Anyone who has ever had to maintain a Falk gearbox knows how important lubrication is for industrial machinery. At every step of the way, moving parts require careful lubrication – from the Falk gear reducer all the way down to the couplings – to prevent failures and maximize the equipment’s life span. Effective lubrication decreases wear and tear on parts and even minimizes the amount of lubricant used; poor lubrication equates to money lost.
Unfortunately, factory maintenance crews face increasing challenges when it comes to keeping rotating parts, such as Falk gear reducer components, properly lubricated. Here’s a look at some of the most common challenges:
Too many lube points. If all you had to worry about was one Falk gear reducer, lubrication would be a breeze; in a large operation, however, it can become a big challenge. Some plants have thousands of lubrication points, some of them hard to reach, that must be regularly monitored and serviced – a huge, time-consuming task for any maintenance crew. Solutions to this challenge include “set and forget” automatic lubricators, which deliver lubrication at pre-determined times, or centralized lubrication systems, which circulate oil to each Falk gearbox as well as the bearings within connecting shafts.
Increasing temperatures. With the pressure on to constantly improve efficiency and productivity, operators are pushing equipment loads. With heavier loads, a Falk gear reducer has to operate under hotter temperatures, which puts an added strain on the lubricant. To combat this problem, choose a lubricant that has been formulated to withstand the entire range of temperatures to which the gears within a Falk gearbox will be exposed.
Water contamination. Water is an inherent part of many production applications. Unfortunately, if gear oil is contaminated with even one percent water content, its lifespan can be reduced by up to 90 percent, leading to untold costs in component failure and unanticipated down time. While most operators are aware of the dangers of water contamination, they may not realize just how quickly the problem can accelerate. Add to that the fact that water contamination often goes undetected until it’s too late, and you’ve got a real problem on your hands. In addition to proactive maintenance practices, the best defense against water contamination is to use a lubricant that is formulated to separate quickly from water. Regular vibration analysis and oil condition monitoring can also help by providing early warning.
Posted under Machinery Maintenance on Monday, March 5th, 2012