Introduction

Gearbox introduction:

From a need for product development as well as transmission of power from a

source such as a motor, through a machine and then to an output, the industrial gearbox

came into existence. [1] The gearbox is known to be able to complete the most common

machine tasks by producing a high torque by reducing or increasing the drive speed the

other way. [2] According to Shigleys mechanical engineering design, the gearbox

comprises of an efficient means of transmitting power: by using rotary motion of a shaft

supported by bearings. [1]

Gearbox reducer:

According to the webpage what is a gear reducer at Wisegeek, the fundamental

theory behind why a reducer differs from a regular gearbox is that the energy output of a

high-speed motor or engine is redirected to turn another mechanical component at a

lower rotational speed and at a higher torque. [3] A gear reducer accomplishes the

energy transformation by changing the ratio of the rotation of two moving parts. Gear

ratios for a gearbox are generally calculated from the ratios of the number of teeth in each

gear. [1]

Gearbox reducer application:

In order to better understand the benefits of using a gearbox reducer in real life,

the example of a modern day automobile can be studied. Internal combustion engines
must operate at high speeds to maintain smooth power generation. In dire situations, the

use of a gearbox reducer, the energy can be used to overcome the inertia of the stopped

vehicle, decrease the momentum of a slowing vehicle or allow heavier loads to be towed

but at a lower velocity. [3]

Types of gears:

Gears have many types. Each gear type has a variety of applications based on its

size and design. Below is a description of some gear types.

Spur gears: This gear type is the most common gear type. It is suitable for most

gear applications. The main function of this gear is to transfer motion between

parallel shafts. The teeth in these gears are parallel to the shaft axis. An advantage

of this gear type that they are the least expensive type which is why they are

commonly used. A disadvantage however is that due to the teeth geometry these

gears produce a lot of noise [1].

Figure 1 Spur Gears [4]

Helical gears: [1] This gear type is the one which our gearbox is

using Unlike spur gears the teeth in helical gears are cut at an

angle. Due to this geometry the teeth engage more gradually

 compared to spur gears. This reduces the noise and the gears

run smoothly. Helical gears are mainly used when the application

requires high speeds and/or large power transmission.

Disadvantages however include the fact that they are expensive

to manufacture and they produce thrust loads.

Figure 2 Helical Gears [5]

Rack and pinion: This gear type is a sort of linear actuator which converts circular

motion into linear motion. It consists of a circular gear (pinion) which engages

with a linear gear (rack). Common applications include steering mechanisms in a

car [6] and an actuator used to control valves in pipeline transport [7].
 Figure 3 Rack and pinion [8]

Worm Gears: This gear arrangement includes a worm which is in

the form of a screw which is connected to a gear. The direction of

rotation of the worm gear, also called the worm wheel, depends

upon the direction of rotation of the worm and upon whether

the worm teeth are cut right-hand or left-hand. It is used to

reduce speed or deliver higher torque [9].

Figure 4 Worm gear [10]

 Bevel gears: The teeth of these type of gears are formed on

conical surfaces. Their main function is to transmit motion

between intersecting shafts. On straight and spiral bevel gears,

the shafts must be perpendicular to each other, but they must

also be in the same plane [11]. These type of gears are used in

car differentials.

Figure 5 Bevel Gears [12]

 References

[1] R. G. Budynas and J. K. Nisbett, Shigley's Mechanical Engineering Design, 9th ed.,

Boston: McGraw-Hill, 2011.

[2] "Introduction to Gearbox," ISHIBASHI Manufacturing Co., Ltd., [Online]. Available:

http://www.ishibashi-mfg.com/en/product/index.html. [Accessed 27 April 2015].

[3] "What is a Gear Reducer?," wiseGEEK, [Online]. Available:

http://www.wisegeek.com/what-is-a-gear-reducer.htm. [Accessed 27 April 2015].

[4] 'Spur Gears - F W Hercus Pty. Ltd - Hercus Gear Cutting - Adelaide', 2008. [Online].

Available: http://www.hercus.com.au/spur-gears/. [Accessed: 17- May- 2015].

[5] 'Helical Gears, Helical Gears Manufacturer, Helical Gear Boxes, Mumbai, India'.

[Online]. Available: http://www.navjivangearsindia.com/helical-gears.htm. [Accessed:

17- May- 2015].

[6]S, Bishop, Rack and pinion variable ratio steering gear, U.S. Patent 3753378A

Abbrev. August, 21, 1973.

[7]" The Role of Rack and Pinion Actuators in On-Off & Modulating Controls', Valve

Magazine, 2010.

[9]D. Gear Nomenclature, 'ANSI/AGMA 1012-G05 (R2011) Gear Nomenclature,

Definition of Terms Symbols', Webstore.ansi.org. [Online]. Available:

http://webstore.ansi.org/RecordDetail.aspx?sku=ANSI%2FAGMA+1012-G05+

%28R2011%29. [Accessed: 17- May- 2015].

[11] K. Nice, 'Bevel Gears - How Gears Work', HowStuffWorks, 2000. [Online].

Available: http://science.howstuffworks.com/transport/engines-equipment/gear4.htm.

[Accessed: 17- May- 2015].

Figure references:
http://www.hercus.com.au/spur-gears/
http://www.navjivangearsindia.com/helical-gears.htm
http://www.directindustry.com/prod/cross-morse/racks-pinions-20096-55133.html