Higher Efficiency & Lower Maintenance Cost in Gearboxes
CHALLENGE
At a large textile plant for synthetic PP woven fabrics, hundreds of Sulzer weaving looms had worm gears operating with excessive loads. This resulted in a short gearbox life - an average of 6 weeks.
Gearboxes are worm gear and bronze wheel, 114 to 1 ratio with 5 Amp motor, 1750 RPM. On November 3rd, 2006, several new gearboxes were coated with REWITEC Surface Treatment to prevent damages.
OUTCOME
After 4 months of uninterrupted operation without any sign of decay, one of the gears was opened to document its condition. The gears were in good condition without wear or damage.
This plant has an important number of looms with different models and sizes, none of the treated transmissions failed as of mid April 2008 and it is expected to last for two years before recoating.
Untreated Gears after |
Gear after 4 months of treated |
RESULTS
Due to the success in the application of REWITEC Surface Treatment with these units, the plant coated all challenged loom gears.
The average yearly repair cost for per unit was $6,400 without considering other cost and expenses like labor, materials, and lubrication.
Total economic benefit to the plant: More than $300,000 per year.
REFERENCE
Propex Inc, Chatanooga, TN, Plant Matehuala Mexico, Eng. Ramó Acosta.