Overhaul of an extruder reducer with 2 indexed output shafts

Client expectation

Given the importance of the co-extruder in their manufacturing process, a French plasticisation company wished to entrust to us the overhaul of the only reducer they had in stock in order to guard against a possible mechanical breakdown.

DV GROUP Solution

In fact, a breakdown of the co-extruder would systematically lead to the stoppage of half of production and as the lead time for the supply of a new reducer would be extremely long, out client could not afford not to have a product in stock. In order to be totally worry-free regarding the condition of the only reducer they had in stock, it was imperative to overhaul it.

Work carried out

DV GROUP technical solution:

3D printing of the shafts’ clamping matrix:

• Given the particularity of an extruder reducer with 2 indexed output shafts, we suggested to our client modelling and 3D-printing the shafts’ clamping matrix in order to guarantee their correct positioning during refitting.

Removal/refitting and overhauling of the reducer in the workshop:

• Visual monitoring of the product
• Measurement of the axial play in the gearing rows
• Benchmarking of the bearing references
• Visual appraisal of tooth spacing (search for the usual signs of deterioration of the teeth)
• Monitoring of the span of the teeth with an impression of the teeth on scotch tape
• Removal of the gearing rows
• Monitoring of the size and geometry of the shaft rows
• Magnetic particle inspection of the teeth
• Inspection of the key grooves and connector spokes by bleeding
• Inspection of the casing size
• Cleaning of the reducer and gearing rows
• Reassembly of all the bearings and joints
• Monitoring and adjustment of the span of the teeth and indexation
• Adjustment of the axial play in the gearing rows
• Reassembly of the cover, waterproofing and upper casing