How do you repare a broken gearbox without spending a fortune?

settembre 14, 2021

Repairing a broken gearbox without spending a fortune is not impossible, very often the parts which break are the internal gears. So why not just change those instead of buying back the whole assembly?

What is a reducer?

A gearbox is a mechanical transmission element whose function is to transmit a rotary motion, reduced in its revolutions, from one shaft to another. Gearboxes are applied in most of the motorized machines wich need to rotate at different speeds. As a first association, the gearbox is thought to be used only in cars or in work machines such as agricultural or earthmoving machines. However, it is also applied in many industrial machinery, subject to easy wear.

Why is it better to replace only the internal gears of the gearbox?

It is often thought that the easiest solution when a gearbox breaks is to replace the whole assembly, ignoring that the gearbox housing rarely suffers damage, what wears out are the internal gears. In fact, with the passing of years and use, the internal gears tend to no longer mesh, making it necessary to replace them.
Recently, in G.S.I. we received a request to replace the internal gears of the gearbox of an industrial machine that had stopped working. The customer arrives in G.S.I. with the broken gearbox, after consulting the manufacturer who proposed the replacement of the whole group at an exorbitant cost.

Let's see step by step how we repaired a broken gearbox

Step 1: Disassemble the gearbox and take out the damaged parts

This is used to evaluate the state of the pieces as well as that of the box and move on to the next phase of creating the mechanical design starting from the broken piece.

Step 2: Analyze the pieces on a technical level to recreate the design

This phase is essential if you want to create a long-lasting product, however it is necessary to have a lot of experience to create a mechanical design without the use of 3D scanning systems.

Step 3: Industrialization of the product

At this point we proceed with the industrialization of the product, creating the production cycle and the related phase drawings.

Step 4: Production of the desired pieces

In this phase the pieces go into production following the defined cycle.

Step 5: Replacing the bearings for the various stages of reduction

Once the pieces have been produced, it is necessary to buy or produce the bearings to be inserted to facilitate the resistance to loads and the durability of the object over time.

Step 6: Assembly in the gearbox box

The gearbox housing may have undergone a lot of effort and therefore needs to be changed to increase the life of the product. Inside, the shaft with gears and bearings must be assembled without forgetting the motor connection flange. Apparently assembling a reducer may seem simple, although there are so many internal and external components, but it is necessary to do it with the utmost precision.

Step 7: Balancing

An extremely important phase to complete the work is balancing, necessary to avoid annoying noises and possible breakage of the gear teeth.

Relying on experience rather than on the brand: the advantages

In conclusion, our customer received a new product, identical to the original one, having saved 50% of the expense that should be faced by buying a new original gearbox. Very often, as in everyday purchases, a non-branded product is comparable in quality to the original one for which we also pay the brand name. In the case of the mechanics sector this principle is even more valid, because very often the original manufacturer relies on an external supply chain, dealing only with the last stages of assembly and balancing.
Thanks to his experience in the design and construction of mechanical transmission parts, G.S.I. has the opportunity to support the customer in the creation of unique pieces starting from scrap. For requests for the creation of spare transmission components, please contact us.