When it comes to the uses of Industrial gearboxes, they are a key component used in agricultural, automotive, construction, industrial, and mining equipment. Industries as varied as pulp and paper, chemicals, cement, rubber, grain, energy, and marine rely on industrial gearboxes to help complete their processes.
What is the Benefit of a Gearbox?
Also known as a gear reducer, a gearbox’s primary purpose and benefit is to increase a motor’s output torque or change its speed. With the motor shaft connected to one end of the gearbox and through the internal gear configuration, the gear ratio determines output torque and speed.
Gearbox Benefits by Type
Gearbox manufacturers make technologically advanced industrial products that help companies fulfill processes by creating maximum power at minimum cost. Industrial gearboxes are essential for both manufacturing products and maintaining systems. There are six types of industrial gearboxes, each with its own set of uses and benefits.
Helical Gearbox
Helical gearboxes feature gears in parallel or crossed positions and locked at 90-degree angles. Low-power and compact, they are particularly suited for heavy-duty operations. Helical gearboxes are often found in plastics, rubber, cement, and similar heavy industrial settings and applications, including crushers, coolers, extruders, and conveyors.
Coaxial Helical Inline Gearbox
Coaxial helical inline gearboxes put the output shaft and driveshaft on the same rotation axis. They offer extremely high efficiency and power density and are manufactured to maximize load and transmission ratios. While suitable for many applications, coaxial helical inline gearboxes are ideal for heavy-duty applications.
Bevel Helical Gearbox
Primarily used in quarries and the mining industry, bevel helical gearboxes have a curved set of teeth on a cone-shaped surface close to the rim. They provide rotary motion between non-parallel shafts. Bevel helical gearboxes operate more quietly and smoothly than spur gears. They are the most commonly used gear in transmissions.
Skew Bevel Helical Gearbox
Rigid and robust, the skew bevel helical gearbox is perfect for transporting heavy loads. Once mounted on the correct motor shaft output, these industrial gearboxes are highly customizable based on the number of teeth and gears.
Worm Reduction Gearbox
Worm reduction gearboxes are often the solution when increased speed is needed. Most are used in heavy industries, such as minerals, chemicals, and fertilizer. The gearbox has a large-diameter worm wheel that meshes with the teeth on the gearbox’s peripheral area. The worm’s rotating motion makes the wheel move as well, thanks to the screw-like movement.
Planetary Gearbox
This type of industrial gearbox got its name from a formation of gears that resembles our solar system. A central gear (sun gear) is surrounded by three or four smaller gears (planet gears). This formation equally moves power through the gears and creates high torque in a small space.
Popular in robotics and 3D printing, planetary gearboxes are ideal for accuracy, endurance, distinct functionality, and precision. They optimize performance and increase equipment lifespan.
Gearbox Maintenance
When an industrial gearbox fails, production can come to a grinding halt, possibly shutting down an entire line or even an entire plant. Lost production, expensive downtime, and safety issues can all result.
Just like any piece of machinery, gearboxes need periodic maintenance.
Follow these steps to reduce downtime and get the best performance and lifespan from your industrial gearboxes.
- Keep the operating environment as clean as possible. You want to avoid potential internal contamination by dirt, dust, and other substances.Youalso want to prevent any buildup of dust or dirt on the gearbox that can increase the potential for overheating.
- Proper lubrication is essential. Consult your distributor or manufacturer to ensure you use theproper lubricant and correct additives for your gearbox application.
- Undertake a regular visual gearbox inspection. Look for oil leaks and signs of overheating (discolored paint). Listen to how it sounds while operating and monitor for unusual vibration levels.
- Monitor gearbox temperature. Use an infrared gun to pick up any sudden changes in temperature, which nearly always means there is a problem.
- Analyze vibration levels regularly. Monitor the vibration of both internal gears and bearings. If the vibration is increasing, problems aren’t far behind.
- Inspect internal gears for signs of pitting or spiraling. Check the gear teeth with marking compounds. If you find misalignment, bearings or housings are worn and need replacing.
- Check that you have the correct type of breathers and that they are as clean and debris-free as possible. Good housekeeping is essential, particularly with dirty applications like cement manufacturing.
- Use a dial indicator to check end play and backlash. Backlash increases mean gear teeth wear, while end play increases indicate wear in bearings or housings.
- Check gearbox ratings to ensure that you continue to operate within factory specifications and power input. Demands on the gearbox may have changed since the original specification.
- Partner with a distributor like NW Industrial Sales, LLC, that can provide extensive gearbox servicing and complete refurb and replacement services. By working with specialists and following an effective maintenance schedule, unscheduled downtime can be nearly eliminated and maintenance costs reduced.
Contact Our Falk Gearbox Distributors
NW Industrial Sales, LLC carries all the parts and products that industries need to have on hand. With our vast inventory of Falk reducers, parts, obsolete units, and more, we help companies avoid production stops and downtime.
As agents of Rexnord’s Industrial Services division, NW Industrial Sales, LLC has access to a nationwide network for repair, remanufacturing, and predictive maintenance services.
Industry knowledge is the cornerstone of NW Industrial Sales, LLC. With over 75 years of combined experience, our specialists can answer all of your questions, provide solutions, and deliver the finest products.
Through intelligent planning and management practices, combined with the right Falk gearboxes, parts, and surplus gear reducers, the impact of unexpected breakdowns can be dramatically reduced. Call NW Industrial Sales, LLC, at (503) 468-0454 to talk with a knowledgeable team member. We’re available 24/7 for all your needs.
