Our paper mill has been facing frequent coupling failures on paper machine drives and disc refiners. The Falk gearflex style couplings we use are lubricated with multipurpose grease, as advised by our lubricant supplier. The failures are due to significant wear on the hub and cover teeth, leading to a locked coupling and higher motor vibration. Although we ensure laser alignment in all installations, the issue persists. Are there any recommendations for a more effective lubricant for this type of coupling? Share your successes with us.
In my experience, failures of gear type couplings are often caused by misalignment or inadequate lubrication, or a combination of both. Misalignment leads to increased sliding velocity along the tooth flanks, which can surpass the capabilities of the lubricant being used. While you mention that misalignment may not be an issue due to laser alignment in all installations, can you guarantee this with 100% certainty? Have you personally observed the alignment process and been satisfied, or did you simply receive a report of the measurements? Considering the possibility of multiple machines experiencing failures, it may be worthwhile to thoroughly scrutinize the lubricant being used. Reflect on whether these failures could be linked to a change in lubricant type or formulation, even if the names remain the same. Instead of solely relying on the lubricant supplier, consult the coupling manuals or reach out to the coupling manufacturer for their updated recommendations. While different lubricants may seem similar in classification, the original equipment manufacturer (OEM) may have specific concerns based on past experiences. I recall an instance from my time at an OEM where using a certain turbine oil in high-speed gearboxes consistently led to excessive foaming issues. John from PA.
I agree with John's suggestion to compare the recommended grease from the coupling OEM to what the lubricant supplier suggests. Speciality coupling greases may be more suitable than general multipurpose greases for optimal performance. It is important to identify the best type of grease for your specific coupling application.
Falk suggests utilizing their unique coupling grease to combat the issue of bearing greases centrifuging and separating the soap from the oil. The larger diameter and higher rotation speed of the coupling can exacerbate this problem. Furthermore, Walt Strong has successfully detected coupling wear using air-borne ultrasonics. For more information, explore discussions on the vibration forum where his insights can be found.
Thank you to everyone for your responses. Our most recent issue occurred with a Disc Refiner that had a 400 H.P. motor rotating at 900 rpm. The motor was properly aligned during installation 18 months ago, as confirmed by my own observation of the alignment results. However, a preliminary check before replacing the damaged coupling revealed that the motor coupling was .017" lower than it should be, indicating that the motor had shifted. Upon further investigation, we discovered that the support foundation was in very poor condition, with cracked welds on the transition base allowing the motor to run misaligned despite the initial alignment. This serves as a reminder to regularly inspect and maintain the foundation of your machinery, as things may not always be as sturdy as they seem. In addressing other coupling failures, I have convinced management to switch to the recommended coupling grease instead of using multipurpose grease. Thank you for your valuable contributions.
David, there is a possibility that the laser was not correctly installed. Even though you have witnessed the outcomes, it is crucial to verify that the alignment gear is properly positioned on the shafts rather than the coupling assembly. I can speak from firsthand experience on this matter. Best regards, Joe Mc Cormack.
From my experience, it sounds like the issue is not necessarily with the lubricant you're using but possibly the coupling selection or even improper installation techniques. Falk gearflex couplings are pretty sturdy, yet the teeth worn out indicates there could be a misalignment or an issue with torque overload. However, if you still believe your lubricant is the cause, consider using a high-performance synthetic lubricant specifically designed for couplings. They tend to provide excellent wear protection under various conditions. But again, make sure to cross-check the alignment, load conditions and coupling specifications before switching lubricants entirely.
I experienced a similar problem with my disc refiners a couple of years back. I switched from using multipurpose grease to a more specialized lubricant designed specifically for high-load applications. The one that worked for me was a heavy-duty, high-load coupling grease. Since the change, I've seen a drastic reduction in wear on the hub and cover teeth. The specific brand I used was Klüberlub BE 41-1501 – it's a tad bit expensive but it's worth it considering the downtime you're avoiding. Just ensuring precise laser alignment won't cut it if the lubricant isn't up to the mark for such heavy-duty applications. Hope this helps!
From my experience, while the type of lubricant you use is important, your problem might not be entirely due to its effectiveness. Since the wear is significant on both the hub and cover teeth, it may also be a frequency issue, meaning you should consider increasing the regularity of lubing the couplings. As for the lubricant reccomendations, I've had success with Klüberlub BE 41-1501. This special grease is known for its high load-carrying capacity, which could be beneficial for your specific situation. Moreover, just to rule out any alignment issues, you may wish to double-check your calibration and alignment at shorter intervals considering the frequent failures.
It sounds frustrating to deal with those persistent coupling failures! While multipurpose grease is often a go-to, you might want to explore synthetic greases specifically designed for high-load applications, as they tend to have superior film strength and can better withstand the conditions in a paper mill. Some users have reported success with lubricants containing additives that reduce wear and lower temperatures, which could help extend the life of your couplings. Additionally, keeping an eye on the operating temperature and vibration levels might provide insights into underlying issues that could be exacerbating wear. It might be worth trying a different lubricant while closely monitoring performance to see if it makes a difference!
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Answer: - Common reasons for Gearflex coupling failures in paper mill machinery include significant wear on the hub and cover teeth, leading to a locked coupling and higher motor vibration.
Answer: - While multipurpose grease is commonly advised by lubricant suppliers for Gearflex style couplings, the discussion suggests exploring more effective lubricant options to prevent failures.
Answer: - Laser alignment is essential to ensure proper installation of Gearflex couplings, but despite this precaution, the issue of wear on the hub and cover teeth persists.
Answer: - Participants are encouraged to share their successes and recommendations for preventing Gearflex coupling failures in paper mill machinery to help address the issue of wear on the hub and cover teeth.
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