GEARBOXES

Gearboxes

Gearboxes

Gearbox is a mechanical device utilized to increase the output torque or change

the speed of a motor. The motor's shaft is attached to one end of the gearbox and

through the internal configuration of gears of a gearbox, provides a given output

torque and speed determined by the gear ratio.

Physical Properties
The physical components of gearboxes vary from one gearbox type to another, as

well as differences between manufacturers. Most gearboxes are constructed from

steel materials such as iron, aluminum and brass. Unlike other gearbox types, spur

gearboxes can also be made with plastics such as polycarbonate or nylon.

Other than the raw materials used, the orientation of the gear teeth play a major

role in the overall efficiency, torque and speed of the system. Straight gear teeth

gearboxes are typically used in low-speed applications. These gearboxes can be

noisy, and may have lower overall efficiency. Helical gearboxes are typically used

in high-speed applications. These gearboxes are quieter in operation than straight

gear teeth gearboxes, which may improve their overall efficiency.

Types of Gearboxes
There are many types of gearboxes manufactured throughout the world. One of the

main differences between individual gearboxes is their performance characteristics.

Choosing from the various gearbox types is application dependent. Gearboxes are

available in many sizes, ratios, efficiencies and backlash characteristics. All of

these design factors will affect the performance and cost of the gearbox. There are

several types of gearboxes which are listed below:

Bevel Gearbox

There are two types of bevel gearboxes which include either straight or spiral teeth

gears. Straight bevel gears have straight and tapered teeth and are used in

applications requiring slow speeds. Spiral bevel gears have curved and oblique

teeth and are used in applications requiring high-performance, high speed

applications.
Physical Properties

Bevel gears are typically constructed from cast iron, aluminum alloy or other steel

materials but vary between manufacturers.Gears made from steel materials can be

noisy when coming into contact with other gears and also make them prone to

wear.

Applications of Bevel Gears

Bevel gearboxes use bevel gears and are mainly used in right angle applications

with the shafts in a perpendicular arrangement.

Print Press

Power Plants

Automobiles

Steel Plants

Hand Drills

Differential Drives

Advantages of Bevel Gears

Right angle configuration

 Durable

Disadvantages of Bevel Gears

Axes must be able to support forces

Poorly cut teeth may result in excessive vibration and noise during operation

Helical Gearbox

Helical gears are cut at angles which allow for gradual contact between each of the

helical gear teeth. This type of innovation provides for a smooth and quiet

operation. Gearboxes using helical gears are applicable in high horsepower and

efficient applications.

Physical Properties

Helical gears are typically constructed from cast iron, aluminum allow or iron

material but may vary depending on the manufacturer.

Applications of Helical Gears

Helical gears are widely used in applications which require efficiency and high

horsepower.

Oil Industry

Blowers
 Food and Labeling

Cutters

Elevators

Advantages of Helical Gears

Can be meshed in parallel or cross orientation

Smooth and quiet operation

Efficient

High horsepower

Disadvantages of Helical Gears

Resultant thrust along axis of gear

Additives to lubrication

Spur Gearbox

Spur gears are made with straight teeth mounted on a parallel shaft. The noise level

of spur gears is relatively high due to colliding teeth of the gears which make spur

gear teeth prone to wear. Spur gears come in a range of sizes and gear ratios to

meet applications requiring a certain speed or torque output.

Physical Properties

Spur gears are typically constructed from metals such as steel or brass, and plastics

such as nylon or polycarbonate. The material used to construct spur gears may vary

depending on the manufacturer.

Applications of Spur Gears

Spurs gears are used in applications requiring a decrease in speed with high output

torque.

Cut-to-Length

Packaging

Speed Control

Construction

Power Plants

Advantages of Spur Gears

Cost-effective

High gear ratios

Compact
 High torque output

Disadvantages of Spur Gears

Noisy

Prone to wear

Worm Gearbox

Worm gears are able to withstand high shock loads, low in noise level and

maintenance-free but are less efficient than other gear types. Worm gears can be

used in right angle configuration. The worm gearbox configuration allows the

worm to turn the gear with ease; however, the gear cannot turn the worm. The

prevention of the gear to move the worm can be used as a braking system. When

the worm gearbox is not active, it is held in a locked position.

Physical Properties

Worm gears are typically constructed of aluminum, stainless steel and cast iron.

The material used varies depending on the manufacturer.

Applications of Worm Gears

Worm gears are used in applications requiring high speeds and loads and can be

configured for right-angle applications.

 Mining

Rolling Mills

Presses

Elevators/Escalator Drive Systems

Advantages of Worm Gears

High precision

Right-angle configurations

Braking system

Low noise

Maintenance-free

Disadvantages of Worm Gears

Limitations

Nonreversible

Low efficiency
Planetary Gearbox

Planetary gearboxes are named so due to their resemblance to the solar system.

The components of a planetary gearbox include a sun gear, ring gear and planetary

gears. The sun gear is the central gear which is fixed in the center, ring gear

(annulus ring) which is the outer ring with inward-facing teeth, and the planetary

gears which rotate around the sun gears and mesh with both the sun and ring gear.

Physical Properties

The sun, ring and planetary gears of a planetary gearbox are constructed of

aluminum, stainless steel or brass. The material used varies depending on the

manufacturer.

Applications of Planetary Gearboxes

Planetary gearboxes are used in applications requiring low backlash, compact size,

high efficiency, resistance to shock, and a high torque to weight ratio.

Slewing Drives

Lifts

Cranes

Machine Tools
 Automotive

Advantages of Planetary Gears

High power density

Compact

Highly efficiency in power transmission

Greater stability

Load distribution among planetary gears

Disadvantages of Planetary Gears

High bearing loads

Complex design

Inaccessibility

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