Reducing Operating Costs By Limiting Downtime
In-shop repair of customer-owned gearboxes is a core competency of NGC. Combining our drivetrain design and manufacturing expertise with a talented local staff of technicians, engineers, and quality professionals, our repair process eliminates known failure modes and ensures a finished product meets the same specifications and performance characteristics as new.
Our Down Tower Repair Process
The process begins by capturing customer expectations and continues when the customer-owned asset is received in our facility, via an incoming inspection.
An incoming inspection is used to identify the general condition of the equipment and to inventory peripheral components such as brake systems.
Complete drive trains are separated at the main rotor shaft and gearbox connection as these main components have very different process paths.
Disassembly is completed only when engineering and quality have reviewed and accepted the inspection report, including critical measurements, images, and disposition of damages.
The engineering team assesses individual gears through a thorough, formal visual inspection. They then look for cracks via a magnetic particle inspection.
A comprehensive cleaning in the wash bay is conducted. These tasks are completed through a combination of manual cleaning, machine washing, and hand polishing.
Gears are dispositioned as required for gear grinding. Both precision grinding and coordinate measuring are conducted in-house to maximize quality and minimize cost.
a. Gears are sent to the Klingelnberg P150 gear checker for pre-regrind measuring/evaluation
b. Gears are reground as needed on the HOFLER Rapid 1600
c. Gears are then sent back to the gear checker for reevaluation/recertification
Any additional critical components which require repair through a machining process are also completed at our in-house machine shop.
Many components of the gearbox are upgraded to the latest revision possible and replaced with new products that improve overall performance.
Some examples include:
a. All bearings
b. All structural components
c. The high-speed, rotor side bearing is upgraded to a notched-and-pinned design, preventing the possibility of bore spin
d. If needed, the housing is machined and bearing bores are sleeved
e. The cooling system is refurbished or replaced
The assembly team delivers the gearbox to the testing department who utilizes a back-to-back style dynamometer rated up to 4MW. Load testing is completed in a predetermined sequence of load spectra while critical measurements are captured and documented. Learn more about our load testing capabilities and process here.
Upon successful completion of load testing, the gearbox is delivered to the final assembly team who puts the finishing touches on the gearbox. This may include mounting and wiring of peripherals, installation of exterior lubrication components, and other requirements called for by customer specifications.
Final assembly inspection assures the customer requirements have been met, prior to releasing back to the warehouse staff for shipping.
Zero Defect Policy
Our philosophy of Zero Defects informs every aspect of what we do and is especially relevant to the repair and remanufacturing aspects of our service offering. NGC assembly and repair teams work in direct collaboration with engineering and quality control teams, creating reports that include the documentation of critical measurements, component serial numbers, and process validation.
Related Products & Services
Core Exchange Program
A subset of our remanufacturing process, our core exchange service helps to limit downtown and drive efficiency for our customers.
In addition to repairing gearboxes owned by customers, we also remanufacture gearboxes and add them to our inventory to support our customers.
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