The basic definition of a gearbox could be that it is a system, an enclosed one that helps in the transmission of mechanical energy to an output device by modifying its speed, torque, and other features to convert it to a format that the output device can use. Almost everything that involves rotary motion power transmission requires a gearbox to change the torque and speed. Therefore, different gearboxes have been designed to be used for various different industrial applications. A gearbox is very essential to be used as it helps in the maintenance of the system. How does it maintain the system? By increasing the torque, decreasing the speed, and matching the inertia, cuts operations for the system. It helps the system by allowing smaller drives and motors for it to be utilized. Therefore, the use of a gearbox is a must in all the rotary motion power transmission systems for their better. Well, this brings us to have a look at all the different gearboxes that are available in the market and for what industrial applications they are designed specifically.
- Helical Gearbox:
A helical gearbox has a set of helical gears that are cylindrical
and have tilted tooth trace, a very compact structure. They consume very little
power and therefore are used for heavy-duty industrial applications. The
industries that construct cement, rubber, plastic, and more of the same heavy
industrial constructions usually use helical gearboxes. All the low-power
applications like crushers, coolers, extruders, conveyors, etc., require a
low-power consuming gearbox for which helical gearbox proves to be ideal. Other
than low power consumption, helical gearboxes also offer various other benefits
like they offer very smooth gearbox operation due to the gradual engagement of
the teeth; hence the shock loads, noise, and vibration is reduced. Apart
from all these qualities, the helical gearbox also has its drawbacks like its
tooth slippage makes it less efficient, its manufacturing cost is very high, it
produces large amounts of thrust force, it produces higher friction and heat as
a result of the sliding action.
- Coaxial Helical Inline Gearbox:
A coaxial helical inline gearbox has a drive shaft and output on the
same axis of rotation and is used for servo applications primarily as spur
gears. It's design and size are very compact due to the coaxial arrangement of
the input and output shaft. Due to their quality, efficiency, and high-power
density, they are very ideal for heavy-duty applications. One can also maximize
the load and transmission ratios in a coaxial helical inline gearbox as they
are made with great specifications. This is a perfect low-power consumer and excellent power transmission gearbox. This gearbox
has no such disadvantages associated with it except for its higher price and
the troublesome manufacturing of its high technical content of the gears.
- Bevel Helical Gearbox:
A bevel helical gearbox has a cone-shaped surface closer to the rim
of the unit with a set of curved teeth; this feature of the bevel helical
gearbox is the most critical. The application of a bevel helical gearbox is
essential for non-parallel shafts as it provides rotary motions between them.
Where there is a need for torque to a high degree to change the direction of the
force, their bevel helical gearbox has proven to be very essential as its teeth
help in preventing the gears from slipping and minimizing the backlash. This
gearbox offers a very quiet operation as they run very smoothly without causing
any vibrations. However, it is very difficult to assemble this gearbox because
of its changeable operating angle. This gearbox is also not good for applications
that require high-speed reduction, and therefore, at high speed, it makes
noises. The shafts of this gearbox experience great force, but the bearing of
it is usually can not withstand such great force.
- Skew Bevel Helical Gearbox:
A skew bevel helical gearbox is a gearbox that has helical gears
with slanted shafts and performs rotary motion at a gear ratio that remains
constant between the shafts. This gearbox has a lot of complexities involved in
its manufacture; therefore, it is used rarely. It has a very rigid and massive,
or you can say very monolithic structure, which makes it good to be used for
heavy-duty applications. Apart from the complexities involved, this gearbox can
offer great advantages when they are mounted on the right motor shaft output.
One can also customize the number of teeth and gears in a skew bevel helical
gearbox to make it suitable for your need. However, the manufacturing of the
gears of this gearbox requires special equipment and tools, which is a
disadvantage. Another thing of this gearbox that can be counted as a
disadvantage is that the error in its teeth can make noise and cause vibrations
during operations.
- Worm Reduction Gearbox:
A worm reduction gearbox, as the name indicates, is a kind of
reduction gearbox, that has a worm pinion input and a worm gear output with right
angle output alignment. It is very good for speed reduction with a high ratio
between non-nonintersecting crossed axis shafts and multiplication of high
torque output; therefore, it has been the top choice for most power
transmission systems. This gearbox can greatly reduce the speed and increase
the torque. The worm wheel that this gearbox has is of a large diameter. Its
screw mesh with the teeth of the gearbox on its peripheral side. This gearbox
causes a similar movement of the wheel due to the screw-like movement of the
rotating motion of the worm. However, it is noted that the efficiency of this
gearbox is low as compared to other gearboxes. It is also very expensive
because of the use of phosphor bronze for making its worm wheel. Another
disadvantage is its low power transmitting capacity. It also needs constant
lubrication due to the production of heat in worm gear drives.
- Planetary Gearbox:
A planetary gearbox has two gears connected by a carrier arranged as
such that the center of one gear revolves around the center of the other gear.
The planetary gearbox is good at slowing down the motors and increasing the
torque; therefore, it is usually used as a speed reducer. It has precision
application, ideal endurance, complete accuracy, and distinct functionality. It
maintains your equipment or system by increasing its life and enhancing its
performance. It also has certain disadvantages like it becomes very noisy
during operations, it requires the gearing to be accurate to have proper load
sharing, its high bearing load damages the system by wearing the dead stud and
sleeve bearing construction; therefore, it costs a lot for its maintenance for
low backlash and longer life.
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