減速機の整備・修理・補修・部品製作ならKBKエンジニアリングへ

Specialist in Maintenance and Service for Speed Reducers KBK Engineering Co., Ltd.

40-plus year record of performance in maintenance and service, fabrication, and repairs
  • Fabrication of gears
  • Tooth contact repairs
  • Maintenance and service of large speed reducers
  • Dynamic balance corrections
  • On-site investigations
  • Repairs for fittings and sliding parts
  • Hard-facing
  • Test runs
  • Maintenance for planetary gear speed reducers
  • Repairs and modifications of casings
  • Replacement of consumable parts, etc.
Manufacturers we support
  • MHI HASEG
  • SEW-EURODRIVE
  • Sumitomo Heavy Industries
  • HITACHI
  • TSUBAKI E&M
  • NIPPON gear
  • MITSUBISHI HEAVY INDUSTRIES
  • Philadelphia
  • ANDRITZ
  • Overseas-made speed reducers (Germany, the U.S.), and so on
  • Click here for inquiries
  • ISO9001のロゴ
    Acquired ISO9001:2015 certificationHead Office Factory and Higashizuka Factory
    *International standard for quality management systems

サムネイル「減速機整備の特徴」

Features of Maintenance and Service for Speed Reducers

Transmission systems are used in many situations to transmit force input by a motor. While there are various speed reducers such as hydraulic, cyclo, and chain speed reducers, gear devices still plays a central role due to their reliability, economic efficiency, and performance. The speed reducer itself does not directly contact with the product, but its control and reliable operation are essential to the stable production of products. In order to stabilize power transmission by a simple mechanism consisting of a case, shaft and gears, it is necessary to perform maintenance and service by an experienced engineer with each component element. The repair quality of the fitting parts not only maintains reliable tooth engagement but also directly protects the bearing and oil seal. Properly set dimensional and geometric tolerances prevent the tooth surfaces from damage, maintain stable rotation and improve control over production machinery.

KBK Engineering’s Maintenance and Service
for Speed Reducers

Planetary gear system, one of the machines that makes up a decanter centrifuge.
It is one of the speed reducers that can achieve a large reduction ratio in spite of its small size by combining multiple gears.
It functions in generating the difference in rotational speed between the bowl and the screw, and the torque of the screw is transmitted, so it is inspected and serviced at the same time as the decanter centrifuge.

At KBK Engineering, we have been engaged in the maintenance and service of these gear systems with complicated mechanisms for more than 40 years, back to the time of Kurashiki Boring Kiko. By developing this technology, we have performed maintenance and service for various speed reducers. We offer integrated service from diagnosis, condition confirmation and non-destructive inspections, to hard-facing, thermal spraying and plating repairs necessary for maintenance and service, machining and dynamic balance corrections, test runs, and diagnosis. We have a record of performance in a variety of repairs, including repairs and fabrications of gears, which are main components, as well as repairs for bearing fitting parts, repairs for lip marks of oil seals, welding repairs for cases, and fabrication of shafts.

We conduct maintenance and service best suited to parts that are needed, for example, high-precision dynamic balance corrections required for stable operation by suppressing vibration, and extending machine life by fabricating new parts that can no longer be repaired. For overseas-made speed reducers, we procure parts and modify them to conform to JIS (Japanese Industrial Standards).

After maintenance and service, the speed reducer rotates smoothly, reducing noise and vibration, thereby extending its service life. In addition, properly adjusted gear backlash and tooth contact stabilize the operation of connected production machines and improve the quality and productivity of products. Indicators for determining the timing of maintenance and service include rising temperatures of oil and bearing fitting parts, abnormal vibrations, and abnormalities of the speed reducer itself caused by abnormal sounds, as well as changes in product properties and process abnormalities.

Gears
Fabrication of various new gears such as helical, worms, spiral bevels, splines, etc.
Shafts
Repairs by surface treatment of fitting parts, fabrication of new shafts, hard-facing repairs by welding
Cases
Welding repairs, repairs for fitting parts, modifications conforming to JIS standards
Investigation
Investigation of various gear elements such as gear modules, pressure angles, materials, and hardness, and consideration of replacement
Support for overseas-made speed reducers
Component procurement, search for compatible standards in various countries, modifications to conform to JIS standards

As shown by the above wide-ranging examples of maintenance and service requested, we are a maintenance and service company that can handle repairs in-house or in conjunction with our partner companies.

Practical Examples of Service, Maintenance, and Repairs

Cases for frequently requested service, maintenance, and repairs.

整備・メンテナンス・修理の 実施例「減速機整備 整備全般」

General maintenance and service for speed reducers

By carefully observing the gears themselves and their tooth surfaces, the condition of the gears can be assessed without fail, and if repairs are possible, appropriate repairs enable reuse, quick delivery, and low-cost maintenance and service. Even when repair is impossible due to severe damage, we work with specialists to fabricate identical products to extend the life of the speed reducer.

Record of performance in maintenance and service
MHI HASEG, SEW-EURODRIVE, Sumitomo Heavy Industries, TSUBAKI E&M, NIPPON gear, MITSUBISHI HEAVY INDUSTRIES, Philadelphia, ANDRITZ, HITACHI, Overseas-made speed reducers (GERMANY, the U.S.), etc.

整備・メンテナンス・修理の 実施例「遊星歯車減速機」

Planetary gear speed reducers

Planetary gear speed reducers, which are the main components of decanter centrifuges, are decelerated by multiple internal gears and planetary gears engaging with a pinion shaft called a sun gear.
In addition to checking the fittings, we also check the gear surfaces and their engagement, and conduct an inspection of the correct positioning, regarding the gear reducers attached to various decanter centrifuges.
KBK Engineering applies its experience and expertise in inspecting and assembling multiple gears engaged simultaneously to the maintenance and service of speed reducers.

整備・メンテナンス・修理の 実施例「嵌め合い部の補修」

Repairs for fitting parts

We offer optimum repair methods for the fitting parts of the speed reducer components such as bearings, oil seals, bosses and collars.
In addition to carefully observing the condition of existing products, we consider the most appropriate repair method in consideration of the torque transmitted, the number of revolutions, and the operating environment. For better operation, we not only repair defective parts but also improve related parts to contribute to stable operation.

整備・メンテナンス・修理の 実施例「ケースの補修」

Repairs for cases

Due to the need for productivity, cost, vibration absorption and noise reduction, many speed reducer cases are made of castings, often with complex shapes and large sizes. In cooperation with Kurashiki Boring Kiko and our partner companies, we perform hard-facing repair that can deal with cracks and abnormal wear of cases and repair fitting parts by thermal spraying that is optimal for complex and large shapes, and conduct machining with appropriate processing machines.

整備・メンテナンス・修理の 実施例「歯車の製作」

Fabrication of gears

Gears, which are the most important parts of speed reducers, need the most careful inspection. Various problems that occur in speed reducers, such as wear of the fitting and seizing due to oil leakage caused by a defective oil seal, can be observed as the condition of the tooth surface. The most suitable gears can be fabricated after consultation with an expert based on the measurement of tooth forms, modules and coefficients, which are different for each product, and taking into account the results of hardness and materials.

整備・メンテナンス・修理の 実施例「試運転」

Test runs

If we consider it is possible, we can perform test runs at our company prior to shipment. Conditions after maintenance and service for the speed reducer are checked by monitoring temperatures, vibrations, abnormal sounds of bearings, and other indicators with specified rpm maintained for a certain period of time. By comparing the obtained operating data with actual past results and similar models, it can be confirmed that repairs have been performed successfully and there is no problem with the assembly process of the products that undergo maintenance and service, and then only those which have been judged to be normal are delivered.

整備・メンテナンス・修理の 実施例「非破壊検査」

Non-destructive inspections

We can conduct Penetrant testing (PT) by qualified personnel. By conducting our own tests without outsourcing, we can not only plan the maintenance and service process flexibly but also reduce costs. We maintain a network that enables us to conduct RT, UT, and other non-destructive tests when deemed necessary. Because we perform maintenance and service for a variety of machines, we have the experience and means to determine which parts need to undergo non-destructive testing.

Record of performance for maintenance and service

  • MHI HASEG
  • SEW-EURODRIVE
  • Sumitomo Heavy Industries
  • HITACHI
  • TSUBAKI E&M
  • NIPPON gear
  • MITSUBISHI HEAVY INDUSTRIES
  • Philadelphia
  • ANDRITZ
  • Overseas-made speed reducers (Germany, the U.S.), and so on

Before & After

Examples of before and after service, repairs and maintenance.

整備のBefore & After01「Before」
Before

Alternating load has continued to act on the pinion due to wear of the fitting part of the parts supporting the output shaft and hanging operation. Since the tooth of the spiral bevel gear has been chipped, and the pinion shaft has also been broken and could not rotate, it underwent maintenance and service.

整備のBefore & After01「After」
After

We sketched the spiral bevel gear and pinion shaft, fabricated new parts, and repaired the fitting parts. Geometric tolerances have been revised to improve gear engagement, and costs have been reduced through modifications to JIS standards, so it can be used continuously.

整備のBefore & After02「Before」
Before

We have serviced the speed reducer used in cooling towers that condense steam and reduce it to water. Since it is installed outdoors, corrosion is severe, and the internal gears may be damaged due to rainwater intrusion from the O-ring, maintenance is applicable.

整備のBefore & After02「After」
After

Eight units were serviced at a time with a short delivery time. In the repair process, especially the fitting parts, in cooperation with Kurashiki Boring Kiko, we performed thermal spraying repairs sequentially starting with the parts that had already been inspected, and were able to complete maintenance and service in a short period of time.

整備のBefore & After03「Before」
Before

This is an example of periodic maintenance and service of speed reducers used in the mining and manufacturing industries. After opening the interior and inspecting the components in detail, we examined where repairs are necessary.

整備のBefore & After03「After」
After

The case cannot be broken, so it is necessary to disassemble each part using a jig. Since this was periodic maintenance and service, there was little damage, so consumable parts were replaced, then it was assembled and painted. The case does not have a separate structure, so it is highly rigid and requires a jig for maintenance and service. The assembly procedure is complicated due to the large number of parts.

整備のBefore & After04「Before」
Before

We received a consultation that there was an abnormal sound coming from the inside, and since the overhaul time had come, we conducted maintenance and service. This is one of the largest speed reducers we have ever handled, and it is decelerated by two-stage helical gears. We replaced and repaired bearings and consumable parts, and conducted MT inspections.

整備のBefore & After04「After」
After

There were several areas that required repair, such as wear at the fitting part of the bearing, corrosion due to crevices, and lip marks on the oil seal. The fitting of the case also needs repair, so after considering the size and weight, it was repaired by thermal spraying.

Please feel free to contact us for consultations, estimates, etc.
If there is a need for an immediate response, please contact us by phone.

Inquiries by Phone
+81-(0)86-450-4577
Business Hours
8:30 a.m. to 5:30 p.m. (weekdays)

For consultations, please feel free to contact us.

Fabrication of parts

KBK Engineering makes high-quality parts available based on technical strengths acquired in maintenance and service for various speed reducers.

Due to manufacturer discontinuation of production and organization scale-down, there are a large number of machines without expectations for after-sales service. In addition to adding the necessary elements, we can determine the materials, fittings, heat treatment, etc., of the parts to be fabricated, based on the information obtained by observing the details in consideration of the use status at the site, the characteristics of the processed materials and products, and the surrounding environment. In order to examine the elements of gears, we measure various elements such as module, materials and hardness as much as possible and fabricate them.

部品の製作「スパイラルベベルギア」

Spiral bevel gears

This is a large spiral bevel gear that needs to be replaced with the JIS because it was made overseas, and the companies that can fabricate it are limited because of its large diameter. We fabricated in consideration of the condition of the tooth surface, and dimensional tolerances for load retention and vibration suppression.

部品の製作「スパイラルベベルピニオン」

Spiral bevel pinion

Spiral bevel pinion gear, which is the other part of a spiral bevel gear. Due to the structure of the machine, an alternating load is applied to the root of the gear, so in addition to changing the design and the materials, heat treatment is devised to increase the strength.

部品の製作「遊星歯車減速機」

Planetary gear speed reducers

Planetary gear speed reducers with a planetary mechanism consist of helical gears, spline shafts, sun gears and planetary frames. Since multiple gears are engaged at the same time, it is important to consider correct tooth surfaces, materials that can withstand torque, and heat treatments that increase hardness.

部品の製作「機能を付加した歯車を製作」

Fabrication of gears with added functions

In cooperation with Kurashiki Boring Kiko, we are able to fabricate gear components that have been thermal-sprayed for wear resistance. After examining the condition of the existing parts in detail, we can add the most optimal materials to the most appropriate part.

Repairs for parts and test runs

Parts are repaired with excellent wear resistance and corrosion resistance added by hard-facing and thermal-spraying Stellite, COLMONOY, EutAlloy, and other rigid bodies.

Through an examination of the causes of breakage and wear, the best choice can be made from various materials, such as hard-facing materials, ceramics and superhard materials, so that parts with even higher resistance can be fabricated. We perform repairs for the purpose of stable operation and quality improvement of speed reducers, including distortion-free hard-facing and thermal-spraying repairs necessary to restore geometric tolerances.We can also respond to dynamic balance required for rotating machines, including repairs for cases serving as casings.

部品の補修・試運転「軸の補修」

Repairs for shafts

We examine various factors, such as the parts to be fitted, what kind of load acts in what direction, and under what condition the damage occurred, and then consider repairs that improve the strength of existing parts.

部品の補修・試運転「ケースの補修」

Repairs for cases

Because cases with complex shapes are often made by casting, it is necessary to request a company that owns a machine capable of repairing them. Repair accuracy is an important factor for stable operation of the case that absorbs vibration and the speed reducer as a whole.

部品の補修・試運転「機能を付加した補修」

Repair with added functions

In areas that have undergone repeated repairs due to frequent wear, we can try out durable repairs for various parts by selecting a variety of thermal-spraying materials and instructing on correct machining before and after the thermal-spraying in cooperation with Kurashiki Boring Kiko.

部品の補修・試運転「試運転」

Test runs

After maintenance has been completed, we can conduct test runs to ensure proper repair, assembly and adjustment. After measuring temperature, vibration, and abnormal sound during operation, we can ensure the quality of maintenance and service by comparing the trends and past data.

Reasons why KBK Engineering is selected for
service, repairs and maintenance for speed reducers

We offer the very best in service and solutions to problems based on our reliable technical strengths.

KBKエンジアリングが選ばれる理由01「安心してお任せいただける整備の技術」

REASON 01 Maintenance and service technology that you can entrust to us with complete confidence

KBK Engineering was spun off from Kurashiki Boring Kiko as an independent company specializing in maintenance and service for decanter centrifuges. Conventionally, maintenance and service for machines relied on an engineer’s intuition and experience, but nowadays, maintenance and service based on mechanical engineering and material engineering is required. In the maintenance and service industry, handing down of technology and technical strengths is of critical importance, and we, with our core of young engineers, perform maintenance and service for all manufacturers’ decanter centrifuges through maintenance and service supported by our reliable technology.

KBKエンジニアリングが選ばれる理由：技術力を表す画像

REASON 02 Technical Strengths

Older decanter centrifuges that have been used for many years may not have data such as drawings available. KBK Engineering uses its advanced measurement techniques and reverse engineering to fabricate hard-to-procure parts. By setting materials and appropriate dimensional tolerances, and making full use of changes in materials and various surface treatment types and heat treatment, the life-spans of existing parts can be extended. We contribute to future improvement in productivity by making modifications to fit existing parts based on dimensional restoration.

KBKエンジアリングが選ばれる理由03「確かな実績」

REASON 03 Proven Record of Performance

We offer our customers the very best in service and solutions to problems with our reliable technical strengths backed by a long record of performance for maintenance and service and manufacturer-certified. Requests for maintenance and service from many users and manufacturers over many years are the fruits of recognition of our technical strengths certified and authorized as well as advanced expertise.

KBKエンジアリングが選ばれる理由04「厳格な管理」

REASON 04 Stringent Controls

Since July 2009, when we received ISO9001:2008 certification, the international standard for quality management systems, our quality management systems have been reviewed and ISO9001:2015 certified. Our work proceeds based on controlled processes, and the maintenance and service history of each customer is recorded and information including dimensional records and photographs, as well as reports, is carefully preserved for future access. We take on the role of machine manager in support of our customers.

KBKエンジニアリングが選ばれる理由05「対応力」

REASON 05 Flexible Response

We provide one-stop response and support from transportation, overhaul and maintenance, fabrication of parts, repairs, dynamic balance corrections, test runs, to delivery. Through our established network, we perform repairs, fabrications and modifications, aiming at realizing delivery schedules in line with customer requirements. For thermal spray repairs, in particular, including before and after machining, we offer an integrated service with our partner company, Kurashiki Boring Kiko, to provide high-quality repairs suitable for every usage condition.

KBKエンジニアリングが選ばれる理由06「人材の育成」

REASON 06 Personnel Training

In maintenance and service of machines, maintenance and service based on mechanical engineering and material engineering is required, and transferring technology and technical strengths is of critical importance. By holding regular study sessions with specialized instructors and experts, our core of young engineers actively absorb knowledge and skills in order to perform maintenance and service backed by our reliable technical strengths and technology.

Please feel free to contact us for consultations, estimates, etc.
If there is a need for an immediate response, please contact us by phone.

Inquiries by Phone
+81-(0)86-450-4577
Business Hours
8:30 a.m. to 5:30 p.m. (weekdays)

For consultations, please feel free to contact us.

Maintenance and Service Flow

We provide high-quality maintenance and service for our customers in accordance with standardized procedures.

Step. 01

整備の流れ：お問い合わせに関する画像

Step. 01 Inquiry

Let us know your machine condition and the details of the problem. Prepare drawings and instruction manuals, if available. In case of an emergency, contact us by phone at +81-(0)86-450-4577

Step. 02

整備の流れ：基本整備見積書提出に関する画像

Step. 02 Submission of an estimate for basic maintenance and service

An estimate for basic maintenance and service will be submitted based on the information provided, discussions, on-site checks, etc.

Step. 03

整備の流れ：搬出(一部機械)に関する画像

Step. 03 Carrying-out (some machines)

Decanter centrifuges, etc., requiring measurements at the time of removal, will be removed on-site and carried out by our staff, as necessary.

Step. 04

整備の流れ：搬入に関する画像

Step. 04 Carrying-in

The removed machine will be carried in to our factory, where a large truck exceeding 10t can enter.

Step. 05

整備の流れ：分解・清掃・検査に関する画像

Step. 05 Disassembly, cleaning and inspection

Disassembly and cleaning are performed according to proper procedures, and each part is measured dimensionally and inspected. A determination is made on the course of repairs and maintenance and service according to the results of an inspection. Various types of non-destructive inspections are also performed as necessary.

Step. 06

整備の流れ：補修見積もり、報告書提出に関する画像

Step. 06 Submission of an estimate for repairs and a report

An inspection report and an estimate for additional repairs will be prepared based on the results of inspections and the course of repairs, maintenance and service are submitted, and the course of repairs, maintenance and service is finalized after consultations with the customer.

Step. 07

整備の流れ：部品補修、部品製作に関する画像

Step. 07 Repairs for parts and fabrication of parts

Repairs for parts and fabrication of parts are performed by planning appropriate processing methods at each subcontract factory. Various types of hard-facing are performed by our skilled engineers.

Step. 08

整備の流れ：動バランス修正に関する画像

Step. 08 Dynamic balance corrections

This process is indispensable to maintenance and service for high-speed rotating machines. Actual running in an unbalanced state will cause a failure, breakage, or an accident.

Step. 09

整備の流れ：組立前検査に関する画像

Step. 09 Inspections before assembly

Repaired and fabricated parts are inspected, and only parts that have been confirmed to meet specifications are used for assembly.

Step. 10

整備の流れ：組立調整に関する画像

Step. 10 Assembly and adjustments

By tightening each part to the proper torque, assembly is performed while adjusting component parts to the minimum. O-rings, oil seals, bearings, and other parts are handled carefully to prevent damage.

Step. 11

整備の流れ：試運転に関する画像

Step. 11 Test runs

After assembly, test runs are performed where possible, and temperature, vibration, and various other data are collected. The results are reflected in a report.

Step. 12

整備の流れ：納品・報告書提出に関する画像

Step. 12 Delivery and submission of a report

After completion of all work, delivery is made to the customer-designated site. Installation of equipment can also be arranged. Based on the submitted report, we can also offer consultations on operation, maintenance and service plans.

FAQs

Frequently asked questions and answers. Please feel free to contact us if you have any questions that have not been posted.

Q1 What are some of the features that KBK Engineering offers?
We provide maintenance and service for high-speed rotating machines, especially for decanter centrifuges. Our group company offers advantages through integrated maintenance and service when it comes to handling all necessary repairs, such as hard-facing and thermal spray.
Q2 What kind of a partner company is Kurashiki Boring Kiko?
Our partner company has a 60-year history and is equipped with machining facilities required for repairs of rotating machines, such as pretreatment, thermal spray, and finishing processing.
Q3 What kind of information is needed to request an estimate?
Please provide us with assembly drawing(s), machine conditions, past repair status, operating conditions, delivery time, etc., to the extent possible.
Q4 What is the difference from manufacturer maintenance and service?
In many instances, when a machine seizes up it is because a component part or parts are damaged. We have the know-how to repair component parts and have an established network for fabrication of component parts, so that short delivery times and low-cost repairs can be guaranteed.
Q5 What if the manufacturer of an older machine is no longer in business?
We can provide maintenance and service even for older machines where drawings are no longer available. New parts can be fabricated from existing parts by reverse engineering and restored to their original state.
Q6 What is your company’s policy concerning customer information and drawings?
We recognize and understand that machines used for operation and raw materials processed are each customer’s confidential information and proprietary assets.
Q7 Can you handle maintenance and service for machines other than speed reducers?
We have a record of performance in maintenance and service for various high-speed rotating machines, and we also offer maintenance and service for diverse machines other than speed reducers.
For details, see the section for maintenance and service for various rotating machines including examples of maintenance and service.

Inquires

Please feel free to contact us by phone, fax, or web form.

Inquiries by Phone
+81-(0)86-450-4577
Business Hours
8:30 a.m. to 5:30 p.m. (weekdays)

Web form

If the e-mail address you entered is correct, a “sent confirmation e-mail” will be sent to you as proof that your transmission has been completed. If you do not receive an e-mail, you may have entered an incorrect e-mail address. In such a case, check your e-mail address and resend, or call us at +81-(0)86-450-4577.

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