Open Gear and Chain Drives
Open gear and chain drives lubricated with grease or with metered oil lubrication are subject to treatment. The purpose is restorative repair and protection of the working surfaces of teeth, sprockets and chains against wear without shutdown for repair.
Units covered by the method
11Method
What is treated
- Open gear and chain drives with a degree of wear of less than 100% that have no damaged or deformed parts (cl. 11.1).
- Drives lubricated both with grease and with metered oil lubrication (cl. 11.1).
- New open gear and chain drives, or those worn by up to 10%, lubricated with oil — as per cl. 11.5 with the oil volume calculated for 300 hours of total operating time.
When treatment is not performed
- Drives with a degree of wear of 100% or more are not subject to treatment.
- Drives with damaged or deformed parts are not subject to treatment.
Preparation
- Before starting the treatment, take measurements of the main operating parameters of the drive and of the geometric dimensions of the parts (cl. 11.2).
- In a separate vessel (container), prepare the volume of oil required to lubricate the gear or chain drive for 500 hours of total operating time (cl. 11.3.1).
- Heat the oil to a temperature of 40 - 60°C (cl. 11.3.2).
- Add the calculated amount of gel and mix the components thoroughly until completely dissolved (cl. 11.3.2).
What is measured before and after
| Parameter | Instrument | How and when |
|---|---|---|
| Vibration level of the bearing supports: vibration acceleration, vibration velocity, vibration displacement | Vibration meters of various types | At fixed points on the housing of the bearing assembly in the vertical, horizontal and axial direction of each bearing support; before the start and after completion of the full treatment cycle |
| Noise level | Sound level meters of various types | At specified locations at a fixed distance from the source of maximum noise, with no extraneous noise sources present; before the start and after completion of the full treatment cycle |
| Tooth thickness of gears and sprockets | Gear tooth calipers of any type with a graduation value no coarser than 0.05 mm | See appendix 3 of these instructions; before the start and after completion of the full treatment cycle |
| Outside diameters of the working surfaces of chain rollers or bushings | Micrometers or indicating lever snap gauges with a graduation value no coarser than 0.01 mm | Before the start and after completion of the full treatment cycle |
What the reports on these components showed
- Increased electric power consumption20 cases · median 9 %, 31 values
- Loss of compression2 cases · median 12 %, 2 values
- Elevated vibration16 cases · median 57 %, 7 values
- Increased fuel consumption2 cases · median 12 %, 3 values
- Increased clearances and backlash32 cases · median 11 %, 18 values
- Elevated operating temperature4 cases · median 11 %, 1 value
- Oil pressure drop4 cases
Consolidated register of the evidence base →
Dosage rates
| Compound | Rate | How and when |
|---|---|---|
| XADO revitalizant gel for gearboxes (industrial) | 9.0 ml of gel per 1 litre of oil | Added to oil heated to 40 - 60°C, into the volume of oil calculated for 500 hours of total operating time of the drive (for new drives or those worn by up to 10% — for 300 hours) |
| XADO revitalizant gel for transmissions and gearboxes | — | For heavily worn gears, sprockets and chains it is permitted to apply the gel additionally, directly onto the worn working surfaces, in order to enhance the restoration effect (note 1); the consumption rate is not specified in the text |
Treatment stages
- Take measurements of vibration, noise, tooth thickness of gears and sprockets, and outside diameters of chain rollers or bushingsBefore the start of the treatment
- In a separate vessel (container), prepare the volume of oil required to lubricate the drive for 500 hours of total operating time500 hours of total operating time
- Into the oil heated to 40 - 60°C, add the gel at a rate of 9.0 ml per 1 litre of oil and mix thoroughly until completely dissolved
- Start the drive in operation, ensuring its lubrication with the prepared compound, and operate it in the normal process modeUntil the prepared compound is completely used up
- After the prepared compound has been completely used up, the treatment of the drive is finished; thereafter the standard oil without the XADO compound is used for lubrication
After treatment
- After completion of the full treatment cycle, repeat the measurements of the vibration level of the bearing supports, the noise level, the tooth thickness of gears and sprockets, and the outside diameters of the working surfaces of chain rollers or bushings — in order to determine the effectiveness of the use of XADO compounds.
- Thereafter, use standard oil without the XADO compound to lubricate the drive.
Points to watch
- For heavily worn gears, sprockets and chains it is permitted to apply XADO revitalizant gel for transmissions and gearboxes additionally, directly onto the worn working surfaces, in order to enhance the restoration effect.
Instruction appendices
Compounds for these units
- Revitalizant gel for gearboxesIndustrial gearboxes, final and central drives, truck and tractor gearboxes, open gear and chain drives.
Reports on this unit
- Zaporozhstal OJSC · 2013↑ 0.05-0.15mm — gearbox tooth thickness, 5.8 → 5.9 and 6.0 → 6.15 mm
- ArcelorMittal Kryvyi Rih · 2011↓ 2.8–3.1% — power drawn by the drive under load, 2578–2692 → 2506–2609 kW
- Tomakovskiy Expanded Clay Gravel Plant · 2007↑ 0.1-0.5mm — tooth thickness over the constant chord on all four gear rims of both gearboxes
- UKROLIIA LLC · 2007↑ 0.2-0.5mm — tooth thickness of stage I and II gear drives, 4.0–6.9 → 4.3–7.2 mm
- DONETSK - VTORMA LLC · 2005↑ 0.05-0.15mm — tooth thickness of the gear drives of both gearboxes
- Mini Maritsa-Iztok, Troyanovo-3 mine · 2004↑ 0.20mm — gear wheel tooth thickness, 12.50–19.00 → 12.70–19.20 mm
Source: Instructions for the use of XADO revitalizant gels IE-24.6-25612000-005-2008, pages 19–20.