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Author Archives: Samantha Mayer

  1. The Role of an Industrial Gearbox

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    An industrial gearbox is an enclosed system where mechanical energy is transferred from one device to a driving tool to increase torque and reduce speed. A gearbox is made of several components that work cohesively to complete a variety of industrial tasks that require high power delivery from the power source.

    Industrial gearboxes are used in countless applications. They can be found in most material handling equipment, crushers, conveyors, cooling towers, and cranes. The manufacturing industry utilizes gearboxes throughout the production process, especially when processing raw materials.

    The most common types of gearboxes are helical gearboxes, helical-worm gearboxes, helical-bevel gearboxes, planetary gearboxes, and worm reduction gearboxes. This article will cover the basics of industrial gearboxes, including their importance and benefits.

    The Importance Of An Industrial Gearbox

    An industrial gearbox is a critical component in countless machines that are used in nearly every industry. Any device that needs to modify torque or speed likely has a gearbox of some kind. Without them, many devices will not function as efficiently. While industrial gearboxes do require maintenance considerations, they also maximize productivity and can minimize workplace accidents.

    Recent technological advancements have made gearboxes, specifically industrial gearboxes, more powerful and affordable than ever before. They are typically used to monitor the direction of rotation and convert torque or power to the desired output. Industrial gearboxes are also quite reliable, making them a common component in modern gate drives.

    Industrial gearboxes are highly customizable, making them well suited for just about any application. Specifications can allow a gearbox to handle various speeds and torque outputs. They can be designed in a way that can maximize speed or torque.

    Industrial Gearbox Benefits

    Industrial gearboxes are a great way to improve a company’s operational capacity. For industrial businesses, gearboxes are an essential component for creating products while also aiding in the maintenance of other systems. Industrial gearboxes can be used to multiply torque, reduce speed, and match inertia. Other benefits include:

    Torque Multiplication

    When mounted to the motor output shaft, gearboxes can provide a mechanical advantage. The number of gears, as well as how many teeth they have, will provide a mechanical advantage defined by a ratio. For example, a 5:1 gearbox can multiply torque by five times, allowing a motor that generated 100 lb-in. of torque to multiply the output to 500 lb-in.

    Speed Reduction

    In some circles, gearboxes are called gear reducers because they decrease the output speed. A motor that is running at 1,000 rpm that is fitted with a 5:1 ratio gearbox will output 200 rpm. The speed reduction improves overall system performance, given that many motors don’t operate efficiently at low RPMs.

    Inertia Matching

    In the past two decades, servomotor manufacturers introduced a series of improvements such as lighter materials, denser copper windings, and high-energy magnets specifically for motors that generate more torque for their given frame size.

    If load inertia significantly exceeds that of the motor, it can cause increased settling times or excessive overshoot. Both problems decrease production line output. Conversely, a motor too large for its intended application is more expensive and requires more power to accelerate its inertia.

    In these scenarios, an industrial gearbox can help balance the motor inertia to load inertia, creating a more responsive system. The motor encounters reflected inertia equal to load inertia when divided by the square of the gearbox ratio.

    Cost Savings

    All of these factors (torque manipulation, speed reduction, and inertia matching) cut costs. Industrial gearboxes enable the use of smaller motors and drives.

    Superior Gearbox Industrial Gearbox Offerings

    Superior Gearbox has been the trusted name for industrial gearboxes for over 45 years. We have expertise in speed control technologies, including a variety of manufactured helical gear motors, worm speed reducers, and bevel gear drives. Regardless of your production size or complexity, we are the company to talk to when it comes to industrial gearboxes.

    We offer:

    • Low Input Speed Worm Gear Reducers
    • Helical Gearmotors
    • Bevel Gear Drives
    • Industrial Worm Gear Drives
    • Custom Gear Drive Solutions
    • Agricultural Gearboxes

    Our methodology utilizes the latest engineering software in the industrial gearbox sector. To learn more about how we can help your business, don’t hesitate to contact us today.

  2. Types of Industrial Gearboxes

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    Industrial gearboxes are embedded systems that deliver mechanical energy to an output device. They modify the torque, speed, and rate of rotation to convert energy into a compatible format. Industrial gearboxes are designed to manage multiple tasks simultaneously, at great speeds for prolonged periods.

    The majority of an industrial gearbox is made of brass, aluminum, or iron and while its primary objective is to increase torque, they also lessen the original mover shaft’s activity. This means the output device rotates at a slower speed, which increases the torque. There are several types of industrial gearboxes to choose from, as well as customized options. This blog will discuss the primary types of industrial gearboxes as well as the solutions available from Superior Gearbox. 

    What Are the Different Types of Industrial Gearboxes?

    Industrial gearboxes are used throughout many industries, and there are a variety of types available to meet these diverse needs. Let’s take a look at some of the most widely-used industrial gearboxes. 

    Worm Gears

    Industrial Worm Gear Reducer

    Worm gearboxes perform heavy-duty functions. They are compact and have a high load capacity while also being the smoothest and quietest gear system available. Worm gearboxes feature a large diameter screw that aligns the teeth in a machine’s periphery. Other key characteristics of worm gears include:

    • They provide precision linear bearings and reduced noise levels
    • They offer high ratio speed reduction and can be used to increase torque
    • They are frequently used in smaller spaces and when large gear refinements are required

    Helical Gears

    Helical gearboxes feature teeth cut to a fixed angle to provide the greatest grind power when it turns in the same direction. They can transmit motion and power between right-angle or parallel shafts. They are smaller in size than other industrial gearbox options, use less power, and are frequently used in high-power and high-load applications. Some common applications for helical gears include rubber and cement production as well as other manufacturing applications. They are also used in low-power applications, such as grinders, coolers, and conveyors. Helical gears provide several unique benefits, such as:

    • High efficiency 
    • Low oscillation with less noise
    • Reliable meshing performance
    • Stable transmission

    Bevel Gears

    Known as power transmission mechanical components, bevel gears are primarily used to adjust shaft rotational direction. They reduce speed while raising torque in non-parallel rotating shafts. Bevel gears feature curved teeth positioned along cone-shaped surfaces that are adjacent to the rim of the unit. They accommodate rotary motions between irregular shafts and are necessary to many industries, including aeronautics, pharmaceuticals, mining, textiles, and more. 

    Key advantages of bevel gears include:

    • Space-saving
    • Able to transmit great amounts of power efficiently
    • Reduced risk of slippage

    Spur Gears

    Known for their cylindrical pitch surfaces, spur gears reliably convey power and movement from one shaft to another. Featuring teeth that fit parallel to the shaft, they have no thrust load and can improve machinery’s running speed while increasing torque. They are commonly used in industrial applications that include speed reducers, gear pumps, conveyor systems, transmissions, motors, mechanical transportation systems, and more. 

    In industrial applications, spur gears provide several advantages, such as:

    • They work well in limited space environments
    • They are well suited for driving systems as they transmit greater power efficiently 
    • They don’t have any slippage
    • They offer a wide spectrum of transmission proportions as well as excellent performance and secure processing

    Custom Gearboxes

    custom gearbox

    While standard gearboxes can meet the requirements of most mechanical OEM applications, developing a custom-designed gearbox provides many unique performance advantages. Whether your needs are related to size, materials, speed, or low backlash requirements, customization allows for every specification to be met. Developing a custom industrial gearbox solution also allows OEMs to be involved in the entire process from design to production. 

    Custom gearboxes are ideally suited for equipment featuring unique torque requirements, or to replicate outdated or discontinued components. Since they are tailored to address the needs of even high-performance applications, they easily integrate into existing equipment. Working with a custom gearbox manufacturer like Superior Gearbox provides you with a component fabricated to meet all of your precise needs. 

    Industrial Gearboxes From Superior Gearbox

    Superior Gearbox has been developing market and customer-specific industrial gear drives for over 30 years. In addition to our diverse standard product line, we also partner with customers during the design process to develop specialty products tailored to application-specific needs. Whether a job requires modifying an existing product, reverse engineering, or developing a new design from scratch, our knowledge and experience enable us to deliver perfectly crafted final products. 

    In addition to all of the standard gearboxes mentioned above, Superior Gearbox offers several other product line options. We provide customized industrial gearboxes with each element tailored to meet the needs of even the most challenging power transmission application. Our custom solutions are developed according to your timeline and budget.

    Superior Gearbox: For All Your Industrial Gearbox Needs

    There are many varieties of industrial gearboxes to choose from, and depending on the needs of your application, developing a customized solution may be the best solution. Superior Gearbox carries all types of standard gearboxes and can also modify any product to meet your exact requirements. To get in touch with an expert about our solutions, contact us today.

  3. Stainless Steel Gear Drives for Sanitary Food Processing

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    A variety of manufacturing and conveying systems help with the production, packaging, and delivery of products in the food and beverage industry.  To ensure this equipment functions properly, these systems require reliable components to facilitate consistent efficiency across the production line.  One of these components is a stainless-steel gear drive. 

    stainless steel gear drive

    Choosing a gear reducer that provides unmatched performance while also being able to endure the severe chemicals and high-pressure washdown requirements found in the food or beverage industry can be difficult. Understanding the additional features now available in washdown-capable gear reducers made from stainless steel components will assist you in choosing the most durable option.

    In this post, we will cover what stainless steel gearboxes are, along with the benefits they offer for a range of sanitary food processing applications, to include applications in other industries that require sterile manufacturing environments.  

    What Is a Stainless-Steel Gearbox?

    Food processing as well as other applications use stainless steel gearboxes when they need to meet strict corrosion and hygiene protection requirements.  For instance, environments with high levels of humidity or seawater exposure often use stainless steel gear drives to prevent corrosion.  Beyond that, applications in the food and beverage industry use these components because their smooth surface is easy to clean and won’t trap moisture, particles, or bacteria, making them suitable for environments where strict hygiene requirements require daily washdown.  

    Washdown cleaning destroys typical gear reducers, from the use of high-temperature and high-pressure water jets, corrosive salt water, caustic and acidic chemicals, or chlorine-based sanitizers typically used in the meat, dairy, and ready-to-eat product manufacturing.  Chlorine is especially hard on aluminum, causing a whitish-colored rust.  In applications that require infrequent washing and sterilization, treated aluminum and cast-iron work well. However, stainless steel is the best choice for your application if components require frequent high-pressure washing and sterilization. Regular washdown cleaning of cast iron and aluminum coatings will eventually separate, creating areas where the water and chemicals used during the cleaning process become trapped and contact unprotected material.

    Our stainless-steel gearboxes are entirely constructed from stainless steel.  Each unit is sealed and leak-proof to operate safely and reliably in wet, hostile, or sterile environments, so you have the maximum performance while maintaining a high level of sanitation. Many of our competitors utilize a plated or coated housing with some stainless internal components, but this is not a true all-purpose washdown gear reducer. It might be corrosion resistant to a point, but an all-stainless box is foolproof.

    Benefits of Stainless-Steel Gear Drives for Sanitary Food Processing

    Stainless steel gearboxes come with multiple advantages that make them ideal for sanitary food processing equipment.  The food and beverage industry relies on a variety of systems to enable sufficient speed, item transfer, and completion of the product cycle at large.

    To meet this industry’s specific needs, gear drives for sanitary food processing offer the following benefits:

    • The ability to support both dry and wet manufacturing environments
    • No fear of rust or paint chips entering the food production process
    • Eliminates the possibility of rust creating a hiding place for bacteria
    • Requires no repainting or other aesthetic maintenance
    • Does not attract unwanted USDA scrutiny
    • Consistently reliable service for many years due to high wear resistance
    • Designs that meet your unique application around torque, speed, load, and other factors
    • The integration of gear reducers for minimized power losses and reduced equipment maintenance costs resulting from corrosion or failure
    • Stainless steel gearboxes eliminate any exterior corrosion

    Food Processing Gearbox Applications 

    With increased automation in food processing comes higher hygiene requirements.  To meet these requirements, gearboxes must feature designs that can hold up to regular thorough cleaning cycles if they make contact with food items.  Stainless steel gearboxes offer superior corrosion resistance and the smooth cleaning surfaces needed to maintain a hygienic environment.   

    Some of the many food processing applications for gearboxes include:

    • Poultry Processing 
    • Brewery Bottling
    • Pharmaceuticals
    • Washdown Dough Mixer
    • General Food Processing
    • Labeling Machinery
    • Packaging Equipment
    • Palletizers
    • Shrink Wrapping
    • Decappers
    • Washers
    • Blenders
    • Grinders
    • Granulators
    • Agitators
    • Filler Equipment
    • Fillers
    • Raw Material Handling
    • Drying and Cooking Lines
    • Cleaning 
    • Sterilizing
    • Drying Bottle Washer Machine
    • Stackers
    • Batching Equipment
    • Loaders and Unloaders
    • Rotary Shakers

    The wide range of applications for washdown motors go beyond the food and beverage industry.  Superior Gearbox Company’s Cleandrive, stainless steel gear reducers, are particularly critical components for use in applications in highly corrosive environments.  Pharmaceutical manufacturing equipment and conveyors require systematic cleanliness and sterility for product quality and to prevent cross-contamination. Where motors propel machine-cutting fluids and water-cooling systems in a range of industries or even simulating rain and saltwater spraying in automotive test tunnels, a stainless-steel gear reducer can keep your machinery running. 

    Superior Gearbox Specific Capabilities

    Stainless steel gearboxes help maintain valuable food processing systems and ensure consistently hygienic environments.  However, it is important to locate the right components for your application to get the best results.

    Superior Gearbox Company is a leading manufacturer of high-quality, cost-effective gearboxes for use in the food and beverage industry, including food processing applications.  Depending on your specific application and requirements, we offer a wide range of gearbox designs, including helical, spur, bevel, spindle, and worm gear drives.  We also carry a variety of bearings, gears, housings, and shaft materials to customize each component of the gear drive, which provides our customers with the ideal solution for their unique application. 

    Our engineering capabilities enable us to design a gearbox that can meet specific horsepower, power consumption, and torque requirements.  Furthermore, we manufacture gearboxes that offer durable longevity and safety in particularly harsh and hazardous environments.  Based on your individual needs, we will provide you with a gearbox design while keeping your desired timeline and budget in mind.  

    In addition to the food and beverage industry, our gearboxes work with applications in many other industries, including: 

    • Agriculture
    • Poultry
    • Printing
    • Chemical 
    • Oil and gas
    • Cement and concrete
    • Pulp and paper
    • Lawn and garden

    Regardless of our customer’s requirements, we have the resources and expertise needed to meet them.  With over 30 years of experience backing us, we offer some of the best gearbox designs available for nearly any application.  Our engineering team can modify or reverse engineer an existing product or start from scratch to supply you with an entirely original design. 

    To learn more about our capabilities, contact us today and we’ll connect you with one of our representatives.

  4. MODEX 2022 – The Premier Supply Chain Event

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    Stop by and see Superior Gearbox Company at MODEX 2022, booth C5275.

    The largest manufacturing and supply chain event, MODEX, is returning to Atlanta on March 28th and Superior Gearbox will be there! We are excited to not only attend this event, but to also be one of the 800 exhibitors who will be displaying solutions and innovations for the manufacturing, warehousing, logistics, and distribution industries.

    Material handling plays a major role in many industries. Superior Gearbox’s wide range of products have been designed with the goal of providing effective material handling with reduced over all cycle time. We are renowned in this industry for supplying products with High Reliability, Long Life, Mounting Flexibility, Robustness and Compactness. These products play a major role in enhancing the performance of material handling. With our wide range of power transmission solutions, we have covered both indoor and outdoor material handling.

    Application

    • Apron Feeder
    • Paddle Feeder
    • Crushers
    • Vibrating Grizzly Screens
    • Vibro feeder
    • Stacker Belt Drive
    • Stacker Luffing Drive
    • Stacker Travel Drive
    • Reclaimer
    • Elevators
    • Pipe conveyors
    • Floor conveyors
    • Belt Conveyors
    • Belt Conveyors
    • Screw conveyors
    • Dribble Feeder
    • Travelling Tripper
    • Movable Shuttle Conveyor
    • Rotary Breaker

    Where can you find Superior Gearbox at MODEX 2022?

    Booth #C5275 – Stop by our booth to meet with a member of the Superior Gearbox Team to learn more about our products and our capabilities.  Make the most of your MODEX 2022 experience!  Plan ahead by setting-up a time to talk with us and keep your day moving along!

    Eric Holmes – National Sales Manager – Superior Gearbox Company – eholmes@superiorgearbox.com

  5. Superior Gearbox Showcases Gear Drives for Meat and Poultry Processing Equipment at the 2022 IPPE.

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    Superior Gearbox Attending IPPE

     

    Superior Gearbox Company is eager to showcase power solutions for the poultry industry at the International Production & Processing Expo (IPPE), January 25-27th in Atlanta. As the world’s largest annual poultry, meat, and feed industry event of its kind, this year’s IPPE will bring together representatives from all over the world including operation and plant managers, purchasing agents, engineers, and researchers from the world’s top feed, meat processing and packing and poultry companies.

    Visit Booth C10856 in C HALL and BC HALL: Meat & Poultry Processing and Packaging at the Georgia World Congress Center to meet with experts from Superior Gearbox Company and learn how our diverse line of drive solutions are helping poultry processing and production facilities improve operational efficiencies.

    Powertrain components are subjected to high pressure, high temperature, and corrosive solutions during washdowns, so the materials and protective coatings they are constructed with, and the physical design of these gear drives are crucial factors in whether they contribute to the problem or are part of the solution. From conveying to pumping to packaging, Superior Gearbox Company’s Cleandrive series is designed for heavy washdown environments where sanitation and safety are critical to the application.

    To schedule a booth meeting, please contact Eric Holmes eholmes@superiorgearbox.com

  6. What Is a Worm Gear?

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    A worm gear, also called a worm drive, is a gear configuration in which a screw or worm meshes with the teeth of a gear. Worm gears are typically used when substantial speed reductions are required. A worm gear configuration enables the rotational speed to be adjusted, which is ultimately determined by the number of starts and teeth on the worm gear.

    Applications of Worm Gears

    Worm gears are used in many applications where low speed and a relatively large amplification of power is required. They appear in simple, everyday home devices as well as heavy machinery. Worm gears have many advantages over other transmission methods—especially for applications that require speed reduction.

    Here are just a few examples that show how worm gears are commonly used today:

    Elevators — Worm gears are standard to use in applications that require fast braking or stopping, such as an elevator. In addition to their compact size, worm gears are used in these applications because, in the proper size and ratio, they can stop and hold a load and won’t go in reverse. These properties help ensure that the load cannot free fall, and they help to regulate the elevator’s speed.

    Tuning Instruments — One of the most common uses of a worm gear is the tuning mechanism found on stringed instruments such as guitars, banjos, and violins. Often referred to as a machine head and usually located on the instrument’s headstock, the worm gear allows the user to adjust the strings and lock the gear into place when the desired tightness is achieved. The worm gears used for tuning instruments are unique because they can be used to tighten or loosen the strings, whereas most other types of gears move only in one direction.

    Conveyors — Conveyors are used extensively in industrial applications to move products from one place to another. Worm gearboxes are an economical way to provide the required torque increase and speed reduction required from electric motors to move the products efficiently.

    Automatic Security Gates — Automatic security gates lock when closed and will not run in reverse. Security gates typically use two separate worm drives to open and close a gate. The ability of a worm drive to lock in place ensures that the gate remains in position and cannot be forced or breached.

    Why Use a Worm Gear Speed Reducer?

    Worm gears are commonly used for speed reduction because multiple conventional gear sets are needed to achieve the same effect. Rather than installing more gear sets, worm gears have an increased reduction ratio, which makes them more effective. The ratio increases depending on the number of teeth on the worm gear and how many threads are included on the pinion. Worm gears are also more cost-effective than conventional gears because they have fewer components and a lower risk of mechanical failure.

    Learn How Superior Gearbox Company Can Help Reduce Speed on Your Work Gears

    Worm gears are one of the most common and economical methods available for reducing rotational speed, and they are integral to many mechanisms, both simple and complex. They’re more practical for many applications than conventional gear kits because they require less space and operate quietly. They’re also more mechanically stable and have anti-reversing properties needed for some applications.

    At Superior Gearbox, we have manufactured high-quality gear drives for power transmission systems since 1975. We offer our clients many gear drives designed for various applications and can also create custom designs to meet your specifications.

    To request a quote or learn more about worm gears, contact us today.