IE A008SERIES OF TWO REPORTS · TREATMENT APRIL–JUNE 2005
Dryer group gearboxes: thicker teeth, lower vibration and current — on both units
Teeth of loaded gears grew in thickness, the drive became quieter and lighter on current. 0.05–0.15 mm — tooth thickness of the gear drives of both gearboxes; 4.5–9 % — drive power consumption at no load, 1.12 → 1.07 and 1.56 → 1.42 kW; 16–35 % — vibration velocity at the bearing housings, 2.8–7.5 → 2.3–6.2 mm/s (2005).
by “DONETSK - VTORMA” LLC
What recurred on both gearboxes
| OBJECT | CONDITION BEFORE TREATMENT | RUN TIME TO RE-MEASUREMENT | WHAT WAS MEASURED |
|---|---|---|---|
| Drive gearbox of dryer group No. 5 | Scratches along the teeth of all wheels; on the stage I pinion shaft — dents up to 1.5 mm across and up to 0.4 mm deep | 695 h | Tooth thickness, drive current and power, noise, vibration of the bearing housings |
| Drive gearbox of dryer group No. 6 | Corrosion spots on the stage I teeth; the other working surfaces without visible damage | 704 h | Tooth thickness, drive current and power, noise, vibration of the bearing housings |
Tooth geometry — measured before treatment and after running time
| GEARBOX | GEAR DRIVE | BEFORE, mm | AFTER, mm | GROWTH, mm |
|---|---|---|---|---|
| No. 5 | Stage I, pinion shaft, shaft No. 1 (high speed) | 2.85–2.90 | 2.90–2.95 | 0.05–0.10 |
| No. 5 | Stage I, gear wheel, shaft No. 2 (high speed) | 3.15–3.20 | 3.20–3.25 | 0.05–0.10 |
| No. 5 | Stage I, pinion shaft, shaft No. 1 (low speed) | 3.00–3.05 | 3.05–3.10 | 0.05–0.10 |
| No. 5 | Stage I, gear wheel, shaft No. 2 (low speed) | 3.45–3.50 | 3.50–3.55 | 0.05–0.10 |
| No. 5 | Stage II, pinion shaft, shaft No. 2 | 4.55–4.60 | 4.65 | 0.05–0.10 |
| No. 5 | Stage II, gear wheel, shaft No. 3 | 4.45–4.50 | 4.55–4.60 | 0.10 |
| No. 6 | Stage II, pinion shaft, shaft No. 2 | 3.60–3.70 | 3.70–3.75 | 0.05–0.10 |
| No. 6 | Stage II, gear wheel, shaft No. 3 | 3.75–3.80 | 3.85–3.90 | 0.10–0.15 |
ShZN-18 gear tooth caliper, three teeth of each wheel at a constant height from the tip; for gearbox No. 6 the drives that ran under load are shown.
Drive power consumption and gearbox noise
| PARAMETER | GEARBOX No. 5 | GEARBOX No. 6 | CHANGE |
|---|---|---|---|
| Current draw, no load | 4.4 → 4.2 A | 6.0 → 5.5 A | −4.5 % / −8.3 % |
| Power consumption, no load | 1.12 → 1.07 kW | 1.56 → 1.42 kW | −4.5 % / −9.0 % |
| Noise level | 78.5 → 77.5 dB | 94 → 92 dB | −1.0 / −2.0 dB |
Standard ammeter and “ATK 2200” current clamps, “0024” sound level meter. The reports themselves state the drop in current and power as 4 % and 9 %.
Vibration velocity of the bearing housings, mm/s
| MEASURING POINT | GEARBOX No. 5 | GEARBOX No. 6 |
|---|---|---|
| pt. 1 — shaft No. 1 bearing housing on the motor side | 2.77–4.26 → 2.29–3.19 | 3.86–4.71 → 3.50–3.73 |
| pt. 2 — shaft No. 3 bearing housing on the dryer unit side | 3.19–4.41 → 2.49–2.62 | 4.21–7.51 → 2.91–3.86 |
| pt. 3 — shaft No. 2 bearing housing on the dryer unit side | 3.60–6.81 → 2.67–4.05 | 4.23–5.44 → 3.05–4.54 |
| pt. 4 — shaft No. 2 bearing housing on the motor side | 2.87–4.01 → 2.35–3.32 | 5.09–6.40 → 3.95–6.17 |
“SENDIG 911” vibrometer, three directions at each point — vertical, horizontal, axial; a reduction was recorded at all 24 points of both gearboxes.
Commission findings on both gearboxes
Current equivalent
- Revitalizant gel for gearboxesGearboxes · transmissions · gear drives
- Revitalizant gel for compressors and bearingsCompressors · bearings · spindles
How such units are treated:
About this result:
Limits of this report: The results relate to two-stage gear reduction gearboxes of dryer unit drives treated with XADO revitalizants without disassembly under working operating conditions; on other units and duty modes the figures may differ. Representatives of the XADO Holding Company took part in the measurements together with the plant’s specialists.