gearbox alignment

Field Service Cooling Tower Gearbox Project

Indianapolis Field Service went on site to look at a gearbox problem toward the end of last year. What we found was not one, but two cooling towers had experienced failures of the old gearboxes at the center of the cooling towers. Cranes were brought in for the material handling and the cooling tower drive train was all removed and taken to the shop for repair. When at the Indianapolis Repair Facility, the age and condition of the gearboxes added together to make repairs impractical if not impossible. A replacement drive (the drive train replaced was the drive shaft, couplings gearbox, [...]

Field Service Cooling Tower Gearbox Project2026-04-14T10:50:51-04:00

The High Costs of Production Losses

In November, Bill Roper received a call from a concerned customer with a failed gearbox. This was a large obsolete gearbox that is coupled to a rubber extruder that mixes a special compound, supplied to other facilities. Bill asked if the Springfield division could commit the manpower to this overtime job and we accepted the challenge. The customer stated that his company was losing $550 every 15 minutes that this extruder was down. So that is $2,200 per hour, $52,800 per day and $369,000 per week! Needless to say, this was a full overtime job, worked around the clock. The customer [...]

The High Costs of Production Losses2023-03-06T11:22:25-05:00

Rolling Mill Gearbox Repair

A customer recently sent in a gearbox that is part of their rolling mill. The rolling mill uses a metal alloy to make engine bearings for large Diesel engines. This line on the mill brings in thicker material and rolls it out thinner to the desired thickness. Much like a rolling pin does with dough. The problem with the gearbox was when it was put under load it would vibrate like crazy. When the gearbox ran unloaded it ran smooth. It was found that the shaft was bent, and the gears were in bad shape. We worked with a quality manufacturer [...]

Rolling Mill Gearbox Repair2021-02-18T18:45:06-05:00

Plastics Company Gearbox and Roll Application Upgrade

An Indiana Plastics Company used a single chain, with a multiple sprocket setup to control their process equipment. They wanted to upgrade their systems to modern equipment and have the ability to vary the line speed. The customer decided to use (1) motor/gearbox and VFD per roll to allow for independent control. Horner was able to provide Sumitomo motor/ gearboxes and Horner Machining Service designed and machined a new drive shaft and coupling for each roll. These 8’ long 20” diameter rolls are water cooled so Machining Services had to figure out how to allow water to flow through the drive [...]

Plastics Company Gearbox and Roll Application Upgrade2021-01-10T16:50:22-05:00

Dredge Motors

A gravel pit in Petersburg, KY contacted John Baumann (Sales) with a problem. They had 2 motors on a dredge. A particular dredge is a floating clam shell type bucket that pulls gravel off the bottom of a lake. The motors drop and pull up the bucket from the bottom of the lake. The team at the gravel pit wanted to upgrade from a wound rotor motor and convert it to a new induction motor to be controlled by a VFD. They also wanted to upgrade the controls to eliminate a diesel generator and go to shore power. If they run [...]

Dredge Motors2019-09-09T18:01:36-04:00

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