Gearboxes are important mechanical components. Across different industries, these are used for power transmission and for adjusting the of speed and torque of machinery. You can find these in varied designs. Each specific design is suitable for a particular application. You need to have a proper idea about the various kinds of industrial gearboxes being used today, so as to choose the right gear box for your operations easily. Take a look at the different types of industrial gearboxes and their applications, along with the role of industrial gearbox suppliers in providing high-quality solutions.

 

1. Helical Gearbox

These come with helical gears, having angled teeth that engage gradually. Industrial helical gearboxes are smoother and more noiseless than spur gears. These types of gears can be used for varied applications, such as:

• Heavy-duty industrial machinery,

• Conveyors,

• Printing presses and

• Equipment used in oil and gas industries

 

These are suitable for all those tasks that need high-quality gearboxes, working more efficiently and producing less noise during operations.

 

• Ratio: Generally, the ratios for Helical Gearboxes are in the range of 3:2 – 10:1. However, based on the design and application, this can vary. Some can have a ratio of even 130:1.

• Bore: The bore size usually ranges from 1/8″ to 5/16″.

• Output rpm: You can get it when you divide the input RPM by the gear ratio.

• Inside part: You can find bearings, shafts, helical gears and a housing.

• Diameter: In case of these gearboxes, there is no standard. The diameter can vary widely, and is based on the desired performance features and the particular application that the gearbox is to be used for.

Versatile in form, these can be used for both non-parallel and parallel shaft applications. As these distribute load over a larger teeth area, these can handle higher loads.

 

2. Bevel Gearbox

Using bevel gears, these gearboxes allow power transmission at various angles. Generally, power is transmitted at right angles. You can find these perfect for all those applications where gearboxes need to change the shaft direction. These are used widely in:

 

• Rail transport systems,

• Power plants,

• Marine applications and

• Automotive differentials

 

Take an in-depth look at these gearboxes:

• Ratio: These can have different ratios, such as 1:1, 2:1, 3:1, 4:1, 5:1, and 6:1. The ratio of Miler Gears is 1:1, which means that the output shafts and input shafts rotate at the same speed.

• Bore: It is diameter of the hole where the shaft enters. It can vary according to the specific gearbox size and application. Usually, it is in the range of 4 – 18 mm. 

• Output rpm: You have to divide the input RPM by the gear ratio for an effective calculation.

• Inside part: Typically, you can find bearings, shafts, hypoid, spiral or straight bevel gears and a housing.

• Diameter: It can vary from a few millimetres to several centimetres. Commonly, these gearboxes have a shaft diameter of 4mm, 6mm, 8mm, 10mm, 12mm, and even up to 25mm. 

 

You should look for a reputable supplier who can understand your specific business needs and provide you with the right kind of bevel gearboxes to match your requirements.

 

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3. Worm Gearbox

Worm gearboxes are most appropriate for all those applications that need them to be self-locking and have high torque. High-quality worm gearboxes have a worm wheel and a worm gear. These are ideal for all those applications that need gearboxes with high torque output and a compact size.

These are ideal for:

• Food processing machinery,

• Conveyor systems,

• Lifts,

• Elevators,

• Mining and

• Material handling

 

Having a unique worm and wheel design, these are able to pick up heavy loads very effectively.

 

• Ratio: Generally, these can be in the range of 5:1 to 100:1 or even more. You can get a wide range of torque amplification and speed reduction.

• Bore: The diameter of the hole for the input shaft can be 6 or 8 mm for smaller sizes and 18mm, 25mm, 28mm, 35mm, 42mm or 50mm for bigger ones.

• Output rpm: You have to divide the input RPM by the gear ratio.

• Inside part: It mainly includes a screw-like gear known as the worm gear that meshes with a toothed gear or worm wheel. You can also find a housing, bearings, input shafts and output shafts.

• Diameter: While this can be variable, based on the size and specific application, input shaft diameters are generally 9mm, 11mm, 14mm and 19mm, while output bore diameters are typically 14mm.

 

If you have custom requirements and want your worm gearboxes to be of a specific way, you should discuss it with your industrial gearbox suppliers before you place an order.

 

4. Planetary Gearbox

These take up a very small space and work with high efficiency. Such types of gearboxes consist of:

 

• An outer ring gear

• Multiple planet gears, and

• A central sun gear

 

Despite being compact in size, this type of gearbox can transfer the biggest amount of torque.

 

• Ratio: Typically, it ranges from 3:1 to 10:1 for each stage. However, through multiple stages, it is possible to get higher ratios.

• Bore: Planetary gearboxes of regular size can have a diameter in the range of 6mm to 42mm or even larger. 

• Output rpm: You have to multiply the input RPM by the gear ratio for a proper calculation.

• Inside part: Its primary internal components include the outer gear or ring gear, planet gears (surrounding the sun gear), sun gear (central gear), and an arm or carrier holding the planet gears. 

• Diameter: Those of miniature size can be 20 mm while larger industrial models can be 60 mm or even bigger.

 

Planetary gearboxes are perfect for medical equipment, wind turbines, aerospace applications and robotics.

 

5. Cycloidal Gearbox

These gearboxes are known to offer high torque transmission with minimal backlash, as these have cycloidal discs and rolling elements. These are perfect for:

 

• Textile machines,

• Industrial machinery,

• Robotics,

• Automation and

• Military applications

 

When there is a need for shock-resistant, long-lasting gearboxes, these are the best options to go for. Take a look at:

 

• Ratio: In a single stage, these can have high reduction ratios – ranging from 30:1 to more than 300:1. In multi-stage configurations, the ratios can be even higher.

• Bore: The bore diameter can vary. In some models, you can get a hollow bore of up to 138mm. In others, it can be in the range of 70 to 220 mm. 

• Output rpm: You need to divide the input RPM by the gear ratio, and calculate the Output rpm accurately.

•  Inside part: These gearboxes consist of a high-speed input shaft, a slow-speed output shaft, a ring gear with pins, a cycloidal disc (or multiple discs), and an eccentric cam.

• Diameter: The diameter of the components of the gearbox, especially the output shaft, can widely vary based on the particular application and model, which can be in the range of Φ12mm to Φ30mm. 

 

How are Gearboxes Used in Different Types of Motors?

 

Helical, worm reduction, and planetary gearboxes can be paired with different types of motors, such as IE2, IE3, and IE4 motors, irrespective of their level of efficiency.

IE2 Motors are High Efficiency motors that come with a moderate energy efficiency level and are an improvement over older motor design. In IE2 motors, Helical Gearboxes are used for heavy-duty applications. Worm Gearboxes are necessary for reducing speed significantly while Bevel Gearboxes are needed for changes in rotational direction.  When there is a need for high torque and more accuracy, Planetary Gearboxes are ideal.

IE3 Motors are Premium Efficiency motors that are more energy efficient than IE2 motors, and help to reduce a lot of energy. IE3 motors need Helical Gearboxes for varied applications, Bevel Gearboxes to change the direction of rotation – as in machinery and conveyors and Planetary Gearboxes for applications requiring high torque and accurate control.

IE4 Motors have the highest efficiency, and are referred to as Super Premium Efficiency motors. IE4 motors require Bevel Gearboxes to change rotation direction, Worm Gearboxes for applications that need high torque and extremely low output speeds, and Planetary Gearboxes for reducing speed and for high torque. Cycloidal Gearboxes are used in applications with limited space.

Keep in mind that you have to choose the best industrial gearbox suppliers who can provide you with efficient, durable, and high-quality gearboxes. If you need custom gearboxes for your specific applications, you should discuss your needs beforehand. Reputable suppliers can offer you excellent maintenance services, technical support and tailored options. You can also get them delivered fast, at rates that suit your budget.