Gearbox Assembly & Test Center
Friday, August 14th, 2009
The Gear Works is proud to announce the opening of its new 20,000 Sq. Ft. Gearbox Assembly and Test Center that will greatly enhance the Company’s gearbox rebuild and test capacity. Located adjacent to the manufacturing facility, the Gearbox Test Center is furnished with an extensive assortment of equipment that will efficiently facilitate the complete overhaul, assembly and testing of large gear drives.
The new TGW Gearbox Assembly and Test Center incorporates a wide assortment of material handling equipment including two 30,000 lb. overhead bridge cranes, two 10,000 lb. overhead bridge cranes, fifteen 2,000 lb. jib cranes, plus a fleet of fork lifts. The facility is segregated into six functional work areas: disassembly, special projects, clean area assembly, gearbox testing, lubrication storage & analysis, and the instrumentation & calibration room. Guest office suites and a conference center are also available.
Multiple workstations in the disassembly and assessment area provide for the simultaneous processing of many gearbox repair projects. Each incoming gearbox receives a through examination that documents the disposition of every major component. All rotating parts are checked for integrity by magnetic particle inspection. Housing bore alignments and gear tooth accuracies are routinely verified with the use of modern CNC inspection equipment.
Gearbox assembly projects are conducted in a clean environment by experienced technicians. All housings and components are thoroughly cleaned before entering the assembly area. All critical fits, bearing settings, and tooth contact patterns are checked and documented in a permanent repair record. All assembled units are then moved to the test area for spin testing under variable speeds.
A separate electrical service is dedicated to the operation of two regenerative gearbox test beds. The small test bed can provide continuous or incremental loads up to 150 HP at variable speeds up to 3000 RPM. The large test bed, currently under installation, will produce loads up to 2500 HP ( 1.8MW ) by means of electrical generation through back-to-back gearboxes. This load test capability will be one of the largest in the country. The facility includes a large assortment of data monitoring equipment that can collect, store and analyze multiple performance points such as torque, temperature, noise, vibration and oil particulates. Special gearbox test projects can also be conducted by means of a foursquare method where the load is applied by inducing torsional twist between the gearbox shaft connections as pictured above.
Our new Gearbox Assembly and Test Center is just another example of our mission to continually improve our products and services. Visitors to our facilities are always welcome. First class service for first class customers; it’s where we want to be.