KTs-2-750 and KTs-1-500 gearboxes: teeth gained metal, drives run lighter

InGOK OJSC, crushing plant, site No. 2 · approved by the chief mechanical engineer of the works, G. N. Panisko · report signed by six managers of the works, the plant and the contractor

Ukraine · treatment 19–21.07.2000 · repeat measurements after more than 450 h of operation · report dated 02.09.2000

TREATMENTXADO revitalizationcarried out by specialists of XADO LLC (Kharkiv) and Krivbassrudprom CJSC on 19–21 July 2000

TEST OBJECTConveyor drive gearboxesKTs-2-750 (three stages) and KTs-1-500 (two stages), site No. 2 of the crushing plant

DOCUMENT TYPEWorks report
dated 02.09.2000bearing the “Approved” endorsement of the chief mechanical engineer of InGOK OJSC

Key results

↑6.1-17.4%

tooth thickness, KTs-2-750, 9.2-16.3 → 10.8-17.3 mm

↑1.8-5.3%

tooth thickness, KTs-1-500, 14.6-19.2 → 15.2-20.07 mm

↓13.2%

no-load current of the KTs-1-500 drive, 76 → 66 A

GEARBOX	CONDITION BEFORE TREATMENT	WHAT WAS MEASURED
KTs-2-750<br/>three stages	Pitting over 70–85% of the working tooth surfaces, tooth wear from 20% to 70% and above	Tooth thickness at each stage, no-load current of the drive
KTs-1-500<br/>two stages	Same condition; there was no hard layer on the working surface — it was cut away by a new smooth-cut file	Tooth thickness at each stage, no-load current of the drive

KTs-2-750 gearbox — tooth thickness by stage

STAGE AND GEAR	BEFORE, MM	AFTER, MM	GAIN, MM
Stage I, bevel gear wheel	9.2	10.8	1.6
Stage II, cylindrical gear wheel	13.03	13.85	0.82
Stage III, cylindrical gear wheel	16.3	17.3	1.0

Tooth thickness increased at all three stages: metal built up on the working surface instead of wearing off it.

KTs-1-500 gearbox — tooth thickness by stage

STAGE AND GEAR	BEFORE, MM	AFTER, MM	GAIN, MM
Stage I, bevel pinion	14.6	15.2	0.6
Stage I, bevel gear wheel	17.1	17.4	0.3
Stage II, central gear wheel	19.05	20.06	1.01
Stage II, far right gear wheel	19.2	20.07	0.87

The gain was obtained on both the bevel and the cylindrical gears of a single gearbox — the layer builds up where the load is carried.

Drive current draw at no load

GEARBOX	BEFORE TREATMENT, A	AFTER, A	REDUCTION, A
KTs-1-500	76	66	10
KTs-2-750	26	24	2

The current was measured with the drive running at no load — this is the direct friction loss in the gearing; the reduction was recorded on both gearboxes.

Recorded in the report

Before the work began, the working surfaces of the teeth were covered with pitting over 70–85% of their area, with tooth wear from 20% to 70% and above, and there was no hard layer on them — the surface was easily cut by a new smooth-cut file. After more than 450 hours of operation the commission of the works recorded: “the working surface of the teeth of the mating parts has taken on the appearance of a smooth ground surface, i.e. the pits have disappeared. A durable metal-ceramic layer has formed on the working surface in the contact zone, which cannot be cut by a new smooth-cut file”. The measurements confirm this: tooth thickness increased at every stage of both gearboxes, and the no-load current of the drives fell. Worn gears gained metal and turned more easily, remaining in service on the plant's conveyors.

The results relate to the KTs-2-750 and KTs-1-500 conveyor drive gearboxes at the crushing plant of InGOK OJSC at the stated degree of gear wear; on other equipment and with a different condition of the units the figures may differ. The original report dated 02.09.2000 is published in full and available for download.

Current equivalent

Revitalizant gel for gearboxes →

Industrial gearboxes, final and central drives, truck and tractor gearboxes, open gear and chain drives.

How such units are treated: Reduction gearbox Gear drive

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