What Is Gearbox?- Definition, Types, and Uses

What is Gearbox?

The gearbox is a mechanical device used to increase the output torque or to change the speed (RPM) of a motor. The shaft of the motor is connected to one end of the gearbox and through the internal configuration of gears of a gearbox, provides a given output torque and speed determined by the gear ratio.

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. In the most basic sense, a gearbox functions like any system of gears; it alters torque and speed between a driving device like a motor and a load.

The gears within a transmission can be one of several types, from bevel gears and spiral bevel gears to worm gears and others such as planetary gears. The gears are mounted on shafts that are carried by roller bearings and rotate about them. The gearbox is a mechanical method of transferring energy from one device to another and is used to increase the torque while reducing the speed at the same time.

Gearboxes are used in many applications including machine tools, industrial equipment, conveyor belts, and virtually any rotary motion power transmission application that requires changes in torque and speed requirements.

How do they work?

An electric or hydraulic motor is applied to one end of the gearbox, while the energy is converted into low-speed drive torque at the other end. Inside the box, the materials used have a long service life, which supports enormous strength. Can you imagine the energy it would take to tackle the wreckage of a cruise ship during the maneuver? Or that of the container crane? Or even an underground digging machine?

Types of Gearboxes

1. Helical Gearbox:

Helical gears and helical Gearbox are both capable of ensuring smooth operation. The teeth of a helical gear are cut at an angle to the face of the gear. During the process, when two of the teeth begin to mesh, contact gradually begins at one end of the tooth and maintains contact as the gear rotates into a full mesh. When it comes to transmissions, helical gears are the most common gear used and even generate large amounts of thrust.

2.Helical gearbox unique point:

Its unique point is that it is fixed at an angle that allows more interaction in the same direction as it moves. This results in constant contact for a certain period of time. The extruder helical gearing is also used when the torsional strength is to be optimally used and also for applications with low excitement. Applications include steel, rolling mills, conveyors, elevators, oil industry.

3.Bevel Helical Gearbox:

Do you know the critical properties of this gearbox? It is a curved set of teeth that are located on the conical surface near the edge of the device. The bevel gear train is also used to provide rotary motion between non-parallel shafts. They play their role in mining quarries, mixers, and conveyor belts.

4. Worm Gearboxes:

The Worm gearbox uses a large diameter worm wheel. The worm or screw engages the teeth on the periphery of the gearbox. The rotation of the worm gearbox causes the wheel to move in a similar way to this due to the screw-like movement. The setup is designed so that the setup can rotate the gear, but the gear cannot rotate the worm.

The angle of the screw is flat and therefore the gear is used in conveyor systems for braking or emergency stop. These gearboxes are also used in pharmaceutical and packaging machines, Bottling plant conveyors, Machines for the Food Industry.

5. Planetary Gearbox:

The planetary gearbox is considered ideal and is also known for its durability, accuracy, and distinctive functionality. It is characterized by precise applications. The planetary gear extends the service life of your devices and optimizes their performance to the full.

This gearbox is available in either a solid hollow format or with a variety of mounting options including flange, foot, or shaft. The use of this gear differs depending on the type of industry. The bottom line, however, is that the gearboxes are designed to simplify their mechanical function in various industries.

FAQs.

What is in a gearbox?

So, it’s clear a gearbox is always a fully integrated mechanical component consisting of a series of mating gears contained in a housing with shafts and bearings (to support and resolve loads) and in many cases a flange for motor mounting.

What is Gearbox and its function?

The gearbox is a mechanical device used to increase the output torque or to change the speed (RPM) of a motor. The shaft of the motor is connected to one end of the gearbox and through the internal configuration of gears of a gearbox, provides a given output torque and speed determined by the gear ratio.

Where are gearboxes used?

Gearboxes are used in many applications including machine tools, industrial equipment, conveyors, and really any rotary motion power transmission application that requires changes to torque and speed requirements.

What type of energy is in a gearbox?

Gearbox. The drivetrain is comprised of the rotor, main bearing, main shaft, gearbox, and generator. The drivetrain converts the low-speed, high-torque rotation of the turbine’s rotor (blades and hub assembly) into electrical energy.

Why gearbox is used with motor?

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.

How does gearbox work?

It drives the individual gears on the main shaft, which rotate freely on the bearings. Thus, the gearbox passes the drive to the wheels depending upon the gear which engages on the main shaft. When you push the shifter-sleeve towards the desired gear, that gear locks onto the main shaft and rotates it.

What is gearbox and types?

In general, there are three different types of gearboxes: concentric, parallel, and right angle. A fourth type called shaft mount is also used in situations where the applications are in a configuration where they cannot be mounted by foot.

What is the difference between a Gearbox and a transmission?

The difference between gearbox and transmission is that, while these two are two separated units, the transmission refers to the whole drivetrain which includes gearbox, clutch, prop shaft, final drive shafts, and differential.

How is a gearbox made?

Smelting at 700°C: Manufacturing the gearboxes requires smelting 15,000 tons of aluminum every year, the amount used to make 220 commercial airliners. The ingots are loaded into kilns at nearly 700°C for smelting. Several injection molding machines solidify the molten aluminum into a rough part in 20 seconds.

What is a gearbox service?

The primary aspect of transmission service is flushing out the old transmission fluid and replacing it with new fluid. However, a complete transmission service should also include: examining the sump pump or pan (if possible), replacing or cleaning the filter, cleaning the pan, and installing it with a new pan gasket.

What is gearbox in engineering?

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. The gearbox is a mechanical method of transferring energy from one device to another and is used to increase torque while reducing speed.

What is Gearbox ratio?

A gear ratio is the ratio of the number of rotations of a driver gear to the number of rotations of a driven gear.

Why do we use gears?

Gears serve two main purposes: increasing speed or increasing force. In order to increase one of these, compromises must be made. For example, to increase the speed of a bicycle’s wheels the force applied to the pedals must be increased. Similarly, to increase the force on the wheels the pedals must be turned faster.

What is the benefit of gearbox?

Industrial gearboxes not only provide essential benefits when it comes to creating goods, but they also aid in the maintenance of your systems. Using a gearbox to multiply torque, match inertia, and reduce speed helps to cut systems operations by allowing smaller motors and drives to be utilized.

Does gearbox increase speed?

Gearboxes reduce speed and increase torque. Whilst there are occasionally gearboxes that will increase speed and reduce torque, in the vast majority of cases, a gearbox will be used to reduce the shaft speed of a motor and increase the torque.

How do gears reduce speed?

The basic gear changing rule is ‘brakes to slow – gears to go’. As the car increases speed, change up through the gears. When you want to slow down, use the foot brake. You need only change to a lower gear when you need the accelerator again to ‘drive’ the car.

What is a 1 speed gearbox?

Using a single-speed gearbox means the drivetrain acts as if you were in top gear in a combustion car. That gear has to move the car at all speeds, from 1 mph to whatever its top speed may be. And that’s fine, even considering that off-the-line acceleration could be improved by having a bonus lower gear.

How do you calculate gearbox kw?

Motor power = torque ÷ 9550 × Rated power’s motor input speed /Ratio /service factor.

How many gears does a gearbox have?

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.

Which factors responsible for selection of gear?

In our experience, at a simplified level, there are three factors that are most important when selecting a gear material. They are strength, durability, and cost, which include both the cost of the material and the cost of manufacturing.

Which gearbox is used in two-wheeler?

Most manual transmission two-wheelers use a sequential gearbox. Most motorcycles (except scooters) change gears (of which they increasingly have five or six) by a foot-shift lever.

How does a clutch and gearbox work?

Where is a gearbox located?

The gearbox is the second stage in the transmission system, after the clutch. It is usually bolted to the rear of the engine, with the clutch between them. Modern cars with manual transmissions have four or five forward speeds and one reverse, as well as a neutral position.

Is clutch and gearbox the same?

As nouns, the difference between gearbox and clutch is that gearbox is that part of a car’s transmission containing the train of gears, and to which the gear lever is connected while the clutch is the claw of a predatory animal or bird or clutch can be a brood of chickens or a sitting of eggs.

How do you maintain a gearbox?

Top Tips to Maintain an Industrial Gearbox:

  • Perform a Regular Inspection of the Gearbox.
  • Monitor the Temperature of the Gearbox.
  • Lubricate the Gearbox Regularly.
  • Ensure proper alignment of the gearbox with the equipment.
  • Check the Gearbox for Dirt and Dust.
  • Observe for gearbox vibrations.

How do I know if my gearbox needs oil?

Signs That You Need to Change Your Transmission Fluid

  • Puddles under your car.
  • Roaring sounds when you accelerate or go around corners
  • Difficulty shifting.
  • Engine revving when going around corners.
  • A chattering noise when you start driving.
  • A slight burning smells.
  • Warning light.

How do you know if gearbox needs replacing?

Signs Your Car Needs Gearbox Repair

  • Problems shifting gears. If you’re encountering hesitation or resistance when putting the car into gear or a jerking motion when shifting gears, this is a sign that something is wrong with the transmission system.
  • Unusual noises.
  • Leaking fluid.
  • A burning smell.