Perfte rail-mounted self-propelled trailer gear failure analysis

The gear system is critical for the traction and transmission of rail-mounted self-propelled trailers. Timely identification and resolution of gear failures ensure stable operation and extend equipment lifespan.​

Common Gear Failure Types & Causes​

1. Gear Wear​

Phenomenon: Tooth surface thinning, uneven tread, or reduced tooth thickness, leading to increased noise and reduced transmission efficiency.​

Causes: Insufficient lubrication (oil shortage or poor oil quality); long-term operation under overload, accelerating abrasive wear; foreign particles (dust, metal debris) in the gearbox contaminating lubricants.​

2. Tooth Surface Damage​

Phenomenon: Pitting (small cavities on tooth surfaces), scuffing (local melting/adhesion), or corrosion (rust spots on teeth).​

Causes: High contact stress from overload or improper meshing; lubricant degradation failing to form protective films; humid environments causing rust on unlubricated surfaces.​

3. Gear Fracture​

Phenomenon: Sudden tooth breakage (partial or full tooth loss) or cracks along tooth roots, often accompanied by sharp operational noises.​

Causes: Fatigue from repeated load cycles (especially frequent start-stop operations); material defects (impurities in gear steel); excessive impact loads during emergency braking or collision with obstacles.​

4. Gearbox  Abnormal Noise​

Phenomenon: Continuous humming, rattling, or grinding sounds during operation, worsening with speed increase.​

Causes: Gear misalignment (installation deviation or bearing wear); loose fasteners in the gearbox; worn bearing raceways affecting gear meshing accuracy.

Solutions & Preventive Measures

Wear/Damage: Replace severely worn gears; clean the gearbox, replace lubricants, and add filters to remove contaminants.​

Fracture: Replace fractured gears with high-strength alloy steel parts; inspect adjacent components for secondary damage (e.g., shaft deformation).​

Abnormal Noise: Realign gears and tighten fasteners; replace worn bearings and recalibrate meshing clearance.