|
|
| Wheel drive life increased by 500%
|
||
The drives utilize highly-loaded, two-stage planetary gearboxes. To manufacture them to the required specs would require special equipment and expertise. Hearing such facilities were available at The Gear Works, Westar officials came for a visit. They found that we had the capability and agreed to give us a "try out" with an order for four of the boxes.
"Without so much as a prototype, we just went for it," says Manfred Chi, The Gear Works' Assistant to the President. But there is, of course, a lot more to the story.
We worked closely with Westar to determine their specific problems. For example, what were the failure modes and in what percentages did they occur? What were the needs in terms of wheel drive service, and what were the long term expectations? These and scores of other questions formed a "data base" that helped guide a successful rehabilitation program for Westar's fleet.
Next came a re-design of the gearing, based on better-quality material and higher accuracy in the manufacturing process. We brought the drives up to very close tolerances, providing accuracy similar to that found in helicopter gear sets. To assure the necessary quality of the finished product, special assembly procedures were implemented, along with a 16-hour test run on each wheel drive.
Knowing Westar's desire to eventually do the assembly work in-house, we provided training based on a teamwork concept that developed procedures based on ideas from both of us. "This involved a lot of customer contact, with a lot of travel back and forth," Chi notes, "and it paid off in outstanding results". Indeed, the record shows that the gear boxes' life expectancy increased steadily as the program developed.
They now average about 30,000 hours of service, or six times the original goal. That record is based on complete overhauls done by The Gear Works and gear sets provided to Westar for assembly over a ten-year period. We also worked with Westar to establish an ongoing stocking program, in which they issue purchase orders based on annual projections. As they determine
 their needs, we produce the necessary parts so there's a reliable and timely supply to keep the trucks rolling.
And what does Westar think of all this? "Well, after ten years of working
with The Gear Works, I have to say it's pretty obvious we're pleased with the job they do for us," says Director of Purchasing Greg McCormick. "The savings in time and money are something any business appreciates. The Gear Works is reliable, too,they respond to our needs in a
timely manner, and the quality is outstanding. And besides," McCormick
adds, "we've enjoyed a good, friendly working relationship with the people
there that has made the whole experience very satisfying."Next Pitch Lines Articles: Vol. 1 No. 2 Repairs that are better than new - Pulp Agitator Drive Vol.1 No. 3 Land Speed Record - Don Vesco's Turbinator III Vol.1 No. 4 Miss Budweiser - Miss Bud, this gear's for you!
A bimonthly publication dedicated to sharing solutions to gearing problems and tips on avoiding them in the first place. Your comments and suggestions are welcome - let us hear from you.
The Gear Works 500 S. Portland St. Seattle WA 98108 |
||
Folks in mining know that if you don't haul the goods, you don't stay in
business. That was precisely the problem facing Westar Mining at their metallurgical coal mine in Sparwood, British Columbia when their truck wheel drives failed to deliver satisfactory service.The company operates a fleet of 22 Lectra Haul 200-ton-carrying-capacity haulage trucks.Their problem was not being able to get at least 5,000 hours of operation from the wheel drives between overhauls. With trucks in the shop more often than planned, availability sank to about 50 percent, an unacceptable figure if production goals were to be met. Attempts were made to have the drives overhauled, but reliability remained elusive.