Concrete mixer gearbox case study

Concrete mixer Gearbox for Honest Bricks Pvt Ltd

1 . Background

Honest Bricks Pvt Ltd. is engaged in construction activities, requiring reliable machinery to mix concrete. They faced a significant issue when their 3-ton concrete mixer’s gearbox failed due to being under capacity for the heavy workload.

2 . Objective

The aim was to provide Honest Bricks Pvt Ltd. with a durable gearbox solution capable of handling the strenuous demands of their concrete mixer, which operates under heavy shock load conditions and is essential to run continuously without failure.

3 . Approach

To meet the client’s urgent need, we initiated a swift and customized engineering response. Our approach centered around designing and creating a bespoke gearbox that would match the specifications of the international make. The primary steps included:

Conducting a detailed analysis of the broken gearbox and the specific requirements for the PAN MIXER application it served. Innovating a wooden pattern design that would allow for the rapid production of the new gearbox.

4 . Implementation

With a clear understanding of the requirements, we quickly moved forward with the implementation phase:

Our team expedited the design process, ensuring that every aspect of the international make’s specifications was meticulously replicated in the wooden pattern.

We adjusted our production workflow to prioritize the manufacturing of the custom gearbox, ensuring that we could commit to a delivery time of 2 to 3 weeks. Throughout the process, we carefully considered the client’s unique mounting arrangement, modifying the new gearbox design to ensure a seamless integration with their existing setup.

3 . Approach

Upon thorough evaluation of the client’s application and operational requirements, the recommendation was made for a replacement gearbox. The new gearbox was selected with careful consideration of its service factor, ensuring it exceeds the standard operational demands by 2.5 times. This service factor was deemed critical to sustain 24-hour operation under the heavy shock load conditions experienced by the concrete mixer.

4 . Implementation

The upgraded gearbox was installed, designed to offer enhanced capacity and resilience, thus preventing the likelihood of future failures similar to what was previously experienced.

5 . Results

The bespoke solution was successfully delivered and installed within the promised 2 to 3-week timeframe, significantly reducing the client’s operational downtime compared to the originally quoted 5 to 6 weeks by the international manufacturer. The PAN MIXER application was back in action promptly, and Santaram Engineers Pvt Ltd was able to resume their production without further delays.

6 . Conclusion

The rapid response and customized engineering capabilities demonstrated in this project underscore the commitment to client needs and our ability to deliver complex solutions under tight deadlines. The success of this project with Santaram Engineers Pvt Ltd establishes a strong precedent for similar future challenges requiring tailor-made engineering solutions.

5 . Results

With the newly installed gearbox featuring a 2.5 service factor, Honest Bricks Pvt Ltd.’s concrete mixer gained the capability to withstand continuous operation and heavy loads without compromising on performance or risking another failure. This change has resulted in increased operational efficiency and reduced downtime for the client.

6 . Conclusion

The strategically selected gearbox has proven to be a superior solution for Honest Bricks Pvt Ltd.’s needs, underscoring the importance of adequate service factors in machinery operating under extreme conditions.