Problems associate for felling the testing of 9 S gear Box
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The document describes testing procedures for a 9S gearbox assembly. Key steps include noise testing to identify issues like high spot noise or abnormal noises; engagement testing to check for problems shifting gears; leakage testing with oil under pressure; and vibration testing during gear engagement. Common defects found include high spot noise, issues with reverse/cruise engagement, tower shifting problems, vibration, and planetary gears not operating properly. Any gearboxes found to have defects are sent for rectification, which involves disassembly, defect identification and rectification, and retesting before final approval.
Problems associate for felling the testing of 9 S gear Box
- 1. TESTING OF 9S GEARBOX ASSEMBLY: 1. Testing consists of - 2. High spot noise. 3. Rev /crw dis-engagement hard 4. Tower shifting problem 5. Ot/ vibration 6. Engagement problem 7. Abnormal and fouling noise 8. Opf runout and face out 9. Gear, humming and rubbing noise 10. Planetary not operating  Machine used for GB testing is Dynaspeed.  Noise testing: In noise testing, gear box is run by giving rotation to input shaft and noise at running condition is tested by shifting on various gear. If there is any noise on any gear some unusual noise are heard by operator i.e. high spot noise, abnormal and fouling noise, gear, humming, rubbing noise.  Engagement of gear: While testing in running condition it there is any problem in gear engagement are determined. Problems may be of rev/ crw engagement or engagement of any other gears  Leakage: In this process 6.5 lit. Oil is filled in GB at 0.2 bar pressure and while running any leakage through casing are detected.  Tower shifting: If any problems in tower is detected.  OT/ Vibration: while testing the assembly if there is any vibration in engagement gets detected by operator.  Planetory not operating: However of the total HSN defect, nearly 48% defect is caused due to planet gears.also of the total defect nearly 18% is of this category.  If gear box doesn’t shows any defect, then it is directly considered as passed. If any of the above defect in GB is observed during testing GB send to Rectification. RECTIFICATION & REASSEMBLY : If there is any defect in GB that probable is noted during testing and send for rectification.  In rectification GB is de-assembled manually and any problem is rectified by operator.  There are many vibration problems due to any defect during machining such defects are removed by charging that gear/sleeve/synchro component.
- 2. ï‚· Also the noise generated during testing is rectified by initially finding defects in gears and later it is rectified. ï‚· Problems for planetary is rectified with precision and care, and if necessary planetary is changed. ï‚· After inspection it is sent again to the testing department and after that is is passed. ï‚· However sometimes there may be a possibility of rejection of gears for the second or rarely for the third time. ANALYSIS OF ZF 9S PRODUCTIONIN ASHOK LEYLAND: DEFECTS SEQ % CUM HIGH SPOTNOISE 1 24.9 24.9 REV/CRWDIS-ENGAGEMENT HARD 2 16.2 41.1 TOWER SHIFTING PROB. 3 13.2 54.3 OT/VIBRATION 4 11.3 65.6 ENGAGEMENT PROB. 5 9.8 75.3 ABNORMALANDFOULING NOISE 6 8.2 83.6 OPFRUNOUT ANDFACEOUT 7 8.0 91.6 GEAR, HUMMING AND RUBBING NOISE 8 7.6 99.2 PLANETORYNOT OPERATING 9 0.8 100 OPFNOT ROTATING 10 0.0 100