Drop-in gearbox solution speeds cold mill overhaul

David Brown Engineering has provided a custom-designed 'drop-in' replacement for the faulty gearbox on a steel coil cold reversing mill for Signode in Swansea

A world leader in the supply of tensional steel strapping for heavy duty packaging and palletized delivery - Signode - was grateful for its own delivery of technical support when David Brown Engineering provided a custom-designed 'drop-in' replacement for the faulty gearbox on a steel coil cold reversing mill.

Oil loss coupled with the potential risk of gear failure was a major issue with the existing gearbox at the Davy United Mill in Swansea operated by Signode, a division of Illinois Tool Works in America.

The gearbox had developed significant leaks because of the flexing of the casing on the 30 year old unit, and it was expensive to operate and maintain because of the continuous oil loss.

Following the installation of the new unit the leaks were eliminated and operating noise was significantly reduced.

The team from David Brown Technical Services, part of Textron Fluid and Power, had previously replaced the combined reduction and pinion gearbox on the main mill drive, so they were already familiar with the operation at the mill.

They designed the unit to exacting specifications incorporating a stronger frame to handle the loads and accompanying separating forces generated by the heavy duty operation, which had driven apart the original joints.

The single helical parallel offset gearbox was supplied with a complete lubrication system, and retained the external dimensions of the original to ensure that it was perfectly interchangeable.

The gearbox also employed a hollow shaft compatible with the advanced expanding and collapsing mandrel sheathing solution used to locate the coil reels.

The 7.5 tonne gearbox was installed in just 10 days during the seasonal shutdown of the mill, and the 'drop-in' design enabled the Signode engineering and production staff to replace the gearbox without additional production down-time.

The coiler works in conjunction with the rolling mill and is used to handle the steel as it passes repeatedly through the mill until it has reached the required thickness, when it is slit and recoiled into bands.

Andrew Freeman, the works engineer at the plant commented: "The care taken to create a drop in solution made a huge difference to the operation and simplified the whole exercise, to enable our own engineers to undertake the removal and replacement right on schedule".

For more information on the advanced engineering solutions provided by David Brown for plant and production installations call Rachel Ingleby, or visit the website.

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