The selection of an appropriate gear reducer can be a daunting task for a design engineer because there are a myriad of potential gear reducer designs and products that may appear to satisfy design requirements. On one hand, a gear reducer that is over-designed for the application may result in the selection of a more expensive product. On the other hand, a gear reducer that is under-designed for the application may lead to premature failure and avoidable downtime. The selection of an appropriate gear reducer therefore involves a careful balance of cost, performance and reliability. It is incumbent upon the design engineer to fully understand the process and criteria by which an appropriate gear reducer is selected.
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Gear reducers convert high-speed rotational energy from an input or driving device, such as a motor, to an output or driven device, such as a shaft. This is accomplished by using two or more gears that are configured to obtain the correct rotational or translational direction, speed or torque relative to the output device. Generally, gear reducers are used to reduce the output speed of a motor, causing a proportional increase in output torque. This enables several different types, styles and sizes of motors, which may operate at different speeds or with different power ratings, to be ideally matched to several different applications. This article will discuss the importance of selecting the appropriate gear reducer based on the application.
One of the fundamental considerations in the selection of a gear reducer involves the geometry of the housing, input and output shafts. Geometrical considerations will determine the type of gear reducer needed, and how it will interface to the equipment, the motor and the load. Other important considerations include loading factors, such as the input and output torque, speed, and horsepower required by the application. Operational factors should also be considered, such as the required number of operating hours, and whether the equipment will be subject to severe chemical, thermal, shock or vibration environments. For example, a gear reducer used in an aggregate conveyor may operate for long hours in a dirty environment and be subjected to severe shock, vibration and thermal loads (Figure 1).
Figure 1: Aggregate conveyor. Source: Peter Craven/CC BY 2.0Using the considerations above, it is possible to calculate the American Gear Manufacturers Association (AGMA) service factor. The service factor defines the ratio of the gearbox rated horsepower (or torque) to the application&#;s required horsepower. The rated horsepower of a gear takes into consideration its resistance to pitting (surface hardness) or its resistance to bending (fatigue toughness). AGMA has published several tables of load ratings and service factors for different types of gears and couplings (spur, bevel, helical) in different applications (conveyors, crushers, cranes) at different operating durations (less than three hours, three to 10 hours, greater than 10 hours per day). Each of these application-specific service duty combinations is assigned a recommended service factor. For example, the AGMA service factor for a worm gear reducer in a stone crusher that operates three to 10 hours per day is 1.75. This means that the worm gear reducer needs to be oversized by a factor of 1.75 to safely operate without failure.
After calculating the AGMA-recommended service factor, the design engineer must consider other conditions, such as extreme temperatures, shock loading and number of starts, stops and reversals. These conditions may require an increase in service factor to ensure a sufficiently safe operating margin and life of the gearbox. Although additional safety factors are available from AGMA, it is often recommended that the end user work directly with the gearbox manufacturer, as some of these safety factors will affect the manufacturing process. For example, to achieve a service factor to operate under an extreme operational condition, the manufacturer may require specialized metallurgy or heat treatments.
The combination of AGMA service factors and safety factors comprise the overall gearbox service factor. Once determined, this factor is multiplied by the horsepower or torque required for the application. The result is the optimum output horsepower or torque that the gearbox will require. The appropriate gearbox can then be selected from the manufacturer&#;s catalog.
WorldWide Electric Corporation is a leading manufacturer of electric motors, motor controls, and gear reducers, established in . The Rochester, New York-based company takes pride in serving its customers with urgency by offering quick shipping and 24/7 customer support. Call (800)808- or visit the company website to learn more about gear reducers.
Speed reducers are a very important part of mechanical power transmission systems. There are several different types available, each with certain features. Installing the wrong gear reducer into an application can be disastrous. The first step to choosing a gear reducer is to know what torque and speed are required as well as the most suitable motor to use. Next, if a gear reducer is needed, you select the proper type and ratio.
So what is a speed reducer? Usually, the benefits are that it can reduce speed and increase torque. The amount of speed reduction will depend on the type of motor used. For example, while one motor might not need a gear reducer to run at low speeds (as low as 1,000 rpm or so), another may need one to run at any speed.
For speed reducers, the gear ratio is calculated using the equation below. G is the gear ratio, and N is the angular velocity of the motor and the load.
Speed reducers multiply the torque output of a motor. For this reason, a smaller, less expensive motor with a gear reducer may be the right decision for your application than a larger motor without one. To calculate the required gear ratio when torque multiplication is needed, use this equation: G is the gear ratio, T is torque and e is efficiency.
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Another function of gear reducers is reducing the reflected load inertia to the motor by a factor of the square of the gear's ratio. For most motion applications, the reduction of reflected inertia from motors is ideal. This is especially true for high-performance applications but is applicable for any motion application. Rather than only considering the gear's ratio, you should also take into account the inertia of the load and the motor. To achieve perfect inertia matching, take the square root of the ratio of motor inertia to load inertia. G is the gear ratio and J is the inertia of the motor and load.
To calculate the speed and gear ratio required for your application, you must know the desired output speed and torque. Once you have these two pieces of information, you can use the following formula:
Output Speed (RPM) = Input Speed (RPM) / Gear Ratio
Where:
For example, let's say you have a load that requires an output speed of 100 RPM and an output torque of 100 lb-ft. Suppose your motor delivers an input speed of RPM and an input torque of 50 lb-ft. In that case, you can calculate the required gear ratio and output speed as follows:
Gear Ratio = Input Torque / Output Torque Gear Ratio = 50 / 100 Gear Ratio = 0.5
Output Speed (RPM) = Input Speed (RPM) / Gear Ratio Output Speed (RPM) = / 0.5 Output Speed (RPM) =
Therefore, the required gear ratio is 0.5, and the output speed is RPM. It's important to note that these calculations provide estimates and may vary based on factors such as motor efficiency and operating environment. It's always recommended to consult with a gearmotor expert when selecting the right gearmotor for your application.
About Sumitomo Drive Technologies
At Sumitomo Drive Technologies, we work hand-in-hand with our customers to ensure that their industrial gearboxes, speed reducers, and accessories remain operational for years to come. Many of our products have been in high-speed and harsh environments for years. Clients make the switch to Sumitomo to experience that durability and decrease the amount of unscheduled downtime and maintenance in their facility. We ensure that every unit we design or repair leaves our Unites States' facilities quickly to keep your application up and running. Please call us at 1.800.762. or contact us by to receive a quote for your facility or information about our industrial gearbox repair services. We will be glad to tell you more about our products and connect you to a representative in your area.
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