FMG: Gearbox Reliability Solved

Challenge:

Fortescue Metals Group (FMG), a major iron ore producer in Western Australia, faced a critical issue: premature gearbox failures on a key conveyor system. Upgraded gearboxes, intended to solve the problem, failed rapidly due to an inappropriate bearing design.

Impact:

These failures caused significant downtime, hindering iron ore production and costing FMG dearly. The manufacturer's theoretical calculations did not translate to real-world performance.

DASH Engineering's Approach:

• Investigated the root cause: We analyzed the failed bearings and determined the culprit: excessive axial loading exceeding the bearing design capacity.
• Identified a superior solution: Drawing on our bearing expertise, we recommended an alternative bearing design better suited for the applied forces.
• Collaborative problem-solving: We presented our findings and proposed solution to FMG, providing detailed technical documentation to support our recommendations.

Results:

• 4+ years of trouble-free operation: The first gearbox rebuilt with the recommended bearing design ran flawlessly for over four years before replacement due to lagging wear, not bearing failure.
• Long-term partnership: This successful project established a strong partnership with FMG. We have since collaborated on various initiatives to improve operational reliability, including the development of the innovative SAPO® seal.