Gearboxes are in your car, they’re in your industrial facility– they’re even in your blender! 

In this article, we’ll take a closer look at gearboxes and how they work. Then, we’ll learn the different types of gearboxes commonly used in industrial distribution and material handling, as well as examine which kind may be right for your application. We’ll also highlight premium gearbox options from our trusted vendor, Dodge® Industrial. 

What is a Gearbox?

If you’ve ever driven a car, you’ve used a gearbox. Gearboxes act as middlemen between a motor and a piece of driven equipment. They are a housed set of gears that are added to a motor, used to adjust the transmission of power from a motor to other components. 

In an automobile, that power output moves from the motor to the gears in your gearbox–your transmission–and eventually, rotates the tires. In an industrial conveying system, it could act as the point of power transmission between a motor and a shaft. That shaft may then connect to a rotating screw conveyor, or transfer motion to the rotation of a pulley. 

Most industrial gearboxes used in conveying would be best compared to an automatic transmission in a car, as there are predetermined gear settings with no physical intervention from the operator required. 

A manual transmission, which uses a clutch to engage and disengage the engine from the transmission to allow gear changes, is now mostly seen in heavy commercial or recreational automobiles. 

However, manual transmissions are still prevalent in many kinds of industrial machinery. From tractors and tillers, to excavators and forklifts, a manual gearbox provides benefits like simplicity, durability, and greater operator control. 

What are Gear Reducers?

Gear reducers are very common in material handling and conveying. While gear reducers are similar to gearboxes, they are not exactly the same–though they are sometimes referred to interchangeably. 

Gearboxes can act as gear reducers, but gearboxes can also increase speed, or transmit power without changing speed or torque significantly. A gear reducer can only reduce speed output from a motor. Therefore, a gear reducer is always a gearbox, but a gearbox is not always a gear reducer. 

What are the Benefits of Gear Reduction?

• Increased Torque: Gearboxes can significantly increase the torque output of a motor. By reducing the motor’s speed, the gearbox creates a “pressure point”, and increases the force applied at the output. This is useful for applications requiring high torque, such as lifting heavy loads or driving machinery.
• Improved Efficiency: Matching the motor speed to the optimal speed of equipment can improve overall system efficiency. Without a gearbox, the motor might run at a speed that is not ideal for the application, leading to wasted energy and decreased performance.
• Enhanced Control: Gearboxes allow for better control over the speed and motion of machinery. By adjusting the gear ratio, you can fine-tune the speed and torque characteristics to meet specific operational requirements.
• Extended Motor Life: Operating a motor at lower speeds can reduce wear and tear, leading to a longer motor lifespan. Gearboxes can help ensure the motor operates within its optimal speed range, reducing stress and extending its service life.
• Noise Reduction: Gearboxes can help reduce noise by allowing the motor to run at a more efficient, lower speed while providing the necessary speed and torque at the output. This is particularly beneficial in applications where noise is a concern.
• Versatility: Gearboxes provide flexibility in adjusting output speed and torque. This allows a single motor to be used in various applications by changing the gearbox to suit different requirements.
  

Considerations for Selecting a Gearbox or Gear Reducer 

No matter what type of gearbox you require, assess the following before making a selection.

1. Torque and Load Capacity: Assess the maximum torque and load capacity required for your application. Gear reducers should always be selected based on the anticipated loads and stresses to ensure reliable performance and longevity.
2. Speed Reduction Ratios: Determine the appropriate speed reduction ratio needed to match the motor speed with the desired output speed for the conveyor. Manufacturers typically indicate this information in their included literature.
3. Efficiency: Consider the efficiency of the gearbox in terms of power transmission. Higher efficiency gearboxes reduce energy loss and operational costs.
4. Material and Construction: Look for gearboxes made from high-quality materials and designed to withstand harsh industrial environments. 
5. Maintenance Requirements: Evaluate the ease of maintenance and availability of replacement parts. 
   

Common Types of Gearboxes

Helical Gearboxes 

Helical gearboxes have gears with teeth cut at an angle (the helix) to the axis of rotation. This allows for multiple teeth to engage simultaneously, and can provide smooth and quiet operation. 

While these may be larger than other gearbox types, they are very efficient, and the angled teeth engagement reduces noise and vibration. You will find these in many conveyor applications, as they are well suited for running continuously with uniform loads. 

Dodge is a trusted partner with IBT, and has long been known for their powerful, efficient gearboxes. Quantis® modular gear drives are engineered for flexibility and power density. A wide variety of mounting configurations and accessories are available for application versatility with Quantis..

The Dodge Torque-Arm family of shaft-mount reducers–featuring TXT™, Torque-Arm II, and Motorized Torque-Arm–is another option. The shaft mount style and a long list of standard features make this reducer suitable for a wide range of environments. The Torque-Arm reducer line has over 75 years of proven dependability, and more than 3 million units in service throughout the world, making it a reliable choice for a variety of applications. 

Worm Gearboxes 

Worm gearboxes have a “worm” (a screw-like gear) and a “worm wheel” (a gear that meshes precisely with the “worm”). This configuration provides high reduction ratios and compact design, along with a self-locking design that often prevents back-driving. 

They are generally less efficient than helical gearboxes due to the loss of energy from heat and friction. Worm gearboxes are a good selection for conveyors with heavy loads or steep inclines, and need to fit in compact spaces. 

The Dodge Tigear®-2 worm gearbox is an excellent option, having proven in the Dodge Innovation Center to outperform the competition in overload testing. The Tigear-2 line of single-reduction, right-angle worm gear reducers is engineered to provide maximum value and durability. Tigear-2 also requires no routine oil changes.

The stainless-steel FoodSafe™ Tigear-2 is also available with a completely-sealed sanitary design, making it suitable for food and chemical processing’s frequent washdowns and exposure.

Gearbox Rebuild Services Are Available

In need of a gearbox rebuild? Our Gearing Inspection & Repair Division technicians will completely disassemble the old gearbox, determine which parts need to be replaced, and provide a cost estimate of all repair services. Our gearbox rebuild process is as follows: 

• Modular designed gear drives are engineered for flexibility, greater torque density in a compact housing configuration, and increased horsepower capability from 1/4 hp to 75 hp.
• Single helical design gearing is ground to provide an ellipsoid tooth form that eliminates tooth wear, and assures meshing in the strongest tooth area.
• All gears are case carburized to ensure high surface durability and resilient tooth core for greater impact resistance and longer service life to reduce unscheduled downtime. 
• Reducers, gears and bearings are splash lubricated with ISO VG220 mineral oil and are filled prior to shipment. 

IBT is an authorized assembler of Dodge Quantis In-Line Helical (ILH) and Right Angle Helical (RHB) reducers in four sizes (38 through 88). Our technicians follow the American Gear Manufacturers Association (AGMA) guidelines, and our CNC hobbing and Wire EDM services ensure we can achieve exact specifications.

RHB input configuration includes C-face clamp collar, and output configurations of solid, straight hollow, and taper bushed shafts. ILH input configurations include C-face clamp collar motor adapters for input motor flexibility, and solid input shafts for v-belt mounting. 

Our dedicated support staff is experienced and knowledgeable about Quantis ILH & RHB gear reducers. If you don’t have specs, we can reverse engineer gears, shafts, and splines from a worn sample without a drawing. We are also experts in repairing and replacing legacy and obsolete gearboxes.

Still Have Gearbox Questions?

Our Gearbox Division experts are always on hand to answer your gearbox and gear reducer questions. Reach out to us with this form, or request a quote here. 

We’d also love to see you at any of our 38 branches–click here to pinpoint the location nearest you. Or, explore all of our products on ShopIBT.com. We look forward to assisting you with your next industrial solution! 

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