Informative 3 Minute Video Script

Introduction

The following video blog was filmed at United Postal Services 525 Jefferson Ave. St. Louis, MO on July 30, 2015.  UPS is a national account and the largest U.S.A. end user of SMA product.  There are roughly over 500 gearboxes within 2 St. Louis, Mo locations.  This video depicts gearbox failure analysis of a Cyclo Helical Bevel BuddyBox that is about to break down.  Understanding the cause and effect of gearbox diagnoses is an important skill requirement of SMA District Sales Managers.

Potential Causes for Gear Failure

(Troubleshooting and Repair)

§  Loud Noise-Most likely caused by insufficient lubrication because the level of lubricant in the reducer has not been properly maintained.  Damaged pins and rollers due to overloading of reducer could also cause a loud noise.  Worm disc due to overloading of unit and failure of bearings because of lack of lubrication generally cause a gearbox to make a loud noise.

§  Lubrication-90% of all gearbox failures is a result of poor or inadequate lubrication.  SMA recommends oil changes after 500 hours of initial operation and every 2500 hours after that.

§  Mounting-Loose foundation bolts creates a weak mounting structure and can damage the internal working of the gearbox.  One should inspect mounting of the reducer and tighten loose bolts and/or reinforce mounting of the structure.

§  Momentary Shock Load-Overloading of the gearbox can take place if the driven equipment gets damaged.  If the overload rating exceeds the gearboxes rating, damage can occur internally within the reducer.  Check rate capacity of the reducer and replace with unit of sufficient capacity or reduce load.

§  Taper Grip Bushing-The keyless TGB system provides a simple and reliable shaft attachment for Sumitomo speed reducers and gear motors.  This device connects the gearbox to the driven shaft on the equipment in motion.

§  Temperature-In general, gearboxes are selected and rated based upon 104 degree ambient temperature.  A gearbox should never run hotter than 100 degrees above this ambient temperature.  If the gearbox runs over this temperature it is most likely because of overloading or improper lubrication.

Conclusion

Since UPS is transporting thousands of packages a day from facility to truck, they cannot afford to have a conveyor line moving these parcels to break down.  It costs the facility thousands of dollars per hour if production comes to a standstill.  Needless to say, a critical spare was ordered as a precautionary measure.