Zhejiang Sankai Mechanical and Electrical Co., Ltd

Gearbox

What is Gearbox

 

 

Gearboxes are mechanical devices which transfer energy from the driving device (usually a motor) to the rest of the system. The gearbox is mounted to the motor shaft and, through the internal configuration of mated gears within the housing, produces an increased output torque and decreased output speed. Advancements in technology and the evolution of gear production have given rise to more efficient and powerful gearboxes being developed and manufactured at lower costs.

 

Advantages of Gearbox

Torque multiplication

Gearboxes can increase the torque output of a motor or engine. This is achieved by reducing the rotational speed of the motor or engine and increasing the torque at the output shaft.

Speed reduction

Gearboxes can be used to reduce the speed of a motor or engine. This is useful in applications where high speeds are not necessary, such as in heavy machinery.

 

Versatility

Gearboxes are versatile and can be used in a wide range of applications. They can be customized to suit specific requirements and can be used in both high and low-power applications.

Durability

Gearboxes are designed to be durable and can withstand high loads and stresses. They are made from high-quality materials and are built to last.

 

FirstLast

Why Choose US

 

 

Our Factory
Zhejiang Sankai Machine and Electric Co.,Ltd is an integrative and professional manufacturer of power transmission device, which specialize in scientific research, production and marketing.

 

Innovation
Adopting advanced detecting equipment and means, company establishes a quality control system that is in accordance with 1S0900 I: 2015. Products are sold all over the country, exporting to Southeast Asia, Europe, America and other regions. Sankai will continue, as we always do, to strive to become a leader of power transmission industry.

 

Our Products
Our company specialize in High Precision Planetary Gearbox, NMRV series Worm Gearbox, UDL series Stepless Speed Variator, SRC series Helical Gearbox, SKM series Helical-Hypoid Gearbox, Precision Gearbox for Robot Arm and PC Helical Gear Unit.

 

Quality services
Sincerely Sankai determine to provide service of better quality, in-time and fast reply to our clients. And Sankai is looking forward to cooperating with domestic and foreign friends and grow together with our hard work and professionalism.

 

Types of Gearbox

Bevel Gearboxes
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. Bevel gears are typically constructed from cast iron, aluminum alloy or other steel materials but vary between manufacturers. Bevel gearboxes are mainly used in right angle applications with the shafts in a perpendicular arrangement.

 

Helical Gearboxes
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. Helical gears are typically constructed from cast iron, aluminum allow or iron material but may vary depending on the manufacturer. Helical gears are widely used in applications requiring efficiency and high horsepower.

Spur Gearboxes

Spur Gears 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.

Worm Gearboxes

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. Worm gears are typically constructed of aluminum, stainless steel and cast iron. The material used varies depending on the manufacturer. Worm gears are used in heavy load applications requiring high speeds. These gearboxes can also be configured for right-angle applications.

Planetary Gearboxes

Planetary gearboxes are so named 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.

 

Planetary Gear Heads

 

Physical Properties of a Gearbox

Most gearboxes are constructed from steel, iron, aluminum and brass but 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. Gearboxes with straight bevel gear teeth are typically used in low-speed applications, as they can be noisy and may have lower overall efficiency. Helical and spiral-bevel gearboxes are typically used in high-speed applications, as they are operate more quietly and with greater overall efficiency than straight gear teeth gearboxes.

How do Gearboxes Work

 

 

All gearboxes operate on a similar principle: the direction in which the gears rotate depends on the input direction and orientation of the gears. For example, if the initial gear is rotating in a clockwise direction, the gear it engages will rotate counterclockwise. This continues down the line for multiple gears.
The combination of different gear sizes and the number of teeth on each gear plays a significant role in the output torque and speed of the shaft. High gear ratios allow for more output torque and lower speeds, while lower gear ratios allow for higher output speed and less output torque.
A planetary gearbox works in relatively the same way. A planetary gearbox system is constructed with three main components: a central sun gear, a planet carrier (carrying one or more planet gears) and an annulus (an outer ring). The central sun gear is orbited by planet gears (of the same size) mounted to the planet carrier. The planet gears are mated with the sun gear while the outer rings teeth mate with the planet gears.
There are several configurations for a gearbox system. Typical configurations consist of three components: the input, the output and one stationary component. For example, one possible configuration utilizes the sun gear as the input, the annulus as the output, with the planet carrier remaining stationary. In this configuration, the input shaft rotates the sun gear, the planet gears rotate on their own axes, simultaneously applying a torque to the rotating planet carrier that in turn applies torque to the output shaft (in this case, the annulus).
The rate at which the gears rotate (gear ratio) is determined by the number of teeth in each gear. So, adding a 3:1 gearbox to a motor with a speed of 300 RPM would result in an output speed of 100 RPM, with the output torque increasing inversely and proportionally. The torque (power output) is determined based on both the number of teeth and which component in the planetary system is stationary.

 

How to Select the Appropriate Gearbox

When considering a gearbox, many factors need to be considered to meet specific application requirements:

Planetary Gear Heads
Planetary Gear Heads
Planetary Gear Heads
Planetary Gear Heads

Gear Ratio
Gear ratios are defined as the correlation between the number of teeth of two or more different gears. Typically, the number of teeth a gear has is proportional to its circumference. This means that the gear with a larger circumference will have more gear teeth. The relationship between the circumferences of the two gears can also give an accurate gear ratio. For example, if one gear has 36 teeth while another gear has 12 teeth, the gear ratio would be 3:1.

 

Output Torque
Output torque depends on the gear ratio used. To obtain a high output torque, a high gear ratio should be selected. This will lower the output shaft speed of the motor. Inversely, using a lower gear ratio will result in a smaller output torque value being delivered into the system, with a greater motor speed at the output shaft. This principle illustrates the inversely proportional relationship between torque and speed.

 

Speed (RPM)
Speed is inversely proportional to the gear ratio of the system. For example, the greater the number of teeth on the output gear, the greater the speed at the output shaft. Conversely, the more gear teeth at the output compared to the input, the lower the speed at the output shaft. In general, the output speed can be determined by dividing the input speed by the gear ratio. The higher the ratio the lower the output speed will be and vice versa.

 

Gear Arrangement
Gear arrangement offers various benefits over the traditional fixed axis gear system design. The unique combination of both power transmission efficiency and compact size allows for a lower loss in effectiveness. The more efficient the gear arrangement, (i.e. spur, helical, planetary and worm) the more energy will be transmitted and converted into torque, rather than energy lost as heat.
Another application factor to be taken into account is load distribution. Since the load being transmitted is shared among multiple planets, the torque capacity is increased. The higher number of planets in a gear system will increase the load ability and enhance torque density. Gear arrangements improve stability and rotational stiffness by creating a balanced system.

 

Fixed-Axis vs Planetary Gear System
In the figure above, the gear arrangement on the left is a traditional fixed axis gear system with a pinion driving a larger gear on an axis parallel to the shaft. On the right, is a planetary gear design system with a sun gear (pinion) surrounded by more than one gear (planet gears) and is encompassed in an outer ring gear. The two systems are similar in ratio and volume, but the planetary gear design has three times more torque density and three times the stiffness due to the increased number of gear contacts.

 

Specification
 

 

Model

Stage

Ratio

ATO-ZB

Frame Size(mm)

1,2,3

3~200

65*65

85*85

118*118

150*150

Weight(kg)

1

3~10

1.2

2.7

20

36

2

9~50

1.5

3.4

25

48

3

60~200

1.9

4.1

30

53

Mounting Position

1,2,3

3~200

Can be mounted in any orientation

Operating Temperature

1,2,3

3~200

-10℃~90℃

Nominal Input Speed(rpm)

1,2,3

3~200

4500

4000

3000

3000

Max. Input Speed(rpm)

1,2,3

3~200

6000

6000

6000

4000

Backlash(arcmin)

Standard

1

3~10

≤10

≤12

≤12

≤12

Precision

≤6

≤8

≤8

≤8

Standard

2

9~50

≤12

≤15

≤15

≤15

Precision

≤10

≤12

≤12

≤12

Standard

3

60~200

≤15

≤18

≤18

≤18

Precision

≤12

≤15

≤15

≤15

Noise Level(dB)

1,2,3

3~200

62

65

65

65

Torsional Stiffness(Nm/arcmin)

1,2,3

3~200

1.8

4.4

9.2

26.7

Max.Radial Load(N)

1,2,3

3~200

265

440

1240

3700

Max.Axial Load(N)

1,2,3

3~200

200

400

1000

3000

Efficiency

1

3~10

97%

2

9~50

94%

3

60~200

91%

Service life(hrs)

1,2,3

3~200

20,000

Lubrication

1,2,3

3~200

Synthetic lubricating grease

Protection Class

1,2,3

3~200

IP65

Nominal Output Torque(Nm)

1

3

20

50

140

310

4

35

90

240

605

5

32

70

240

605

10

15

20

90

250

2

9

25

50

140

340

12

25

50

140

340

15

25

50

140

340

20

40

100

260

680

25

35

80

260

680

40

35

80

260

680

50

35

80

260

680

3

60

35

60

260

450

80

44

110

260

680

100

44

110

260

680

120

25

60

260

450

125

30

90

260

680

160

44

110

260

680

200

40

90

260

680

 

6 Top Tips to Maintain an Industrial Gearbox
 

Perform a regular inspection of the gearbox
A regular inspection helps you identify minor concerns and identify the onset of any major issues. It enables you to resolve them on time, and in a way, and to a considerable extent, maintain operational efficiency. So, inspect the gearbox for oil leaks on the output and input shafts. Besides, look for discoloration of the paint that perhaps signifies overheating. Furthermore, listen to the gearbox and inspect it for excess vibration.

 

Monitor the temperature of the gearbox
Overheating or sudden changes in the temperature may affect the performance of the gearbox. Hence, consistent and maintaining the necessary temperature levels plays a critical role in ensuring efficient gearbox operations. In this view, monitor the temperature of the gearbox with the help of an infrared gun. A sudden change in the temperature may be pointing towards the onset of significant concern.

 

Lubricate the gearbox regularly
Lubrication constitutes a very critical part of the overall maintenance activity. Connect with Top Gear's experts to know what lubrication and additives are appropriate for the gearbox, and use it as per Top Gear's specifications. Keep the gearbox well hydrated with the lubricant appropriate and crucial for efficient operations.

 

Ensure proper alignment of the gearbox with the equipment
proper alignment of the gearbox with the equipment is very important. Appropriate couplings should be used for doing so, without creating an interference fit between mating parts.

 

Check the gearbox for dirt and dust
Often, gearboxes operate in and encounter a lot of dirt and dust while in operation. To avoid dirt and dust accumulation, overheating, and the entry of contaminants in the gearbox, ensure that you keep it as clean as possible. Have the gearbox undergo regular cleaning to keep the gearbox as clean as possible.

 

Observe for gearbox vibrations
Doing a vibration analysis is crucial, especially when the gearbox operates in a commotion. A consistent vibration indicates the quality of the gear train and the bearings. An increase in the vibration signifies a critical concern.

 

 
FAQ
 
 

Q: What is a gearbox and its function?

A: A gearbox, also known as transmission, is a mechanical component that helps to transfer power from the engine to the wheels by using different gear ratios. It is usually located between the engine and the wheels, consisting of several gears, shafts and bearings.

Q: What is a gearbox on a motor?

A: A gearbox—otherwise known as a gear reducer or speed reducer—is a set of gears that can be added to a motor to drastically decrease speed and/or increase torque. Groschopp offers four different types of gear reducers: Planetary, Parallel Shaft, Right Angle Worm and Right Angle Planetary (Bevel).

Q: Is the gearbox the engine?

A: A car's engine is responsible for the power required to move the car. However, the generated power must be sent through the car gearbox or transmission between the engine and the wheels. Not passing the generated power through the gearbox will mean the wheel will run at a high speed.

Q: Is a gearbox a transmission?

A: A transmission (also called a gearbox) is a mechanical device which uses a gear set—two or more gears working together—to change the speed or direction of rotation in a machine. Many transmissions have multiple gear ratios, but there are also transmissions that use a single fixed-gear ratio.

Q: Is gearbox a clutch?

A: The clutch is a separate connection in the transmission, linking the engine to the gearbox. It thus enables starting away from rest and changing gear. The clutch is operated via the clutch pedal and the clutch release system.

Q: Why do motors need gearbox?

A: The gearbox serves two functions: it increases the torque that the motor provides, and it protects the motor from overload.

Q: Why does an engine need a gearbox?

A: As internal combustion engines only operate in a narrow speed range, gearboxes transform this into the wheel speeds needed to produce the various driving speeds. They do this by providing various transmission ratios to adapt the engine speed to different driving situations.

Q: What is the difference between transmission and gearbox?

A: A transmission is what allows the power to be transferred from the engine to the drive shaft which then sends that power to the driving wheels. As a part of the transmission, a gearbox houses the gears that determine how much power is transferred to the drive shaft via revolutions or 'revs'.

Q: Do all motors have gearboxes?

A: In traditional internal combustion engine vehicles, a gearbox is used to change the ratio of engine speed to wheel speed, allowing the vehicle to operate efficiently at different speeds. However, in electric vehicles, the electric motor can produce maximum torque at low speeds, making a gearbox unnecessary.

Q: Do cars need gearboxes?

A: Cars need gearboxes to provide different gear ratios for efficient power delivery at different speeds.

Q: What connects engine to gearbox?

A: The torque converter connects the engine to the transmission and uses pressurized fluid to transfer power to the gears. This apparatus replaces a manual friction clutch and lets the vehicle come to a complete stop without stalling.

Q: What is a gearbox in engineering?

A: The most basic definition of a gearbox is that it is a contained gear train, or a mechanical unit or component consisting of a series of integrated gears within a housing. In fact, the name itself defines what it is; a box containing gears.

Q: Does a gearbox increase power?

A: It is impossible to increase power in a gearbox. Power is rate at which work is done or energy used and has units of Joules/second. A gearbox can only lose power to bearing drag, gear meshing loss, oil churn and windage. The power output from a gearbox is always less than power input.

Q: How many gears does a gearbox have?

A: Contemporary manual transmissions for cars typically use five or six forward gears ratios and one reverse gear, however, transmissions with between two and seven gears have been produced at times.

Q: Do automatics have a gearbox?

A: Automatic cars still have gearboxes, they just work slightly differently. Instead of you manually choosing which gear to be in, the gearbox automatically does all the work for you. There are a few basic modes on an automatic gearbox that you can select, and these will tell the gearbox what to do.

Q: What is the difference between a gearbox and a gear motor?

A: Simply put, a gear motor is an electric motor coupled with a gearbox. In most cases, the addition of a gearbox is intended to limit the speed of the motor's shaft and increase the motor's output torque.

Q: Is a CVT a gearbox?

A: The meaning of the abbreviation CVT is Continuously Variable Transmission, and it is a type of single-speed automatic gearbox. The CVT gearbox has been used in various different cars, but you'll usually find it fitted to a small car.

Q: How do I know if it's the clutch or gearbox?

A: If the main symptom you've noticed is difficulty changing gears, then this could also be due to a faulty gearbox. To check whether the clutch or the gearbox is to blame, turn off the engine and try changing gears. If you can then the issue often lies with the clutch.

Q: Where can I use a gearbox?

A: Thus, the gearboxes such as Bevel Helical Gearboxes and Parallel Shafts are used to apply the functionalities such as Engine augmentation, reduction in speed, and many others. In such type of industry, gearboxes are utilized to increase the amount of engine torque to the most possible level.

Q: What are the three functions of the gearbox?

A: The goal is that these components can produce a movement either in the form of shifts or rotations. The gearbox can also be used to adjust the power or torque of the rotating motor, and also change the power of the rotating motor to be greater. Cars also require a gearbox that plays a role to transfer power.

As one of the most professional gearbox manufacturers and suppliers in China, we're featured by quality products and competitive price. Please rest assured to buy gearbox for sale here from our factory. Contact us for quotation and free sample.

Hypoid Spiral Bevel Reducer, Harmonic Drive Strain Wave Gear, Helical Hypoid Gearbox
国产一级无码不卡视频_国产亚洲欧美在线专区_夜夜精品亚洲综合_精品欧美A∨一区二区三区在线看