Gear Repair
Gear Repair Services – Precision Restoration for Optimal Performance
Why Choose Gear Repair Over Replacement?
Industrial machinery relies on gears for seamless operation, and any failure can lead to costly downtime and lost productivity. Replacing a damaged gear can be expensive, time-consuming, and often unnecessary. Here’s why gear repair is the smarter choice:
1. Cost-Effective Solution
Gear repair services can reduce costs by up to 50% compared to purchasing new parts. Instead of investing in entirely new components, repairing and remanufacturing existing gears help businesses maximize their operational budgets.
2. Reduced Downtime
Manufacturing and ordering new gears can take weeks or months. Our repair services provide a fast turnaround, minimizing downtime and keeping operations running efficiently.
3. Extended Gear Life
Through precision grinding, re-hardening, and re-manufacturing processes, repaired gears can function like new, significantly increasing their lifespan and reducing the frequency of replacements.
4. Custom Engineering and Enhancements
We don’t just repair gears; we enhance them. Using modern materials, heat treatments, and advanced coatings, we can improve the durability and efficiency of repaired gears, ensuring better performance than before.
5. Environmentally Friendly
Choosing to repair instead of replace reduces waste and promotes sustainable industrial practices by minimizing the demand for new raw materials.
Our Gear Repair Process
At Hanson Gear Works, our meticulous repair process ensures that every gear is restored to meet or exceed OEM specifications.
Step 1: Initial Inspection & Diagnosis
Upon receiving the damaged gear, our team conducts a comprehensive inspection to assess visible wear, cracks, or misalignment. Using advanced magnaflux technology, we identify internal defects that might not be visible to the naked eye.
Step 2: Deep Cleaning & Disassembly
Before any repairs take place, we thoroughly clean the gear to remove oil, grease, and contaminants. The gear is then carefully disassembled to prevent additional damage and prepare it for detailed diagnostics.
Step 3: Precision Measurement & Damage Assessment
Using high-precision measurement tools, we analyze gear tolerances, backlash, and shaft alignment. This step ensures that all necessary adjustments are made to restore optimal function.
Step 4: Gear Repair & Remanufacturing
Depending on the level of wear or damage, we apply one or more of the following repair methods:
- Gear Grinding:Restores gear surface smoothness and precision.
- Re-Hardening & Carburizing:Strengthens gear teeth to withstand high loads.
- Reverse Engineering:If OEM specifications are unavailable, we reverse-engineer the gear to create an exact replica.
- Component Replacement:Worn bearings, seals, and other critical parts are replaced as needed.
Step 5: Reassembly & Testing
After repairs are complete, the gear is carefully reassembled and tested under simulated real-world operating conditions. This ensures proper fit, function, and alignment.
Step 6: Quality Assurance & Final Inspection
A final inspection verifies that all components meet or exceed OEM specifications. Our team provides a detailed repair report outlining the services performed and recommendations for future maintenance.
Step 7: Delivery & Continued Support
The fully restored gear is shipped back to the client, ready for installation. Our team offers ongoing technical support and maintenance guidance to ensure long-term reliability.
Industries We Serve
Our gear repair services cater to a wide range of industries, including:
- Manufacturing & Heavy Industry– Ensuring uninterrupted production with reliable gear restoration.
- Oil & Gas– Repairing gears used in drilling, refining, and extraction equipment.
- Power Generation– Restoring gears in turbines, generators, and renewable energy applications.
- Mining & Construction– Extending the life of gears in high-load, high-impact machinery.
- Marine & Transportation– Enhancing performance in propulsion systems and industrial vehicles.
Common Gear Issues We Repair
Tooth Wear & Pitting: Over time, gear teeth degrade due to constant friction and load-bearing stress. Our precision grinding and surface treatments restore gear functionality.
Cracked or Broken Gears: Fractured gears can be repaired using welding, re-cutting, or re-hardening methods.
Misalignment & Backlash Issues: Incorrect alignment causes inefficiency and excessive wear. Our team ensures gears are properly calibrated for seamless operation.
Bearing & Shaft Damage: Replacing worn bearings and shafts prevents further damage to gear components.
Frequently Asked Questions (FAQs)
If your gear is showing signs of wear, misalignment, or performance issues, a professional inspection can determine whether repair is a viable option. In most cases, repairs can restore gears to like-new condition at a fraction of the cost of replacement.
Our standard gear repair services take anywhere from a few days to a couple of weeks, depending on the complexity of the repair. Emergency repair services are available for critical downtime situations.
Yes, our advanced reverse engineering capabilities allow us to restore gears even when OEM specifications are unavailable. We use high-precision measurement tools to create accurate replicas.
Yes, we provide on-site assessments for large-scale industrial applications. However, major repairs are typically performed in our specialized facility for maximum precision.
We follow stringent quality control measures, including magnaflux inspections, precision grinding, and performance testing. Every repaired gear undergoes thorough final inspections to ensure it meets or exceeds OEM standards.
Yes, we offer customized maintenance plans to help extend the lifespan of your gears. Proper lubrication, alignment checks, and routine inspections can prevent future failures.
Absolutely. We offer enhancement options, including advanced coatings, heat treatments, and optimized materials to improve gear durability and efficiency.
Get Your Gear Repaired by Industry Experts
At Hanson Gear Works, we take pride in delivering industry-leading gear repair services that keep your machinery running efficiently. With fast turnaround times, precision craftsmanship, and cost-effective solutions, we help businesses maximize the lifespan of their gears and reduce operational costs.
Contact us today to schedule an inspection or learn more about our gear repair services!
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