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:
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.
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.
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.
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.
- 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.