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Lubrication and oil monitoring for gearboxes

Lubrication and oil monitoring for gearboxes - Seminar (3 days)

Appointment on request
Location as desired
In-HouseGerman
7,900.00 € plus VAT
Appointment on request
To be determined
OilDoc Academy
Price on request

Gearboxes – they transmit and translate energy, movements and forces. Their lubricant influences their performance and service life and thus the efficiency and safety of the connected units.

Our graduate engineer Rüdiger Krethe will introduce you to the practical basics of lubrication of industrial gearboxes, rolling and plain bearings, gearboxes in motor vehicles and lubrication of circulation systems. Operation-related changes in lubricants will be covered as well as wear mechanisms and typical gear damage.

You will learn in detail about the possibilities of lubricant analysis, which you can use to determine condition-dependent oil change intervals and reliably detect wear indicators. You can also find out how you can use online sensors and on-site measurements to monitor the oil condition and check for contamination and wear particles.

Target Group

  • Skilled employees and executives working in the field of maintenance
  • Mechanics and service technicians of gear and machinery producers
  • Technically skilled employees working in construction, serive and sales
  • Sales engineers and sales people of lubricant proucers und their resellers
  • Technical purchasers for lubricants and operating fluids
  • Application engineers working in mobile labs as well as for on-site condition monitoring and fluid management
  • Appraisors and surveyors for damage analysis and machine malfunction
  • Technically interested employees who want to extend their knowledge in the areas lubrication techniques and tribology

Aims

  • Safe selection of the best suitable gear for the applicable application
  • Simplification of amount of sorts of lubricants in use
  • Extension of oil changing intervals
  • Early recognition of unusual wear and failures
  • Investigation of causes of faliure after breakdowns
  • Extraction of meaningful oil samples
  • Oil analysis in pro-active maintenance
  • Interpretation of lab reports
  • Warning values for evaluation of machine damages and oil condition
Seminar (3 days)

Basis-Training (3 days)

Lubrication, Friction and Wear

  • Lubrication and Formation of lubricating film
  • Hydrodynamic and hydrostatic lubrication
  • Importance of viscosity and temperature
  • Mechanisms of wear and their causes

Fundamentals of lubricants

  • Mineral oils, partially synthetic and synthetic oils in comparison
  • Charactersitics and areas of application of Mineral oils, hydrocrack, PAO, Ester oils and polyglycols, especially in the area of greases
  • Types, active principle and application of lubricants addtives
  • Grease thickener: Soap based and soap-free thickener, characteristic and important applications of particular thickener
  • Requirements of the food and animal feed industry
  • Environmental relevance of lubricants

Gear oils

  • Requirements and characteristics
  • Characteristic values and their meaning
  • Standardized gear oil types and their area of application

Lubricating oils for slide and anti-fricition bearings

  • Lubrication requirements in comparison to interdigitation
  • Characteristics and characteristic values of lubricating oils for bearing lubrication
  • Testing procedures that got included into the gear oil norm for bearing lubrication and their influence
  • Differences of typical gear oils used in the industry and circulating lubricating oils

Gear and circulating lubricating oils in specific areas of application

  • Wind energy
  • Cement industry
  • Paper machines
  • Railway
  • Tool machines
  • Food industry

Gear oils for vehicles

  • Requirements and specifications overview
  • Manual, automatic and duplex transmission
  • Power shift transmission
  • Axle gears, self-locking differentials, final drives
  • General purpose oil for construction vehicles, tractors and agricultural equipment

Operational alterations of lubricating oils

  • Application-specific strain and oil aeging
  • Oil oxidation, hydrolysis and cracking
  • Reduction of antioxidants and other additives
  • Contamination through water, dust and external oils
  • Air content and foam formation
  • Diesel effect and cavitation
  • Cloudiness, contamination and phase separation

Wear mechanisms and gear tooth damages

  • Fundamental wear mechanisms
  • Wear mechanisms and forms of wear
  • Typical gear tooth damages and their causes
  • Impact of the lubricating oil in use

Oil analysis for industrial facilities

  • Why, when, how, how often, how many?
  • Methods and devices for sampling
  • Required data, grease sampling datasheet
  • Online portal: lab report, data entry, enquiries
  • Data migration into a maintenance program

Analysis techniques

  • Analysis sets, areas of application and explanatory power
  • Identification of wear characteristic values: element analysis, PQ-Index, optical particle analysis
  • Characteristic values for oil condition: viscosity, oxidation etc.
  • Reduction of additives: antioxidants, FT-IR and RULER, BN and AN
  • Contamination: water and particles, purity level, soot, mud, external oils, intermixture
  • Air separation capacity and foam formation
  • Water separation capacity, demulsifying behavior
  • Optical particle counting
  • Analytical ferrography
  • Mechanical test methods (Brugger, VKA, FZG, SRV)
  • Control analyses for incoming goods

Oil analyses to clarify the causes of damage

  • Recognizing the causes of wear and damage
  • Reasons for vibrations (noise) or high temperature
  • Increased foam formation
  • Turbidity, dark coloration
  • Deposits, sludge formation
  • Shortened filter service life and filter blockages

Evaluation of laboratory results

  • Warning/limit values and trend evaluation
  • Damage analyses: complexity and pattern recognition
  • Detection of ambient conditions
  • Consideration of the application-specific specifications
  • Group work, exercises with lab reports
  • Dealing with typical external and internal queries

Online sensors and on-site measurements

  • Online, on-site or external
  • Sensors for monitoring the oil condition
  • Sensors for wear particles and contaminants
  • Advantages and disadvantages of each method
  • Overview of available sensors and sensors under development

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Services included in the seminar price:

  • Participation in the seminar
  • Hot lunch
    on all days *
  • Coffee/tea and snacks
    during breaks *
  • Non-alcoholic
    beverages during
    seminar *
  • Detailed print documents
    + digital as PDF
  • Certificate of participation
    (*if present in Brannenburg)

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