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Basics of Gearbox Selection

Selecting the proper gearbox requires considering several key factors: 1) Sizing to the load rather than the motor ensures a cost-effective gearbox that fits the application. 2) Important sizing aspects include the service factor, ambient temperature, load type, output style, and housing style. Not accounting for these could result in an improper gearbox. 3) Industries have additional specific considerations - power transmission looks at output RPM, motor specifications, and overhung load while motion control examines input speed, inertia, dynamic motion, shaft loads, and motor shaft details. Providing accurate information is key to achieving the best gearbox solution.

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Patil Amol Pandurang
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142 views

Basics of Gearbox Selection

Selecting the proper gearbox requires considering several key factors: 1) Sizing to the load rather than the motor ensures a cost-effective gearbox that fits the application. 2) Important sizing aspects include the service factor, ambient temperature, load type, output style, and housing style. Not accounting for these could result in an improper gearbox. 3) Industries have additional specific considerations - power transmission looks at output RPM, motor specifications, and overhung load while motion control examines input speed, inertia, dynamic motion, shaft loads, and motor shaft details. Providing accurate information is key to achieving the best gearbox solution.

Uploaded by

Patil Amol Pandurang
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Basics of Gearbox Selection

Introduction

Selecting a gearbox can be quite difficult. Customers have a variety of


gearboxes to choose from that are capable of fulfilling diverse
requirements. A wrong decision could result in the purchase of a more
expensive gearbox. The power transmission industry may need a gearbox
that will support overhung loads while the motion control or servo industry
may need a gearbox that will handle dynamic motion.

One of the first problem areas for sizing arises from sizing to the motor
versus sizing to the load. Sizing to the motor may be simpler and result in a
gearbox that works, but it will result in the purchase of a larger gearbox
than is needed. This gearbox will also be overqualified for the application.
However, sizing to the load will ensure a gearbox fits the application and is
more cost-effective as well as potentially a smaller footprint.

Common Aspects of Sizing Applications:

There are several aspects of gearbox sizing that apply to every situation.
This section will detail those criteria and offer insight.

1.       Service Factor
Before sizing an application, the customer should determine the service
factor. Service factor can be generally defined as an application’s required
value over the rated value of the unit. Service factor should be determined
for conditions such as non-uniform load, hours of service, and elevated
ambient temperature.
How would one interpret a service factor? A service factor of 1.0 means a
unit has just enough capacity to handle the application. There is no
tolerance for additional requirements, which could cause the gearbox to
overheat or fail. For most industrial applications, a service factor of 1.4 is
adequate. This service factor signifies that the gearbox can handle 1.4
times the application requirement. If the application requires 1,000 inch-
pounds, the gearbox would be sized to handle 1,400 inch-pounds.
Different factors will affect how much service factor should be used in a
given application. The changes to the service factor depend on the
manufacturer. Please examine the manufacturer’s specifications.

2.       Ambient Temperature and Environment


Higher ambient temperatures increase internal pressure, which will require
an increase in the service factor used. High or low temperatures can
require different seal materials and lubrication viscosities.

The environment the gearbox will operate in is also an important


consideration for sizing. Harsh environments can increase wear on the unit.
Dusty or dirty environments often require special material to prevent
corrosion or bacteria growth. Food or beverage plants require specific FDA
compliant coatings and oil. Vacuum environments will require special
grease and heat dissipation considerations since there will be no air for
cooling. Failure to account for these environmental features can result in a
gearbox that cannot support the application properly. All of these aspects
must be considered when sizing a gearbox.

3.       Shock Load or Type of Load


High shock or impact loads can cause increased wear on the gear teeth
and shaft bearings. This wear could cause premature failure if not
accounted for when sizing. These loads will require an increased service
factor. Uniform loads are loads that remain constant during the application,
while non-uniform loads change during the application. Non-uniform loads,
even if small, will require a higher service factor than uniform loads. An
example of a uniform load would be a conveyor with a consistent product
amount riding on it. A non-uniform load would be any sort of intermittent
cutting application. This intermittent cutting force causes a periodic
increase in the torque on the gearbox, which is a non-uniform load.

4.       Output Style or Mechanism


Output mechanisms include a sprocket, pulley, or toothed pinion, to name a
few. Different output configurations, such as double output shaft or shaft
mounted bushing, will decrease how much overhung load the unit is rated
for. Different output mechanisms add different shaft loads that must be
considered. Most mechanisms will cause high radial load, but things like
helical gearing can also cause an axial load. These outputs could require
different bearings to account for the increased radial or axial load.

5.       Output Shaft or Hollow Bore Size


When sizing an application, the output shaft and bore size must meet
customer requirements. These could include a stainless output on the unit,
and whether it has a keyed or keyless shaft, a keyed or keyless hollow
bore, or a flanged output combined with any of the previous. Getting the
correct bore size on a unit may force the customer to purchase a larger
gearbox or a different style of gearbox to fit their current shaft. In some
instances, the customer can modify their shaft to use the most cost-
effective unit while providing an optimal solution.
6.       Housing Styles
It is also important when selecting a gearbox to consider how it will mount.
A unit could have mounting feet, a flange on the output or just basic tapped
holes on one or more sides. These housing styles could limit how a unit is
mounted so having a variety of options could prevent custom frames or
brackets from being needed. For example, having tapped holes on the
bottom face of the unit would prevent the need for a special L-bracket to
mount around the output.

Power Transmission:
Some elements that affect the sizing process are industry-specific. For the
power transmission industry, output RPM, motor horsepower and frame
size, and overhung load all impact the application calculations.

 Output RPM
The customer must determine the ratio needed for the gearbox to
operate, or provide input/output speed and operating hertz (Hz) for
calculations. The standard is a 1750 input RPM at 60 Hz. Any
changes will need to be specified when sizing as it will change the
ratio calculation. Failure to account for changes will result in a
gearbox that does not match the customer’s requirement.

 Motor HP and Frame Size


The gearbox size and input option must be determined before
calculating the service factor. Once the gearbox is sized, use the
required HP to compute the actual service factor. Large HP motors
generate heat that can adversely affect the reducer’s mechanical
ratings. This reduced rating, based on the increased heat, is known
as the Thermal Capacity of a reducer and must be considered
when using large motors.

 General Shaft Load


The sizing must verify that the load will not damage the gearbox.
The force, measured in pounds, that the output shaft is capable of
sustaining is known as the Overhung Load rating. If the rating is
less than the application, the speed reducer will be damaged.

Motion Control:
For the servo industry, input speed, inertia, dynamic torque motion, specific
shaft loads, and motor shaft diameter affect the sizing process.

 Input Speed
Input speed should not exceed the gearbox ratings or premature
seal wear will occur due to increased pressure. Input speed can be
accidentally increased if there is an output mechanism with a ratio
that is not considered when sizing, which is another reason why
specifying any output mechanisms is so important.
 
 Inertia
An inertia mismatch of less than 10:1 is desired for fine controlling
of the output. This is important to obtain the high accuracy needed
for some applications. Reducer size and ratio are the main
influences from the gearbox on inertia. Control engineers may
request smaller mismatches or even specific amounts. Often a
motor is chosen for its dynamic capabilities, not for its torque. It is
common to use a motor with much more torque than needed for
the application due to its increased rotor inertia. Some motor
manufacturers even make motors specifically for high or low inertia
ratings. This allows for better tuning of the application because of a
lower inertia mismatch. When doing this, it is important to limit the
output torque in the motor to prevent breaking the gearbox.
 
 Dynamic Motion
Cyclic motion may require using a higher service factor than
continuous motion. This is because constant starts and stops
cause additional wear on the gear teeth and seals. Cyclic
reversing, which is a constant back and forth motion between two
points, requires an even higher service factor than cyclic or
continuous.
 
 Specific Shaft Loads
Radial, axial, and moment shaft loads must be checked against the
unit’s ratings. Failure in doing this could result in a broken shaft or
damage to the bearings or gear teeth. Generally, the same service
factor is applied to these ratings to determine an appropriately
strong gearbox. Additional bearing types can increase these
ratings if the application needs them.
 
 Motor Shaft Diameter or Length
The motor shaft must fit in the unit, and the shaft must be long
enough for full engagement with the coupling. Without full
engagement, input slippage could occur. While this will not affect
the service factor needed, it is important to consider in order to
avoid problems mounting the motor. Some manufacturers have a
large input design allowing the reducer to accommodate the larger
motor without increasing the unit size.
Conclusion:
To achieve the best gearbox solution, customers should size from the load.
This will ensure they receive a cost-effective solution that fits the
application. The service factor, environment, ambient temperatures, shock
load, output style, and hours of service are all important aspects of sizing.
The more information the customer provides, the more accurate the sizing
process. This will ultimately yield a solution that matches the customer’s
requirements! There are numerous sizing programs available that can help
determine what gearbox is most appropriate for your application.  

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