Locomotive Gearbox Refurbishment
Customer Problem: A manufacturer of locomotive gearboxes needed to reduce the cost of rebuilding gearboxes for its customers. The manufacturer was scrapping a large number of gears at a high cost. The manufacturer wanted an independent assessment of its gear reuse criteria and assistance in developing criteria that minimized the unnecessary scrapping of gears.
Our Approach: RBB Engineering visited the manufacturer’s rebuild facility and audited the current gearbox rebuild process. We examined details of the application, life requirements, and consequence of failure. We examined the condition of used gears, categorized the types of damage observed, and determined the likelihood of each damage mode progression. We reviewed scrap rates and costs using the manufacturer’s existing reuse criteria, and proposed changes to significantly reduce scrap rate and costs with little to no effect on the failure rate of gears.
Outcome and Benefit to the Customer: Armed with our project report, the customer was able to reduce the scrap rate of gears and the cost of refurbishing gearboxes, while maintaining the high reliability required in the application.