A gearbox is a mechanical component that is used to alter the speed (RPM) of a motor to enhance the output (torque).
The shaft of the motor is connected to one end of the gearbox that goes through the gears in a gearbox and produces an output torque as per the speed set by the gear ratio.
Gearboxes are mostly made up of materials such as aluminum, steel, brass, and iron. Spur gearboxes, however, can also be made up of plastic or nylon.
Types of Gearboxes
Gearboxes vary in terms of torque and speed, and both of these characteristics depend on the number of gear teeth present in the gearbox. Moreover, their orientation can also make a lot of difference.
For example, there are gearboxes that have straight gear teeth. These are used in applications that require low speed to operate.
On the other hand, high-speed applications need gearboxes that run fast such as helical gearboxes.
Applications Of Planetary Gearboxes
This particular gearbox has three components: a ring gear, sun gear, and planetary gear.
It is used to lift and move heavy loads and is called a planetary gear due to its shape.
You can go to the planetary gear page here to know more about this type of gearbox and its many uses.
The ring gear is the outermost ring which has inward facing teeth. A sun gear is a ring gear in the middle, while the surrounding gears are planetary gears.
The central gear (sun gear) is fixated in the center and the planetary rings mesh with both the sun and ring gears. It depicts the same movement as a solar system which is why it is called a planetary gearbox.
Planetary gearboxes can be made of steel, brass or aluminum. Steel planetary gearboxes can be a bit noisy and are also not very durable. Therefore, aluminum and brass are considered better choices.
Applications that need low backlash, high efficiency, and protection from shock make use of this type of gearbox.
A planetary gearbox would do great in these applications:
- Lifts
- Automotive
- Cranes
- Slew drives
- Machine tools
.
Pros of Planetary Gearboxes
- Compact size
- High density in terms of power
- More efficiency (power transmission
- Planetary gears distribute the load
- Stable
.
Cons of Planetary Gearboxes
- Complex design
.
Applications of Helical Gearboxes
This gearbox is used in many applications and is quite different from a planetary gearbox. Its teeth are arranged in cuts and all the teeth come into contact with each other as they rotate.
They operate silently and are quite powerful. It’s made of several materials such as aluminum, iron, cast iron, and steel.
They are used in many industries and applications that require high-end power and efficiency. These include:
- Elevators
- Blowers
- Oil industry
- Cutters
- Food and labeling
.
Pros of Helical Gearboxes
- Can be used to adjust the rotation angle by 90 degrees
- Smooth in running
- Operates quietly
- Provides higher horsepower
- Efficient
.
Cons of Helical Gearboxes
- Greater sliding friction among the gear teeth
Applications of Spur Gears
These have straight teeth that and are mounted on a shaft (parallel). Due to their design, the collision, and meshing power is more compared to other gearboxes.
While it is a great plus, it can have downsides as well since such gearboxes make a lot of noise due to the design.
These are available in various sizes and hear ratios to accommodate different applications that operate on different output torque.
You will find these gearboxes in steel, brass, plastic, and nylon as well. This huge versatility makes these gearboxes perfect for several applications.
They can offer up to 50K KW, which is among the highest. You can, however, decrease speed as needed.
They have a simple design and the working mechanism is also quite basic. They are used in:
- Speed control
- Cut to length
- Power plants
- Construction
- Packaging
.
They are reliable because they offer stable and constant gear ratio. Their uses are several which is one of the main reasons why they’re very high in demand.
Pros of Spur Gears
- High torque output
- More efficient than a helical gear of similar size
- Reliable
- Cost effective
- Compact
.
Cons of Spur Gears
- Low-speed gears
- Noisy
- Not suitable to transfer energy over long distances
.
Applications of Bevel Gearboxes
This type of gearbox is found in two orientations; with straight teeth and with spiral teeth as well.
Straight teeth bevel gearbox is used in applications that need low-speed rotation. On the other hand, spiral teeth gearbox is ideal to be used in applications that require high-speed rotation.
These are made in a variety of materials such as iron, steel, and aluminum. However, aluminum and iron are mostly used because steel bevel gearboxes can be a bit noisy and they wear down quickly, too.
These are used in several applications such as:
- Automotive
- Print press
- Steel plants
- Differential drives
- Hand drills
.
Pros of Bevel Gearboxes
- Right angle configuration (mounted on a shaft that is 90 degrees apart)
- Extremely durable
.
Cons of Bevel Gearboxes
- Must be mounted accurately
Which Is The Most Efficient Gearbox Among All?
For us, planetary gearboxes are the best. They are said to be 96% to 98% efficient even when running on low speed. That’s not all, they are compact and provide almost three times the torque compared to spur gearboxes.
They are widely used because of their ability to distribute the weight upon individual planetary rings. This is also the reason why they are highly efficient.
There’s another feature of this gearbox which pushes it ahead of the other gearboxes. It is compatible with helical and bevel gearboxes as well. This increases the efficiency to a great deal.
However, the right option for you largely depends on why you need a gearbox.
The Conclusion
These four are the most commonly used gearboxes in industries. They make it easy to convert energy and allow us to get more without having to put more effort.
