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Industrial Gearboxes by Ankit Ranjan
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- 2. Points going tobe discussed- What is gearbox?? Scope of gearbox?? Types of Gearbox?? What is Industrial geared motors?? Type of Geared motors?? How to select suitable geared motors?? Selection criteria of gearbox??
- 3. Introduction It isused to change the speed and torque of vehicle according to variety of road and load conditions. Also facilitates change of direction of output shaft for reversing. Automotive gearboxes are used to reduce load on the engine by manipulating torque and speed. Most gearboxes are used to increase torque & reduce the speed of a output shaft.
- 4. Gears are usedwhere:- To avoid slipping. Velocity Ratio is important. When distance between driver & follower is small. To transmit large power and high efficiency.
- 5. Slipping Slipping isa common phenomenon in transmission of motion which affects in reducing Velocity ratio. Condition of slipping:- Slipping occurs - when Tangential force > Frictional resistance Avoidance of Slipping:- By using toothed wheels.
- 6. Main Components ofGearbox
- 7. Types of Gearboxes Thereare mainly four types of gearboxes:- Sliding Mesh Gear box Constant Mesh Gear Box Synchromesh Gear Box Epicyclic Gear Box
- 8. Sliding Mesh Gearbox Normally3 forward and 1 reverse gear ratios •Spur gears are used •Gear wheels on the main shaft engage with gear wheels on the lay shaft (counter shaft) by sliding themselves.
- 9. All thegears are always in mesh Gears on counter shaft are fixed to it Gears on main shaft are free to rotate Dog clutches can slide on the main shaft and rotate with it Dog clutches engage with gears on the main shaft to obtain desired speed Advantages over Sliding mesh Gearbox: Helical and herringbone gear can be used in these gearboxes and therefore, constant mesh gearboxes are quieter. Since the gears are engaged by dog clutches, if any damage occurs while engaging the gears, the dog unit members get damaged and not the gear wheels. Constant Mesh Gearbox
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- 11. The only differencebetween constant mesh gearbox and synchomesh gearbox is that it contains a synchroniser instead of dog clutch. The device works like a friction clutch. Sliding sunchronizing units are provided to equalize the speeds of gear and dog before meshing. Equal speeds ensure smooth meshing. Synchromesh Gearbox
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- 13. Epicyclic geartrains are used to get the various gear ratios. At least one wheel not only rotates about its own axis but also rotates about some other axis Automatic gearboxes typically use one or more compound planetary gear sets having two sun gears and two sets of intermeshing planet gears. There is still only one ring gear. Epicyclic Gearbox
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- 16. Industrial Gearboxes Anindustrial gearbox is an enclosed system that transmits mechanical energy to an output device. Gearboxes can modify their speed, torque, and other attributes to convert the energy into a useable format. Industrial gearboxes are used to modify the ratio of speed sent to the transmitted power. For light duty industrial automation applications, industrial gearboxes, mechanical speed variator, and gear motors smoothen the flow of operations. Whatever gearbox you pick look for quality and durability. The quality doesn’t only mean fine raw material or robust internal small parts used, but it also means perfection in cuts and designs. It should be according to your specification of the work if you want gearboxes to play a major role in your work. It should go through various efficiency tests and failure analysis. Problem in the small components of the industrial gearbox may reduce the efficiency.
- 17. Industrial Geared Motors A geared motor is a single component that integrates a gear reducer with either an ac or dc electric motor. It is designed to produce high torque while maintaining low speed, motor output. Gear motors can be found in many different applications like automotive vehicles, construction equipments, cranes etc:- They are of three types:- Universal Geared Motors ◦ Series M – Helical Inline Geared Motor ◦ Series C – Right Angled Helical Worm Geared Motor ◦ Series F – Parallel Shaft Mounted Geared Motor ◦ Series K – Right Angled Helical Bevel Geared Motor Planetary Geared Motor Compact Geared Motor
- 18. Series M –Helical Inline Geared Motor Series M inline geared motors and reducers provide a very efficient and compact drive solution up to 160kW with maximum output torque capacity of 20000Nm. The end result is speed reducing and geared motors offering high load carrying capacity, high efficiency, quiet running and reliability.
- 19. Right anglehelical worm geared motors and reducers provide a highly efficient and compact solution up to 45 kW with maximum output torque capacity of 10,000Nm. The end result is speed reducing and geared motors offering high load carrying capacity, increased efficiency, quiet running and reliability Series C – Right Angled HeliWorm Geared Motor
- 20. Series Fright angle drive helical bevel helical geared motors offer ratios from 5:1 to 100:1 in two stages, up to 320:1 in three stages and 5000:1 in four stages. Motors are available up to 45kW with an output torque capacity of up to 8000Nm. Units may also be supplied with an output flange suitable for mounting horizontally or vertically. The end result is speed reducing geared motors offering high load carrying capacities, increased efficiency, quiet running and reliability. Series F –Parallel Shaft Mounted Geared Motor
- 21. Series Kright angle drive helical bevel geared motors offer ratios from 8 : 1 to 125 : 1 in three stages or up to 10,000 : 1 in five stages. Motors are available up to 160kW and output torque capacity up to 33000.Nm. Units are also available shaft mounted or with output flanges and are available for mounting horizontally or vertically. The end result is speed reducing geared motors offering high load carrying capacities, increased efficiency, quiet running and reliability Series K – Right Angle Helical Bevel Geared Motor
- 22. Planetary Geared Motor The range of Series P Planetary units has 10 sizes with ratio coverage from 3.6:1 to 3200:1 providing an efficient and compact drive solution up to 90kW and 65000 Nm torque capacity. They provides high torque thus used in tractors . The end result is a high quality series of planetary gear reducers and geared motors offering a high load carrying capacity, high efficiency, quiet running, reliable drive solution.
- 23. Compact Geared Motor These are also called as Inline Gear Reducers with solid and hollow input shafts, Foot/flange mounted Geared Motors. They are available in the range of 0.12 kw to 11.0 kw and having ratio from 5:1 to 200:1. Salient Features:- ◦ Stylish Design ◦ Compact & Light Weight ◦ Reduction in Mounting dimensions ◦ Low Noise & Vibration ◦ Simple to assemble & dismantle ◦ Each unit tested under air pressure to ensure leakproofness Factory filled long lasting EP grease as lubricant.
- 24. Selection criteria ofgearbox Of course, buying industrial gearboxes is a capital investment, so you would look for more and more features at the same prices. According to industry type and use, choose the size, design, and style of gearboxes. Industry size and purpose play a vital role in the selection of any industrial gearbox. Prime Mover (e.g. Electric Motor) power and speed. Speed of driven equipment. Absorbed power of machine either in kW or Nm torque. Ambient Temperature. Operating Conditions (e.g. dusty, wet etc.) Operating hours per day or required gearbox life (hrs.)
- 26. Benefits of usingthe finest quality gearboxes are: No complexity and convenient to operate. Upgrade the original performance. Increase productivity and efficiency. Save time and cost. Lesser maintenance cost. Reduces the noise. Increment in operational output in the shorter period of time. Less Consumption of power.
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