Introduction
Gearbox introduction:
From a need for product development as well as transmission of power from a
source such as a motor, through a machine and then to an output, the industrial gearbox
came into existence. [1] The gearbox is known to be able to complete the most common
machine tasks by producing a high torque by reducing or increasing the drive speed the
other way. [2] According to Shigleys mechanical engineering design, the gearbox
comprises of an efficient means of transmitting power: by using rotary motion of a shaft
supported by bearings. [1]
Gearbox reducer:
According to the webpage what is a gear reducer at Wisegeek, the fundamental
theory behind why a reducer differs from a regular gearbox is that the energy output of a
high-speed motor or engine is redirected to turn another mechanical component at a
lower rotational speed and at a higher torque. [3] A gear reducer accomplishes the
energy transformation by changing the ratio of the rotation of two moving parts. Gear
ratios for a gearbox are generally calculated from the ratios of the number of teeth in each
gear. [1]
Gearbox reducer application:
In order to better understand the benefits of using a gearbox reducer in real life,
the example of a modern day automobile can be studied. Internal combustion engines
must operate at high speeds to maintain smooth power generation. In dire situations, the
use of a gearbox reducer, the energy can be used to overcome the inertia of the stopped
vehicle, decrease the momentum of a slowing vehicle or allow heavier loads to be towed
but at a lower velocity. [3]
Types of gears:
Gears have many types. Each gear type has a variety of applications based on its
size and design. Below is a description of some gear types.
Spur gears: This gear type is the most common gear type. It is suitable for most
gear applications. The main function of this gear is to transfer motion between
parallel shafts. The teeth in these gears are parallel to the shaft axis. An advantage
of this gear type that they are the least expensive type which is why they are
commonly used. A disadvantage however is that due to the teeth geometry these
gears produce a lot of noise [1].
Figure 1 Spur Gears [4]
Helical gears: [1] This gear type is the one which our gearbox is
using Unlike spur gears the teeth in helical gears are cut at an
angle. Due to this geometry the teeth engage more gradually
compared to spur gears. This reduces the noise and the gears
run smoothly. Helical gears are mainly used when the application
requires high speeds and/or large power transmission.
Disadvantages however include the fact that they are expensive
to manufacture and they produce thrust loads.
Figure 2 Helical Gears [5]
Rack and pinion: This gear type is a sort of linear actuator which converts circular
motion into linear motion. It consists of a circular gear (pinion) which engages
with a linear gear (rack). Common applications include steering mechanisms in a
car [6] and an actuator used to control valves in pipeline transport [7].
Figure 3 Rack and pinion [8]
Worm Gears: This gear arrangement includes a worm which is in
the form of a screw which is connected to a gear. The direction of
rotation of the worm gear, also called the worm wheel, depends
upon the direction of rotation of the worm and upon whether
the worm teeth are cut right-hand or left-hand. It is used to
reduce speed or deliver higher torque [9].
Figure 4 Worm gear [10]
Bevel gears: The teeth of these type of gears are formed on
conical surfaces. Their main function is to transmit motion
between intersecting shafts. On straight and spiral bevel gears,
the shafts must be perpendicular to each other, but they must
also be in the same plane [11]. These type of gears are used in
car differentials.
Figure 5 Bevel Gears [12]
References
[1] R. G. Budynas and J. K. Nisbett, Shigley's Mechanical Engineering Design, 9th ed.,
Boston: McGraw-Hill, 2011.
[2] "Introduction to Gearbox," ISHIBASHI Manufacturing Co., Ltd., [Online]. Available:
http://www.ishibashi-mfg.com/en/product/index.html. [Accessed 27 April 2015].
[3] "What is a Gear Reducer?," wiseGEEK, [Online]. Available:
http://www.wisegeek.com/what-is-a-gear-reducer.htm. [Accessed 27 April 2015].
[4] 'Spur Gears - F W Hercus Pty. Ltd - Hercus Gear Cutting - Adelaide', 2008. [Online].
Available: http://www.hercus.com.au/spur-gears/. [Accessed: 17- May- 2015].
[5] 'Helical Gears, Helical Gears Manufacturer, Helical Gear Boxes, Mumbai, India'.
[Online]. Available: http://www.navjivangearsindia.com/helical-gears.htm. [Accessed:
17- May- 2015].
[6]S, Bishop, Rack and pinion variable ratio steering gear, U.S. Patent 3753378A
Abbrev. August, 21, 1973.
[7]" The Role of Rack and Pinion Actuators in On-Off & Modulating Controls', Valve
Magazine, 2010.
[9]D. Gear Nomenclature, 'ANSI/AGMA 1012-G05 (R2011) Gear Nomenclature,
Definition of Terms Symbols', Webstore.ansi.org. [Online]. Available:
http://webstore.ansi.org/RecordDetail.aspx?sku=ANSI%2FAGMA+1012-G05+
%28R2011%29. [Accessed: 17- May- 2015].
[11] K. Nice, 'Bevel Gears - How Gears Work', HowStuffWorks, 2000. [Online].
Available: http://science.howstuffworks.com/transport/engines-equipment/gear4.htm.
[Accessed: 17- May- 2015].
Figure references:
http://www.hercus.com.au/spur-gears/
http://www.navjivangearsindia.com/helical-gears.htm
http://www.directindustry.com/prod/cross-morse/racks-pinions-20096-55133.html
