For a lot of industries, onsite machining services are hugely beneficial. It can save you both time and money and better enable you to recover after a mechanical failure.

If you would like to learn more about onsite machining, contact Northern Engineering today.

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3 Important Standards Your Gearbox Should Meet

gearbox repairTo the non-mechanic, just the word gearbox can be mind boggling. Even for the professionals, these sophisticated pieces of machinery require a great deal of understanding, care, and expertise to successfully install or repair. If you’re not accustomed to dealing with these devices, it can be hard to understand the amount of work involved in your gearbox repair and renewal or even your gearbox in general.

In the past, we have offered explanations of what a gearbox is, and the common warning signs that there might be an issue (excessive noise, vibration, fluid leaks, and oil contamination). In this blog, we will help you understand what standards you should be looking for when determining the success and value of a gearbox.

  1. Minimal Energy Use
    Your gearbox is the primary instrument for converting torque, therefore it makes sense that you would want your gearbox to be as efficient as possible. In order to reduce power waste, you will need a gearbox with minimal friction, reducing the amount of heat generated and the number of secondary units and cooling mechanisms needed to mitigate it.
  2. Low Maintenance Costs
    What good is a tool that you need to pay to get fixed every few weeks? A good gearbox will need to be built in a way that reduces wear and tear to a minimum, which again means a reduction of the friction inside the gearbox.
  3. Compact Size
    You might have noticed the way to improve the past two standards was to reduce friction. This is where things get trickier. You can keep friction to a minimal level with a gearbox that is spacious, but a large gearbox means less space for other important components. It then becomes important to have a gearbox that has low friction and is compact so that it doesn’t burden the total machine.

Even for people with a good understanding of how a machine works, understanding each specific piece can be difficult. Hopefully, this guide has imparted a better understanding of what a gearbox should offer.

Northern Engineering is an industry leader for engine heads and valves repair and renewal, industrial gearbox repair and renewal, and analytical assessment and test of mechanical equipment. If you have any questions, contact us today.

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3 Common and Easily Preventable Causes of Machinery Issues

analytical assessment and test of mechanical equipmentMachines are a huge part of the American landscape: they help us work our fields, mine the earth for its valuable resources, and fly through the sky and sail over the ocean. The United States produces so many machines that in 2010 we exported approximately $42.7 worth of industrial machines around the world.

But for all they do to ease the burdens and trials of modern life, they are hardly infallible: machines break down. Industrial gearbox repairs, and conveying and propulsion systems repair and renewals, are a part of life for anyone who works with heavy machinery.

In the past, we’ve talked about common problems and symptoms faced by various types of machinery and equipment, as well as the analytical assessment and test of mechanical equipment needed to repair them. This time, we are going to dig into some of the more common, and preventable, causes of such problems.

  1. Not Reading the Manual

    While this may be common sense, a surprising amount of machinery breakdowns occur because the operator neglected to read the manual. While it might be tempting to gloss over the information in a manual and assume that operation is, more or less, the same as previous equipment, it is imperative that you take the time to read the manual.

  2. Improper Maintenance

    Whether it is because you are skipping a regularly required step, like cleaning out certain functions or not monitoring components closely enough, this is again directly preventable by practicing more thorough machine care. And while it might feel taxing to spend the extra time taking care of your machinery, the rewards, in the long run, will be more than worth the effort.

  3. Overreaching the Capability

    Put simply, just because a piece of machinery can run at a certain level does not mean that you should always run it at the extreme of its performance capability. While it might help you finish your immediate job more quickly, it can also cause significant wear and tear on your machinery.

If you find yourself constantly running into the same types of problems with your machinery, consider having an outside company run an analytical assessment and test of mechanical equipment in order to determine whether or not your issues are the result of a simple and preventable cause.

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4 Applications of Worm Gears: What You Should Know

gearbox repairA gearbox or transition an invaluable piece of equipment in a wide range of machinery. Trucks, boats, elevators, forklifts, conveyors, cars — anything that relies on torque to produce its energy will need a gearbox. That’s because the gear box is the mechanism in which torque, the force generated by rotation, is converted into electrical energy.

Among the many different types of industrial gearboxes, one of the most common types is the Worm gear. The average worm gear has two parts, a steel worm gear and a bronze worm wheel that cross in space. They are used at 90-degree angle and where you need low energy consumption, or high reduction.

Because of its unique design, worm gears have a very specific type of use. Here are some of the most common utilizations.

  1. When Stopping Fast Is a Priority: Since back driving is nearly impossible with the worm gear, they have become a popular tool for devices where stopping needs to be done quickly and assuredly. Typical examples would be elevators and lifts.
  2. When Too Much Noise is a Problem: The two different materials in the worm gear can greatly reduce the noise pollution from your gearbox, making it perfect for spaces where noise would be distracting — or worse, cause panic. Theatres, airports, and again elevators stand out as beneficiaries of this perk.
  3. When Space is a Concern: It’s not only majestic ships sailing through the ocean blue or trucks barreling down a deserted highway who benefit from a gear. Many machines that need to use torque must do so in confined spaces. The unique shape of the worm gear allows a greater flexibility and versatility for engineers. Packaging equipment, conveyors, and generally all small machinery will benefit here.
  4. Where Shock Loading is a Reality: Again the worm gear benefits from its uniquely different materials. The softer metals can more easily absorb the energy of sudden shock with less damage. This is particularly useful to rock crushers and heavy duty machines.

Whether you are looking to increase the speed of your convey belt or trying to find a quiet solution to your machinery needs, the worm gear has a number of advantages that might make it the right tool for your job.

Whether you are looking for shaft and bearing replacement, on site machining services, gearbox repair, or vibration analysis services, the industrial gearbox repair professionals at Northern Engineering are here to meet your needs.

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What Exactly Is A Gearbox

industrial gear drives repair and renewalIf you aren’t a mechanic, it can difficult to understand the multitudinous problems that affect your machinery. Whether you need a gearbox rebuild or industrial gear drives repair and renewal, it can be overwhelming for anyone without a concrete understanding. Let’s take a minute to explain it in broad strokes.

What exactly is a gearbox?

Gearbox is another word for transmission. Its primary function is to convert the energy generated by the engine into toque, or a force of rotation. While there are a wide range of variations on the industrial gearbox, at its most basic, a gear box consists of three types of components: shafts, gears, and bearings.

  1. Shafts

    The most important components are the shafts. The input shaft is connected to the engine and takes the force into the gearbox. That energy is then passed through the lay shaft, either in full or at a reduced rate depending on the gears (more on that in a minute), and outputted by way of the main shaft to the propeller shaft.

  2. Gears

    The gears help optimize the amount of torque, increasing or decreasing relative to input energy based on the desired effect. When starting to accelerate, a car will need much more torque in order build momentum. Once momentum has been built, however, a great deal less torque is required to maintain speed. The utilization of torque is a function of the ratio between the gears of the main shaft and the lay shaft.

  3. Bearings

    The bearings are designed to reduce the friction of the shafts, preventing overheating and wear and tear inside the gearbox. While these bearings are built to withstand a great deal of pressure, it is important not to take them for granted. Unless properly lubricated, these bearings will break down and possibly cause some serious damage to your gearbox.

When Might Something Be Wrong

The biggest clues that your gearbox may be in need of repair are excess noise, fluid leaking, oil contamination, or vibration. If you experience these problems, see a professional; you could experience anything from leaky seals, electric fluting or even bearing failure.

Hopefully, this little guide will help you understand this staple of modern engineering and will give you a little more comfort the next time you need an industrial gearbox repair or industrial gear drives repair and renewal.

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