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FAULT ANALYSIS OF GEARBOXES IN OPEN PIT MINE
Authors:
Milan P. Vasić1
, Blaža Stojanović1, Mirko Blagojević1
1Department for mechanical constructions and mechanization, Faculty of Engineering, University of Kragujevac, Serbia
Received: 04.05.2020.
Accepted: 10.06.2020.
Available: 30.06.2020.
Abstract:
The paper presents the results of testing gearboxes in coal open pit mine which have been damaged by various mechanisms. Gearboxes, as constituents of belt conveyors, bucket-wheel excavators and bucket chain excavators and spreaders, are the most loaded segments of drive units the functionality of which affects the operation of complete coal and overburden systems. Therefore, special attention has to be paid to their condition so that the analysis of relevant condition indicators could lead to correct conclusions as to their functionality, as well as point to the factors causing their fault. Tests were carried out on 95 gearboxes throughout 2017, during general repairs at Drmno mine workshop. After examination, all identified failures were illustrated with an appropriate photo, classified according to the appropriate standard, and described in the form of manifestation and cause. The research has shown that the most dominant were faults of bearings and lubrication, whether seals and cuffs or a thin hermetic layer between the housing and covers. In addition, some of the faults happened on gears and toothed and stepped shafts. Major irregularities in operation, resulting from damage to gearbox elements, are show by fault tree analysis (FTA).
Keywords:
Gearboxes, Fault information visualization, Wear type statistic, Fault tree analysis (FTA)
References:
[1] J.X. Li, X.X. Pang, Y.J. Li, Research of Dynamic Characteristic of Belt Conveyor, 3rd Annual International Conference on Mechanics and Mechanical Engineering, 105, 2016: 304-312. https://doi.org/10.2991/mme-16.2017.42
[2] Z. Q. Chen, C. Li, R. V. Sanchez, Gearbox Fault Identification and Classification with Convolutional Neural Networks. Shock and Vibration, 2015 (2), 2015: 1-10. https://doi.org/10.1155/2015/390134
[3] P. Matuszewski, Condition Monitoring in BOT KWB Belchatow mine, (Ph.D. Thesis). Mining Faculty, Wrocław, 2007.
[4] N. Zuber, R. Bajrić, R. Šostakov, Gearbox faults identification using vibration signal analysis and artificial intelligence methods. Eksploatacja i Niezawodnosc – Maintenance and Reliability, 16, 2014: 61-65.
[5] R. Zimroz, R. Król, Failure analysis of belt conveyor systems. Mining Science, 128, 2009: 255-270.
[6] A. Skoć, Dynamics of bevel gears in mining machines. Wydawnictwo Politechniki Śląskiej, Gliwice, 1996.
[7] W. Bartelmus, New Focus on Gearbox Condition Monitoring for Failure Prevention Technology. Key Engineering Materials, 588, 2014: 184-191. https://doi.org/10.4028/www.scientific.net/KEM.588.184
[8] B. Gerike, E. Kuzin, I. Panachev, Development of the preventive maintenance system for belt conveyors reducers, The 1st International Innovative Mining Symposium, 15, 2017: 1-6. https://doi.org/10.1051/e3sconf/20171503008
[9] ISO 10825, Gears – Wear and damage to gear teeth – Terminology, 1995.
[10] I. Atanasovska, D. Momčilović, The effect of teeth failures on machine safety – testing and analysis. Structural integrity and life, 7(1), 2007: 37-46.
[11] S. Tanasijević, Osnovi tribologije mašinskih elemenata. Naučna knjiga, Beograd, 1989.
[12] B. Ivković, A. Rac, Tribologija. Jugoslovensko društvo za tribologiju, Kragujevac, 1995.
[13] M. Ognjanovic, Progressive gear teeth wear and failure probability modeling. Tribology in industry, 26 (3), 2004: 44-49.
[14] R. Basan, M. Franulović, M. Lengauer, B. Križan, Rolling – sliding – contact fatigue damage of the gear tooth flanks. Engineering Review, 30 (2), 2010: 37-46.
[15] Y. Lee, J. Pan, R. Hathaway, M. Barkey: Fatigue testing and analysis – Theory and practice. Elsevier Butterwoth – Heinemann, Burlington, 2005.
[16] S. Khoshaba, V. Haralanova, Failures in gearboxes due to material problems. Materials, Methods & Technologies, 10, 2016: 112-136.
[17] C. Moolwan, S. Neptu, Failure Analysis of a Two High Gearbox Shaft. Procedia – Social and Behavioral Sciences, 88, 2013: 154-163. https://doi.org/10.1016/j.sbspro.2013.08.491
[18] ISO 15243 Rolling bearings – Damage and failures – Terms, characteristics and causes, 2004.
[19] G. Šiniković, Bearing damage detection in ultrasonic domain, (Ph.D. Thesis). University of Belgrade. Faculty of Mechanical Engineering, Beograd, 2012.
[20] R.K. Upadhyay, L.A. Kumaraswamidhas, S. Azam, Rolling element bearing failure analysis. Case Studies in Engineering Failure Analysis, 1 (1), 2013: 15-17. https://doi.org/10.1016/j.csefa.2012.11.003
[21] SKF Bearing investigation, Extract from the Railway technical handbook, 1 (6), 2012: 122-135.
[22] S. Šćepović, D. Šorta, V. Šorta, Diagnostics of oil from gear-box. Tehnička dijagnostika, 8 (4), 2009: 5-10.
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This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License (CC BY-NC 4.0)
Volume 10
Number 1
March 2025
Last Edition
Volume 10
Number 1
March 2025
How to Cite
M.P. Vasić, B. Stojanović, M. Blagojević, Fault Analysis of Gearboxes in Open Pit Mine. Applied Engineering Letters, 5(2), 2020: 50-61. https://doi.org/10.18485/aeletters.2020.5.2.3
More Citation Formats
Vasić, M. P., Stojanović, B., & Blagojević, M. (2020). Fault Analysis of Gearboxes in Open Pit Mine. Applied Engineering Letters, 5(2), 50–61. https://doi.org/10.18485/aeletters.2020.5.2.3
Vasić, Milan P., et al. “Fault Analysis of Gearboxes in Open Pit Mine.” Applied Engineering Letters, vol. 5, no. 2, 2020, pp. 50–61, https://doi.org/10.18485/aeletters.2020.5.2.3.
Vasić, Milan P., Blaža Stojanović, and Mirko Blagojević. 2020. “Fault Analysis of Gearboxes in Open Pit Mine.” Applied Engineering Letters 5 (2): 50–61. https://doi.org/10.18485/aeletters.2020.5.2.3.
Vasić, M.P., Stojanović, B. and Blagojević, M. (2020). Fault Analysis of Gearboxes in Open Pit Mine. Applied Engineering Letters, 5(2), pp.50–61. doi:10.18485/aeletters.2020.5.2.3.
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FAULT ANALYSIS OF GEARBOXES IN OPEN PIT MINE
Authors:
Milan P. Vasić1
, Blaža Stojanović1, Mirko Blagojević1
1Department for mechanical constructions and mechanization, Faculty of Engineering, University of Kragujevac, Serbia
Received: 04.05.2020.
Accepted: 10.06.2020.
Available: 30.06.2020.
Abstract:
The paper presents the results of testing gearboxes in coal open pit mine which have been damaged by various mechanisms. Gearboxes, as constituents of belt conveyors, bucket-wheel excavators and bucket chain excavators and spreaders, are the most loaded segments of drive units the functionality of which affects the operation of complete coal and overburden systems. Therefore, special attention has to be paid to their condition so that the analysis of relevant condition indicators could lead to correct conclusions as to their functionality, as well as point to the factors causing their fault. Tests were carried out on 95 gearboxes throughout 2017, during general repairs at Drmno mine workshop. After examination, all identified failures were illustrated with an appropriate photo, classified according to the appropriate standard, and described in the form of manifestation and cause. The research has shown that the most dominant were faults of bearings and lubrication, whether seals and cuffs or a thin hermetic layer between the housing and covers. In addition, some of the faults happened on gears and toothed and stepped shafts. Major irregularities in operation, resulting from damage to gearbox elements, are show by fault tree analysis (FTA).
Keywords:
Gearboxes, Fault information visualization, Wear type statistic, Fault tree analysis (FTA)
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License (CC BY-NC 4.0)
Volume 10
Number 1
March 2025
Last Edition
Volume 10
Number 1
March 2025