power transmission, gear drive, Falk renew
In many manufacturing or operating systems, the gear drive is a key element. Even the stoutest Falk gear drive will eventually break down. If you use active gear drives, this is bound to happen. When it does, you will need to decide whether to rebuild or replace the gear drive.
Many manufacturers recommend that you replace a worn power transmission or gearbox. However, this isn’t always your most ideal or cost-effective option. There are many factors to consider in this decision. Here are some things you should think about when you’re deciding whether to replace or repair a gearbox.
Cost
For most people, the cost difference between replacing a gearbox and repairing the gear drive is the most important aspect to consider. It’s a safe bet you’ll want to find the most cost-effective solution. While you calculate the difference between replacing and rebuilding, here are a few things to keep in mind:
Factor in downtime. With time being money, as you well know, the money you lose waiting around for a replacement can negate any savings there may be over repairing your Falk gearbox. Be sure to factor in the money lost during downtime when considering whether to rebuild or replace a gearbox.
Have it inspected by a professional. You usually can’t accurately assess everything that could be going on with a broken gearbox with a visual inspection alone. Even your company’s most skilled maintenance person may miss some details that could cause problems. A trained technician is your best bet if you need someone you can trust to do a complete and thorough inspection of gear drives or a power transmission. Their professional knowledge gives them greater expertise in assessing whether to repair the unit or replace it.
Avoid introducing new challenges. If the decision comes down to an even split between repairing the unit to like-new condition or replacing it with a new one, your best bet is likely a repair. That’s because training staff to use a new machine can cost you a lot of time and money. Also, if your old unit has a warranty, you could save on part or all of the repair cost.
New units often require adjustment. Chances are that your Falk gearbox was designed specifically for your setup. Working components you’ve been using with your old unit may need to be modified or replaced to be compatible with the new unit. Don’t overlook this when making your decision.
Time
Building new units is usually a longer process. While repairing or rebuilding a broken Falk gearbox will take time, it usually takes much longer to build a new unit. If your gear drive unit was made specifically for your operation system, this is especially true.
Parts availability. In business, turnaround time is essential. Availability of parts is a major factor in repair time for a Falk gearbox. A manufacturer’s standard model that isn’t obsolete should have parts readily available for it. Finding parts for a custom-made unit, however, may be more problematic. Parts for some custom-made units can be difficult or impossible to find. In this case you’ll have no choice but to replace the unit entirely.
Other Things to Consider
When deciding whether to repair or replace a unit, time and money aren’t the only factors to consider. Here are some other things you should keep in mind.
Some components require regular replacement. While you may not need to replace an entire unit, certain parts should always be replaced on a regular basis. Bearings, seals, and shim gaskets are a few examples. Be sure to stick to your maintenance schedule and replace these parts, even if the power transmission or gear drive is still operating properly.
Consider the unit’s age. While you may be fond of your custom-built gear drive’s uniqueness, and you may have fond memories of the years you’ve had with it serving you well, all machines must eventually be retired. If it’s obvious that you won’t be able to find replacement parts in 5-10 years, it’s probably time for a replacement.
The bottom line is that, in most cases, a broken Falk gearbox can readily be restored to like-new condition more quickly and cost-effectively than being replaced. This is especially the case when Falk Renew service is a possibility. On the other hand, if your unit is very old, you may well be better off replacing it and starting new.