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Retrofit drafting system drive 4000kg - case study

Why you save a lot of money with a gearbox retrofit, Increase machine availability and improve product quality The advantages of industrial gear unit modernization compared to a new investment - more performance and lower costs With older gearboxes, at some point the question arises: Investment in a new gearbox or gearbox modernisation? With a modernization, the customer benefits twice over: 1. older gear units are usually in good mechanical condition. With a retrofit, the original performance of the gear unit can even be exceeded, which increases service life and productivity. 2. downtime is significantly reduced because a retrofit takes considerably less time. Conclusion: The bottom line is that the customer saves a lot of money and time. Here is a concrete example of how Kachelmann has reduced downtime to a minimum by retrofitting a drafting system drive. The problem ___________________________________________________________________________ The customer from the chemical industry turned to Kachelmann with a request for technical support. After a company takeover, the production line for the production and processing of technical yarns and fibres was to be overhauled. Several gears were heavily corroded due to outdoor storage. The original supplier of the spur gear units no longer existed. It was a highly sophisticated multiple gear unit with 25 gear combinations combined with 10 sets of change gears, 3 input levels with 20 output shafts per level, 2 traversing shafts with cam plates. The total weight of this transmission is 4,000 kg. The most important requirement of the customer was: to reduce the downtime to a minimum. After detailed technical consultation and assessment by our gearbox experts, two alternatives were available: 1. a completely new development of the heavy duty gearbox. 2. a retrofit of the existing gearbox. A completely new development was rejected for two reasons. First, a new development would take at least 6-8 months. Secondly, the add-on parts could be taken over unchanged without major constructional measures. The customer therefore decided to modernise the gearbox units instead of a new development of the gear system.

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The solution ___________________________________________________________________________ The gearbox was completely disassembled and the delivery condition was documented in writing and in picture form. All parts were cleaned, stripped of paint, measured and a complete set of production drawings was created. All shaft seats and the bores of the gear wheels as well as their tooth flanks were inspected. And all roller bearings and seals were replaced. Finally, 98% of the internal parts were reworked, including the running surfaces of the sealing rings on the shafts. To minimize noise, all gear parts were flank ground. The gearbox was then assembled and during the subsequent test run on the in-house gearbox test bench and the acceptance was recorded. The customer benefited above all from a well-founded know-how in special gear construction and the many years of experience of well trained employees. The permanent coordination between the specialists of Kachelmann Getriebe and the maintenance department of the customer ensured a smooth process. Kachelmann services plants in the chemical industry worldwide - starting with agitator gears, calander and extruder gear units, drafting system gears and reel-up gears. Special gearboxes from Kachelmann can be found in all industrial sectors worldwide.

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The result ___________________________________________________________________________ After a total lead time of only 12 weeks, the customer was able to put the completely renewed gearbox back into operation. In contrast, a new gearbox development would have taken at least 8 months (32 weeks). The gearbox was delivered with a factory warranty of 24 months after delivery. All gearboxes on the production line were successively overhauled and are running smoothly today. Summarized once again: The 8 advantages of a retrofit 1. lower investment costs than for a new acquisition 2. longer service life through higher quality of the installed parts. 3. downtime and operating costs are reduced through optimal maintenance and higher efficiency. 4.previous performance of the gear unit is even exceeded, noise reduced 5. increased productivity through decisive reduction of downtimes. 6. the availability of spare parts is ensured. 7. the gearbox can be prepared for predictive maintenance with sensors. 8. additional Kachelmann factory warranty of 24 months

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Kachelmann Getriebe is a family run company in the fourth generation. More than 500,000 Kachelmann gears are in use in all industrial sectors worldwide. The core business of the company are stationary drives for all industrial sectors. In 2017, the product portfolio was supplemented by the manufacture and maintenance of start-up and safety couplings of the Metalluk brand. The comprehensive gear know-how across many industries forms the foundation of a strong partnership with our customers worldwide. Flat hierarchies, high quality in production and last but not least the will to find solutions for the benefit of the individual customer are decisive points when it comes to the optimal realization of gear projects. In 2019 Kachelmann celebrates its 125th anniversary. retrofit@kachelmann.de | Phone +49 (9543) 84 55 11