Rubber Mill Bearing and Shaft Repair
A facility faced a critical failure in their rubber mill, a 100-year-old machine manufactured in the 1920s. The failure was caused by a bad bearing which resulted in significant damage to one of the shafts and the brass lining. All Enterprises Inc. was brought in to provide a comprehensive repair solution to restore the machine's functionality and prevent future failures.
Challenges
- Old and Damaged Equipment: The rubber mill, being over a century old, had seen numerous repairs over the years, including a spray weld done 40 years ago. The current failure required precise machining and innovative solutions to avoid repeating temporary fixes.
- Tapered Shaft and Bearing Issues: The shaft where the bearings go was tapered, adding complexity to the repair. The previous spray weld repair was extensively damaged, making it unsuitable for another spray weld or chrome fix.
- In-house Machining and Sleeving: The repair involved turning down the shaft and pressing a sleeve on it, shrunk by 150 thousandths to ensure it would not come off, avoiding any temporary fixes like spray metal or chrome.
- Multiple Clearances and Damaged Parts: Multiple clearances needed to be accommodated for new bearings, and extensive damage to the brass pieces required in-house braze welding and thrust bearing repairs.
- Coordination and Timeline: The facility ran 24/7 and needed a quick turnaround to avoid prolonged downtime. All repairs had to be completed within three weeks to minimize the impact on the facility's operations.
Innovative Solutions
All Enterprises Inc. employed a strategic approach to address these challenges effectively:
- Shaft Repair and Sleeving: Using an in-house lathe, we turned down the end of the shaft and pressed a metal sleeve on it, ensuring a permanent fix without the risk of future failures.
- In-house Machining and Welding: All damaged parts, including the brass pieces, were repaired in-house. We braze welded a thrust bearing and manufactured new bronze piston rings to seal the oil, replacing the damaged ones.
- Precision Machining and Chroming: The inner dimension of the shaft was machined and chromed to build up what was removed, followed by ID grinding to achieve the correct size. Two gears were also repaired and reinstalled on the shaft.
- Comprehensive Planning and Coordination: We developed a detailed game plan, identified all damaged parts, and utilized old drawings to ensure the repairs met the required tolerances and clearances. The entire process was coordinated to ensure a quick turnaround and successful outcome.
Project Outcome
The project was completed within the tight three-week timeline, significantly faster than the months it would have taken other companies relying on outsourced repairs. All Enterprises Inc. demonstrated their capability to handle complex repairs with in-house expertise and equipment, ensuring a seamless and durable solution for the client. The machine continues to run effectively seven years after the repair.
Key Highlights
- Project Complexity: Tackled a 100-year-old machine with outdated drawings and numerous previous repairs, requiring precise machining and innovative solutions.
- Cost-Effective Solution: Provided a permanent fix with in-house machining and sleeving, avoiding temporary solutions like spray metal or chrome.
- Efficiency: Completed the project within a critical three-week timeline, minimizing downtime for the facility.
- Expertise: Extensive experience in handling similar failures and providing comprehensive repair solutions, including mechanical, rigging, machining, and coordination.
For more information or to discuss how All Enterprises Inc. can assist with your complex machinery repairs and maintenance needs, please contact us.