Installation Tips for Gears
There is no doubt that for a gear unit's successful performance the most
vital factor is the proper installation practices. Let's see what are the
important parameters in the successful installation of gears.
Parameters for Installing Gears
- A rigid and level foundation
- Properly aligned shafts
- Proper installation of accessories
- Adding of required grade and quality lubricants
- Special instructions if any is carefully followed.
Foundation
The gear unit must have a level and secured base for operating. There
should be horizontal mounting of the base. This should be the case unless
other wise specified like designs for mounting in a tilted position. There
need to be a precise and accurate levelling of the base. It should be kept
in mind that only tilting by a few degrees can have an adverse effect on the
lubrication efficiency. If a gear unit needs to be mounted in a position
that is unlike the initial design, then changes are required for providing a
proper lubrication.
Gear units generally comprises of a drain plug in the base for the purposes
of oil drainage. The units need to be mounted above the floor level. For a
convenient drainage in place of drain plugs a valve or pipe extensions can
be used. For mounting a gear unit on structural steel beams, it is a must to
have a base plate between two beams in which the unit is to be attached.
The base's thickness should be either equal to or more than the thickness of
the unit feet. An insufficiently rigid Mounting can lead to consequences
like excessive vibration or deflection.
Procedure
For installing gear unit first there is a need for a proper alignment. It
can be done by placing broad and flat shims under all the mounting pads.
Starting should be done at low-speed end and then level across the width and
finally throughout the length of the unit. Checking of the backlash is also
important.
Check list for Gear Installation
- Make sure that there is proper installation of all the couplings,
shims or pinions. So as to avoid misalignment.
- Hubs, sprockets, pulleys, and like components need a careful
installation (not haphazardly driven on by a hammer)on shafts.
- Couplings also need to be aligned this is to make sure that the
parallel and angular alignment falls within the specified limits of
coupling manufacturers.
- Need to monitor distance between shaft ends or coupling hubs for
ensuring they conform to specifications.
Installing of Gear Drives
For a gear drive to function successfully the key is a perfect
installation. The following points need to be given special attention.
- There should be accurate alignment of all the shafts.
- With improper alignment there is every chance of a gear failure. A
flexible coupling may be used for a slight misalignment.
- While mounting, the bolt size should be maximum and a rigid
foundation is to be used for securing the reducer.
- The drain and breather plug should be arranged as per the mounting
position. Location of the breather plug should also be in the fill
position.
- Auxiliary drive components (like pulleys, sprockets and gears) need
to be mounted on shafts close to the housing. This minimizes the danger
of overhung loads.
- For input speeds refer to instruction manual.
- To Mount speed reducers in overhead positions may be fraught with
risks. Applying external guides or some sort of support is a good option
in cases of overhead mounting.
Standard Mounting Postions
Foot Mounted Horizontal
Foot Mounted Vertical
Output Flange Mounted
