INDUSTRIAL CASE|MINING|GEARBOXES · GEAR DRIVES
COMMISSION REPORT · TROYANOVO-3 MINE
KA218 bevel gearbox: metal built up on the teeth, drive load went down
PRODUCTXADO revitalizant gelfor transmissions and gearboxes · 3 stages of 2.330 kg at 8-hour intervals · 700 l oil bath
TREATED UNITBevel gearbox
KA218-1000 kW/1216-F2station T6 · pinion z=22, wheel z=99 · module 10.75 mm · 980/260 rpm
KA218-1000 kW/1216-F2station T6 · pinion z=22, wheel z=99 · module 10.75 mm · 980/260 rpm
DOCUMENT TYPECommission report
of the Troyanovo-3 minemeasurements before and after treatment in the presence of mine and May OOD representatives
of the Troyanovo-3 minemeasurements before and after treatment in the presence of mine and May OOD representatives
Key results
↑0.20mm
wheel tooth thickness in the wear zone, 12.50-19.00 → 12.70-19.20 mm
↓8.3%
drive motor current at no load, 36 → 33 A
| EQUIPMENT | CONDITION AND PARAMETERS BEFORE TREATMENT | WHAT WAS MEASURED |
|---|---|---|
| Bevel gearbox KA218-1000 kW/1216-F2, station T6 | Deliberately picked as the most worn unit: deep pitting on the wheel teeth, under load noisier than the three neighbouring gearboxes of the station | Tooth thickness with a gear tooth vernier caliper, condition of the working surfaces |
| Bevel gear pair and drive electric motor | Pinion z=22, wheel z=99, module 10.75 mm, 980 / 260 rpm; oil bath 700 l | Motor current at no load and under load |
Wheel tooth thickness — metal gain at every point of the wear zone
| TOOTH AREA | HEIGHT FROM TIP | BEFORE, mm | AFTER, mm | GAIN |
|---|---|---|---|---|
| 158 mm from the end face | 5 mm | 12.50-12.55 | 12.70-12.75 | +0.20 |
| 158 mm from the end face | 8 mm | 14.60-14.75 | 14.80-14.95 | +0.20 |
| 158 mm from the end face | 11 mm | 16.80-16.90 | 17.00-17.10 | +0.20 |
| 158 mm from the end face | 14 mm | 18.90-19.00 | 19.10-19.20 | +0.20 |
| 40 mm from the end face | 5-14 mm | 11.75-18.25 | 11.75-18.25 | no change |
Gear tooth vernier caliper, three marked teeth at each height. Metal built up on the section towards the smaller diameter — where the pitting was concentrated.
Pinion tooth thickness — measured 11 mm from the tip
| TOOTH | BEFORE, mm | AFTER, mm | GAIN |
|---|---|---|---|
| Tooth 1 | 17.10 | 17.50 | +0.40 |
| Tooth 2 | 17.10 | 17.30 | +0.20 |
| Tooth 3 | 17.15 | 17.70 | +0.55 |
Measured 158 mm from the tooth end face, on the same marked teeth before and after treatment.
Load on the drive electric motor
| MODE | BEFORE | AFTER | CHANGE |
|---|---|---|---|
| No load | 36 A | 33 A | −8.3 % |
| Rated load | 39-51 A | 36 A | below the previous range |
Current measured in both standard operating modes of the station, before and after treatment.
Condition of the working surfaces of the wheel teeth
| TOOTH AREA | 24.03.2004 — BEFORE | 26.05.2004 — AFTER |
|---|---|---|
| Middle part of the profile | Isolated pitting cavities 1-1.5 mm in diameter, 0.1-0.2 mm deep | Pitting cavities filled in, a visible layer of XADO metal-ceramics formed |
| Start of the tooth on the smaller-diameter side | Severe pitting damage, cavities up to 3-5 mm in the largest dimension, 2-3 mm deep | Partial filling of the pitting by the XADO layer |
| Operation under load | Noisier than the other three gearboxes of the station | Noise level dropped significantly |
Inspection and noise assessment by the mine commission after the gearbox top cover was removed, on 24.03 and 26.05.2004.
Commission conclusion
The gearbox was selected for treatment as the most worn unit at station T6: deep pitting on the wheel teeth, cavities up to 3-5 mm and 2-3 mm deep. Two months later the commission recorded, on the same teeth, filled cavities and a visible layer of XADO metal-ceramics.
Commission of the Troyanovo-3 mine: “Treatment by XADO technology of the KA218-1000kW gearbox of shut-off station T6, specially selected for this purpose because of its heavy wear, produced a positive result. Restoration of the bevel gear parts worn during operation led to a considerable improvement of the gearbox operating parameters: vibration and noise levels were reduced, the load on the electric motor decreased and the condition of the gearbox teeth and bearings improved. The results obtained give every reason to state that the use of XADO technology in heavily loaded machinery will significantly extend service life.”
Commission of the Troyanovo-3 mine: “Treatment by XADO technology of the KA218-1000kW gearbox of shut-off station T6, specially selected for this purpose because of its heavy wear, produced a positive result. Restoration of the bevel gear parts worn during operation led to a considerable improvement of the gearbox operating parameters: vibration and noise levels were reduced, the load on the electric motor decreased and the condition of the gearbox teeth and bearings improved. The results obtained give every reason to state that the use of XADO technology in heavily loaded machinery will significantly extend service life.”
The results relate to the KA218-1000 kW/1216-F2 bevel gearbox of station T6 at the Troyanovo-3 mine and to its operating conditions; on other equipment and in other modes the figures may differ. The original commission report is published in full and available for download.
Current equivalent
- Revitalizant gel for gearboxesGearboxes · transmissions · gear drives
- Revitalizant gel for compressors and bearingsCompressors · bearings · spindles
How such units are treated: