Falk Coupling
Downtime and gear failure—these are two abhorred words among plant managers. On the factory floor, a stopped line means lost time—and lost money to boot. With that said, the complexity of power transmission lines means that various factors impact productivity. Operators must mind multiple details simultaneously to maximize output. From proper part installation, to working within manufacturers’ specifications, to monitoring temperature and vibration data, there are plenty of variables that go into boosting plant output. Today we’re taking a close look at one aspect of preventative maintenance: Long term grease.
Falk recommends Long Term Grease (LTG) for all of its couplings, for several reasons. First, unlike general-purpose greases, specialized LTG will not separate under centrifugal conditions. When subjected to ongoing rotation, most grease will divide into oil and thickener, shortening the lifespan and potentially causing damage due to excessive contact. Falk’s Long Term Grease is specially formulated to resist separation. This not only improves operations; it also allows operators to use the same LTG for longer periods of time.
Second, Falk LTG is fluid enough to prevent unnecessary blockage. Lubrication is that too heavy may become stuck in couplings’ tooth mesh, eventually leading to early mesh failure.
The consistency of Falk LTG actually changes during operation. Long Term Grease near seals settles into a heavier thickness, while LTG in areas of movement becomes semi-fluid. This means that seals are better protected against leakage, while moving parts benefit from improved lubrication.
With that background information in mind, let’s consider how LTG inhibits malfunction in Falk couplings.
Long Term Grease: How it Prevents Failure in Falk Couplings
1. Grease Prevents Overheating.
Friction between parts cause heat, and heat can cause damage, gear failure, and downtime. By protecting metal surfaces, LTG provides consistent lubrication, minimizing heat.
2. Grease Minimizes Wear Over Time.
Falk LTG is composed of a lithium base, with rust and oxidation inhibitors. This combination delivers strong protection of surfaces that come in contact during plant operations. With proper lubrication, parts wear out more slowly, and productivity is maximized. This is especially important in situations of high shock loads and shaft misalignment.
3. Minimizes Damage in Wet Conditions.
Falk LTG includes rust and oxidation inhibitors, protecting parts that must operate in moist settings.
In general, the coupling manufacturer will specify which coupling grease to use. For instance, for installation of interference fit hubs, Falk recommends lightly coating seals with grease before mounting hubs. To ensure consistent application of lubrication, plan to add more grease when checking motor alignment as well as scheduling annual grease replenishment. Finally, ensure that you’re using LTG within the recommended temperature and speed ranges. Falk specifies that its LTG can be used between -20 and 250 degrees Fahrenheit. In certain low speed operations, Falk suggests that EP oils may be superior to LTG grease. Read your couplings’ installation and maintenance manual for detailed information on operation speed and lubrication selection.
When caring for Falk couplings, it’s also important to schedule and carry out regular oil changes. Check the coupling and its fluid at least once a year; more frequent observation is recommended in severe or atypical operating conditions. If coupling fluid is overheating, changing to a darker color, or emitting a burnt smell, an immediate fluid change is required. For the most effective rate of fluid changes, check with your fluid provider. Oftentimes, they can test fluids and recommend a maintenance schedule based on their expert analysis of fluid degradation.
Posted under Products/Services on Wednesday, October 29th, 2014