Learn How to Achieve Gear Coupling Reliability

For connecting process equipment gear couplings are among the most commonly used methods. They can provide long life and good reliability if properly selected, installed, and maintained.

Compared to other couplings, gear couplings offer several benefits, including very high torque density, moderate misalignment capacity, and exceptional torsional stiffness.

However, when the question arises regarding gear coupling reliability, you will find many areas where failures may be initiated. Due to the lack of knowledge or execution of certain basics, these failures begin. These are necessary for these gear coupling to run reliably.

Design, Selection, and Sizing

For gear coupling reliability selecting the correct coupling for the application is critical. 

Select the coupling style and design.

From the original equipment manufacturer’s (OEM) gear coupling charts you need to select the service factor (SF). If adequate SF is not used, shock loads or variable loading can cause premature failure. For gear coupling sizing some gear coupling manufacturers may even specify a misalignment factor when higher coupling misalignment is expected.

Based on the design of brake horsepower (BHP), SF, and speed you should calculate application torque (T) requirements.

You should select a coupling with a torque capacity greater than the torque requirements. There is no reason to add additional capacity because the service factor is already factored in.

Compared to the actual application bore, you need to confirm that the coupling selected has a greater bore capacity. Frequently the maximum bore size will even increase the coupling torque capacity two to three times what was previously calculated and drive the coupling sizing process.

You need to verify the shaft depth available for the coupling hub and compare it with the actual hub depth. In case the hub is too long, it must be either overhung or machined off. You will find some good gear coupling suppliers according to your type.

Make sure that the coupling will fit around the equipment and guard. When there is a design modification on existing equipment this is typically something that can become an issue. In the long run, guards that allow maintainability will encourage proper maintenance.