Gearbox failures, heard weeks before they are loud.
Stage-wise vibration on input, intermediate and output shafts, gear-mesh and sideband tracking, bearing defect frequencies and oil temperature, against each gearbox's own baseline. Overhauls go into shutdowns, not emergencies.
One gearbox, whole-line stakes.
A plant event, not a repair
A large gearbox failure stops the plant. Lead times run months; monitoring turns catastrophe into a scheduled overhaul.
Too big to hear
By the time a 5-tonne gearbox sounds wrong, damage is advanced. Gear-mesh and bearing frequencies move weeks earlier.
Months-long lead times
Pinions and bearings for heavy boxes are not shelf items. Time-to-fault estimates buy the procurement window.
Work out a gear-mesh frequency.
The same arithmetic MachineWise tracks live, stage by stage. For bearings, use the bearing frequency calculator.
Gear-mesh frequency = teeth × shaft speed. Wear and damage show as growing sidebands spaced at shaft frequency around it.
OEE, condition monitoring and predictive maintenance for this floor.
Load and duty history
- Utilisation and load profiles per drive
- Overload and shock events logged
- Duty-cycle history for overhaul planning
- Fleet view of every heavy drive
Stage-wise sensing
- Tri-axial vibration on every stage
- Gear-mesh frequency and sidebands
- Oil temperature, optional debris sensing
- Per-gearbox learned baselines
Warnings with components named
- Bearing and gear defects, stage by stage
- Time-to-fault with named components
- Severity trend: watch, plan, act
- Overhauls scheduled in shutdowns
The equipment we monitor here.
Where this connects to the rest of the platform.
Straight answers.
How is a large gearbox monitored?
How early can gearbox damage be detected?
What is gear-mesh frequency?
Which gearboxes can be monitored?
Put your most critical gearbox under watch this month.
Two machines, thirty days, zero cost to start. Your data stays on-premises throughout.