Reconditioning Procedure Overview

Gear Receiving & Classification - Each draft gear received at the Independent Draft Gear (IDG) facility is immediately received and classified. The classification process identifies the gear as either a customer’s gear, which is to be reconditioned and returned, or a gear being purchased by IDG. The gear is also classified by date which determines if the gear falls into the Pin Only, Test & Pin, or Recondition criteria (please see the enclosed Date Criteria Sheet). Further, the classification process requires that the gear be inspected for the quantity of broken friction components and obvious case cracks, excessive case wear, and case bulging beyond acceptable tolerance. Gears are then stored inside the IDG facility and brought to room temperature before being processed further.

Disassembly Gears to be reconditioned are placed on one of three disassembly lines to ultimately be processed under one of the 150-ton presses. The specific line the gear is placed on depends on the type of gear and the quantity of broken friction components. Once the gear is fully dismantled, the friction components are gathered and sent to the blast and gauge area of the facility. The springs, rubber pads, or elastomeric components of the gear are also gathered and moved to the inspection and gauging area of the facility.

Case Reclamation - Once the gear is fully disassembled, the empty case moves down the line where it is vacuumed, gauged and fully inspected for cracks, wear and bulging. Cases meeting the criteria for reconditioning are welded and ground as necessary and then re-inspected. Cases not meeting the criteria for reconditioning are immediately removed from the line and discarded per the IDG Quality Assurance Manual.

Friction Component Blasting & Gauging - All friction components generated by the dismantling process are tumble grit blasted on site at the IDG facility. Once the blasting process is completed, the friction components are separated by gear model and then moved to the gauging area. Each and every friction component is inspected and gauged to assure it is within tolerance and is mechanically sound. If the part is deemed to be acceptable, it is stored with like parts in preparation for transportation to the gear rebuilding area. If the part is not acceptable, it is immediately considered scrap material and is handled according to procedures outlined in the IDG Quality Assurance Manual.

Next »
© 2007 A. Stucki Company. All Rights Reserved.