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Emergency Gear Box Repair of Slitting Line Drive Unit for the Steel Processing Industry

Emergency Gear Box Repair of Slitting Line Drive Unit for the Steel Processing Industry

Our client from the steel processing industry approached Dayton Gear with a gear box for a slitting line drive unit that had failed, requiring emergency repair via hobbing, CNC turning, heat treating, and rebuilding, to get two of the customer’s slitting lines back on line as soon as possible. The gear box failure and line shutdown was costing the customer $1,000 per hour, and the OEM had quoted a turnaround and delivery time of 16 weeks for a replacement. Working around the clock, Dayton Gear personnel analyzed and diagnosed the internal helical gear and drive shaft failures, and reverse engineered these components to provide the correct replacements.
Dayton Gear fully manufactured the internal components in-house, and provided all new components needed for rebuilding the full drive unit, including bearings, seals, spacers, and power transmission components. With our engineers working non-stop to provide the replacement as soon as possible, we completed the rebuild in 40.7 hours, which translated to a total savings of $240,000 for the customer.

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Emergency Gear Box Repair of Slitting Line Drive Unit – Project Highlights

Product Description Dayton Gear Rebuilt this drive unit with updated  components to avoid future failures.
Capabilities Applied/Processes Diagnosis
  • Technical Staff Diagnosed Internal Component Failure
Reverse Engineering
  • Reverse Engineered Helical Gear & Drive Shaft
  • Utilizing:
    • Calipers
    • Micrometers
    • Coordinate  Measurement Machine (CMM)
Helical Gear & Drive Shaft Manufacturing
  • Hobbing
  • CNC  Turning
Drive Unit Rebuild/Assembly
  • Unit  Rebuilt w/ New:
    • Bearings
    • Seals
    • Spacers
    • Power  Transmission Components
Rebuilt in 40.7 Hours
Tightest Tolerances Assembled to Industry Standard Backlash
Material Used Alloy Steel
Max Material Finish Heat Treatment
  • Shaft Heat  Treated to 45Rc
In process testing performed 100 % Dimensional Inspection
Operational Testing
  • Run Gear Box
    • Vibration  Analysis
    • Temperature Analysis
Customer Savings $240,0000
Industry for Use Steel Processing
Delivery Location Northern   Ohio
Standards Met Customer supplied specifications
Product Name Emergency Gear Box Repair of Slitting Line Drive  Unit
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Dayton Gear - Gear Cutting and Gearbox Repair & Rebuilding Services