Industrial Gearbox Service & Maintenance

Introduction:

Kumera Service Team is at your disposal for all kinds of maintenance and upgrading works with a wide range of services. Those are:

Inspections on site or at our Service Center
Professional inspection report including proposal for upgrading
Refurbishment or upgrading
Condition monitoring (Guard Gear)
Guaranteed improved measures with the highest expertise

Benefits to make the difference:

Latest manufacturing and measuring equipment
Advanced gear technology for optimization of load capacity and efficiency
High expertise in specific industries
Decades of gear manufacturing experience

Press Drives Applications

Steel & Aluminium Rolling Mills

Marine Applications

Rubber and Plastic Industries

Cement Mills and Mining

Agitators in Chemical Industry

Kumera Gearbox Lifecycle Management

Condition monitoring:

Kumera Guard Gear online condition monitoring

Vibration
Lubrication oil
Quality
Level
Temperature
Rotation speed
Connection options:
Ethernet
3G/GPRS
Bluetooth (PAN)

Preventive maintenance:

Lifecycle Management Contracts
Inspections and preventive maintenance
Measurements
Vibration
Stray current (bearing current)
Alignment checking
Inspections
Thermal camera inspection
Endoscope inspection
Process parameter analysis
Report of results with recommendations

Detailed listing on measures to cover Kumera / Keller made and other makers’ gearboxes

“Classic” Service:
• Spare parts delivery
• Drop-in replacements
• Gearbox upgrades
• Measurement
• Inspection
• On-site or onboard repair
• Preventive inspections
• Maintenance

Engineering:
• Finite-Element-Analyses (FEA)
• Torsional vibration analyses
• FEA Workbench tools

o RIKOR (load distribution and tooth modification)
o Heat balance calculation
o Efficiency calculation

• Hydraulic systems
• Bearing calculations
• Root Cause Analyses

Testing capabilities:
• Endoscope inspection
• Oil analyses
• Vibration measurement
• Laser adjustment
• Noise measurement
• Surface crack testing VT/PT/UT
• Gear measurement up to ø4000mm
• Hardness measurement
• Leakage testing
• 500kW test rig capacity

Resources for special needs

Preventive maintenance:

Scheduled inspections during standstills (also in weekends and holidays)
Quick and professional emergency assistance
SCC-trained personnel
Most of the vital components & steel raw materials on stock
24/7 Service Hotline +49 2241 988 988

24/7 Service Hotline
+49 2241 988 988

Large number of succesful refurbishment cases

Modifications:

Recalculation
Re-design

Bearing life Lh10

	Actual State 3000 kW	Actual State 4000 kW	Redesign 4000 kW	Redesign 3340 kW	Redesign load collective
Drive shaft – drive side	85.911	33.028	50.019	91.133	96.253
Drive shaft – output side	93.510	35.890	46.077	83.767	88.456
Intermediate shaft – drive side	339.510	127.625	135.349	253.744	268.774
Intermediate shaft – output side	85.219	32.405	64.224	118.243	125.016
Output side – drive shaft	52.439	20.098	34.392	61.740	65.109
Output side – output side	77.694	30.307	31.131	54.729	57.595
Output shaft – axial bearing	74.079	61.485	61-485	69.448	70.163

Case study - Cross Roll Piercing Mill Gearbox

Certifications and Quality Memberships

Quality management system according to DIN EN ISO 9001:2015
Certification according to SCC** 2011 (Safety Certificate Contractors)
Certification by Bureau Veritas
Membership Forschungsvereinigung Antriebstechnik e.V. (FVA)
Membership VDMA

Summary

Kumera Getriebe GmbH provides comprehensive maintenance and service
Production facility for all manufactured parts
- High quality original spare parts
- High standard quality management
Repair and service for all makers’ gearboxes
- Other makers’ bevel, helical and planetary gearboxes, even without original drawings or BOMs
Optimisation with advanced engineering
- Re-design of gears and bearings
- Re-design of lubrication systems
- Improvement of load density
Professionally trained service personnel
- On-site inspections, maintenance and service worldwide through Kumera Service Centers