For decades, gearboxes have been a vital part of industrial applications. They act as an excellent tool to enhance operational output. Another important function of this equipment is to deliver the rotational force needed for a device to move.
Given the rising demands, businesses only rely on high-speed gearboxes that promise consistent and smooth daily operations. Whether your company operates in the paper and pulp, steel, aerospace, sugar, or cement industry, the right gearbox can make or break your business.
As per Future Market Insights analysis, the industrial gearbox market is projected to have a value of $47.16 billion by 2033. It is currently growing at a CAGR of 4.6%. As your competitors invest in top-quality branded gearboxes, you must not let your business lag behind.
However, we understand how challenging it can be to choose the right system. In this article, we will discuss six important considerations that will help you select the right gearbox for your needs.
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Service Factor
The process of choosing the right industrial gearbox must begin with the appropriate service factor. This factor is defined as the ratio between the torque required for the industrial application to the torque rated on the gearbox.
The numeric value of the service factor largely varies depending on the thousands of different combinations of gearbox types. As a result, each system is designed for a unique purpose. According to Cotta, it is possible to have gearboxes designed for specific industrial needs.
The service factor rating usually starts at 1.0, which indicates that a unit has the capacity needed to handle industrial applications. On average, a rating of 1.4 works for most industrial needs. An incorrect service factor may lead to overheating and system failure.
To choose the right service factor rating, identify the application class number (Class I, II, or III). This will further depend on the application itself as well as the time for which the system will be used.
You must also keep in mind the type of gearing – spiral bevel, worm, helical, etc. In case your operational conditions are atypical, it’s best to opt for a service factor higher than the recommended rating.
Operating Environment and Temperature
The process of choosing high-performance gearboxes also involves selecting the right operating environment and temperature. Even the service factor rating will depend on the operating temperature.
For instance – if the operating temperature is high, the internal pressure will increase. This, in turn, will require a higher service factor rating. Moreover, the lubrication thickness will differ based on whether the gearbox operates under high or low temperatures.
Furthermore, high temperature increases the risk of wear, thereby requiring special materials that prevent bacterial growth and corrosion. If you do not account for such features, you will end up investing in a gearbox that is unsuitable for your industrial application.
Output Shaft
This is also a crucial component of the overall transmission, responsible for bearing stress and torsion. Along with the shaft length, the bore size is also something to consider. These will depend on whether the unit has a keyless or keyed shaft, a steel output, or a flanged output with a combination of the aforementioned.
To choose the relevant bore size, you may need to invest in a larger gearbox or one of a different type that matches the existing output shaft. In case of doubts, you can ask the gearbox manufacturer to provide a technical blueprint with accurate dimensions of the output shaft.
Shock Loads
Similar to the hammering effect, there can be a sudden dramatic increase of load on the gearing. Also known as the shock load, this phenomenon leads to increased wear on the unit due to strain. If not accounted for properly, the increased stress can cause premature failure of the system.
So, consider the type of shock load and choose a gearbox that supports its needs. Generally, there are two categories of shock loads – uniform and non-uniform. Uniform loads remain fairly stable through the operation, whereas non-uniform loads change mid-application.
Depending on the use, the motor speed and torque will help you select the shock load rating. If the application is such that the load will remain largely stable, you can opt for static loads.
Output Style or Mechanism
The output mechanism or style will add varying degrees of shaft loads. This comprises the pulleys, chains, toothed pinion, and more. For instance – output configurations like double output shaft and shaft-mounted bushing can reduce the load to a numeric value lower than the unit’s rating.
As a result, different bearings account for the rise in radial or axial load. An example would be helical gearing which causes an increase in axial load. But, most other output mechanisms lead to a higher radial load.
Gear Placement
Gear placement is determined by the housing style of gears within the gearbox. This factor also helps in determining the gearbox’s heat production and efficiency.
The general thumb rule is to choose a gearbox where the torque produced is greater than the heat generated. Besides this, you must also consider even weight load distribution while choosing the right industrial gearbox.
Finally, the above-mentioned factors will help you in your quest for the ideal industrial gearbox. However, you must also ensure that the supplier is reliable. They will play a crucial role in meeting your specific needs and maximizing the value you extract from your gearbox.
