Detecting Lubrication Issues in Gearbox Testing by IR Monitoring

Monitoring Temperature Rises to Ensure Gearbox Health and Preventing Damage in End-of-line Inspections ?????

Detecting Lubrication Deficiencies in Gearbox Testing Through Temperature Monitoring?

Proper lubrication is essential for the longevity and performance of transmission gearboxes. Without it, friction between gears increases, causing a rise in housing surface temperature and leading to accelerated mechanical wear.?

Before a vehicle reaches the market, it undergoes rigorous end-of-line testing, including thermal assessments of the gear transmission system. An abnormally hot gearbox after a short test cycle or uneven heat distribution can signal insufficient lubrication, requiring immediate attention. If left undetected, poor lubrication can cause overheating, compromising internal components and leading to long-term quality issues.?

Traditional methods of verifying lubrication levels are time-consuming and demand high precision from operators, increasing the risk of late-stage fault detection. Attaching contact temperature sensors to every gearbox is impractical in high-volume production, while visual inspection is impossible during bench testing. Even when temperature sensors are used, they may be unreliable or require integration with additional test bench systems, complicating the process further.?

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Implementing automated thermal imaging solutions can streamline this process.?

Quickly Detecting Temperature Variations to Ensure Proper Lubrication and Preventing Gearbox Damage?

Thermal imaging cameras, such as the PI 640i, quickly and accurately detect temperature variations. They ensure that gearboxes are appropriately lubricated before they leave the factory, saving time and enhancing the reliability and quality of the final product.?

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An infrared camera measures the surface temperature of the gearboxes and differential housings, which are sealed and opaque. Once the engine is switched on, the gearboxes' surfaces become hot if the moving gear inside is insufficiently lubricated or not lubricated due to mechanical friction.?

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Low-temperature thermal imaging cameras, such as the PI 640i??or the Xi 400, effectively measure the surface temperature. The lacquered metal boxes are advantageous as the coating increases their emissivity, allowing low-temperature thermal imaging cameras to be used. The speed of measurement is a key advantage, as Optris infrared cameras can connect to control systems to send visual, audible, or alarm signals at specific temperature thresholds. This ensures a quick response to fault situations, such as sending a signal to shut down the motor immediately if there is a risk of gear damage.?

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This testing process can also be automated. Thanks to the compact installation, the operator can save time efficiently with minimal effort without negatively affecting parallel testing processes.?

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High Thermal Sensitivity and Fast Response: Essential for End-of-Line Gearbox Testing?

The Optris Xi 400, Xi 410, and PI 640i?thermal imaging cameras offer an advanced solution for quality assurance in final inspections. They enable fast and precise measurement of gearboxes and differential housings. Lubrication can decrease over time due to seal ageing. By monitoring temperature distribution in real-time, the cameras can detect anomalies immediately and send signals to the appropriate control authorities for a prompt response.?

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These thermal cameras detect and communicate with peripheral devices such as data loggers, PLCs, and simple controllers. Their application extends beyond final inspection to include preventive maintenance of stationary motors used in these systems.?

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Optris infrared cameras provide detailed thermographic data, enabling immediate analysis and adjustment. They offer various communication options, including remote communication and adjustment via Ethernet networks, such as the control room.?

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The sophisticated, license-free PIX Connect?software opens many possibilities for implementing a detection system that easily integrates into existing processes without disrupting manufacturing or inspection workflows. This enables customers to optimise and significantly enhance the efficiency of their processes.?