Gearbox Failure: Early Detection Saves Millions
Gearbox failure: identifying keyway clearance early helped Cal Trevo save R$ 1.3 million in maintenance costs.
The early identification of a gearbox failure helped Cal Trevo save USD$ 236.114,64. Check out this success story:
Cal Trevo team uses Dynamox technology to monitor the vibration and temperature of their assets. This continuous monitoring enabled the identification of an abnormality in the gearbox vibration levels.
The equipment showed consistent vibration and minimal changes in RMS acceleration data. Additionally, analysts identified a similar behavior in the motor, but with greater amplitude.
Problem Diagnosis
With the trend data from both components, it was reasonable to assume the defect was in the coupling elements between the motor and the gearbox.
The spectra indicated the presence of vibration at 1x RPM and its harmonics, leading to a diagnosis of looseness.
Gearbox and Motor Failure
The maintenance team carried out a scheduled shutdown and confirmed the presence of looseness in the keyway connecting the motor and the gearbox, which corroborated the vibrational behavior of the assembly.
The team estimated the potential cost of an unplanned equipment shutdown and reduced the cost through planned maintenance. In total, Cal Trevo avoided spending USD$ 223.686,29 by preventing a catastrophic failure through predictive maintenance.
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I'm an electrical engineer by training, but my biggest project has always been people.After working at major industrial companies like WEG and spending more than a decade in the public sector, I realized there was an enormous gap between technical knowledge and its practical application on the factory floor. That's how Modular Cursos was born — a company I founded with the goal of transforming the way Brazil trains and values maintenance professionals.Today, I lead the largest maintenance planning and control (PCM) community in the country, connecting specialists, technicians, and managers who are looking for more than just information: they want results.My role isn't to be the technical expert. It's to be the strategist — the one who builds the right team, develops solutions, and clears the path for the people who make maintenance actually happen.If you also believe that education changes processes, people, and companies, let's talk.
Geovan Lamin
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