TYPES OF GEAR BOX

Pawan Kandurke, Karan Agarwal, Karansign Gaware, Shreyash Karekar, Tanmay Kasliwal, Paratik Kathe

What is a Gearbox? 

The gearbox is a mechanical device used to increase the output torque or to change the speed (RPM) of a motor. The shaft of the motor is connected to one end of the gearbox and through the internal configuration of gears of a gearbox, provides a given output torque and speed determined by the gear ratio.

Bascially Gearbox is a contained gear train, or a mechanical unit or component consisting of a series of integrated gears within a housing. In fact, the name itself defines what it is a box containing gears. In the most basic sense, a gearbox functions like any system of gears, it alters torque and speed between a driving device like a motor and a load.

Types Of Gearbox?

1.Worm Reduction Gear Box

A worm gear reducer is one type of reduction gear box which consists of a worm pinion input, an output worm gear, and features a right angle output orientation. This type of reduction gear box is generally used to take a rated motor speed and produce a low speed output with higher torque value based on the reduction ratio. They often can solve space-saving problems because the worm gear reducer is one of the sleekest reduction gearboxes available due to the small diameter of its output gear.​

Worm gear reducers are also a popular type of speed reducer because they offer the greatest speed reduction in the smallest package. With a high ratio of speed reduction and high torque output multiplier, it's unsurprising that many power transmission systems make use of a worm gear reducer. ​

Manufacturing of Worm Reduction Gear Box

The typical method for manufacturing worm gears is hobbing using a hob or cutting tool; this cutting tool is similar to the gear with which the worm gear will mate. Worms can be turned, hobbed, milled, or ground.

Hobbing is a method for producing gear teeth using a set of customized bits that are designed to make the correct pitch for the gear‘s application. Hobbing is a cold working forging process where a punch with the correct geometry is pressed into the workpiece. The tool that is used, the punch, is referred to as a hob and is made of hardened steel that forms a helical hob cutter. The pressure and cold forging produce very accurate dimensions and excellent surface quality in the cavities.

In the milling process, the gear is cut in a milling or jig grinder using a gear cutter and indexing or rotary table. The teeth of the gear are created by a rotating multi-edge cutter that creates teeth that are similar to the cutter. The cutter moves axially along the length of the gear tooth at the correct depth. Once the teeth are cut, the cutter withdraws, and a new blank is indexed.

Applications of Worm Reduction Gear Box

• Press
• Mining 
• Escalator
• Rolling Mills 
• Manufacturing and Packing industries
• Small Machiner

2. Spur Gearbox

Spur gears are a cylindrical shaped toothed component used in industrial equipment transfer mechanical motion as well as control speed, power, and torque.These simple gears are cost-effective, durable, reliable and provide a positive, constant speed drive to facilitate daily industrial operations. They consist of a cylinder or disk with teeth projecting radially. Spur gears can be classified into two main categories: External and Internal. Gears with teeth on the outside of the cylinder are known as "external gears". Gears with teeth on the internal side of the cylinder are known as "internal gears".

Application Of Spur Gearbox

• Transmissions
• Conveyor systems
• Speed reducers
• Engines and mechanical transportation systems
• Gear pumps and motors
• Machining tools

3. Coaxial Helical Inline Gearbox

The purpose of gearboxes is to increase the output torque or to change the speed (RPM) of a motor. The shaft of the motor is connected to one end of the gearbox and through the internal configuration of gears, provides a given output torque and speed determined by the gear ratio.

R series helical inline Coaxial helical inline gearbox is a machine that realizes electromechanical integration, high transmission efficiency and low energy consumption, and is widely used in metallurgy and sewage treatment.

Working

R series helical inline Coaxial helical inline gearbox  has a high-rigidity cast iron box with ribs; the hard-toothed face gear is made of high-quality alloy steel, the surface is hardened by carburizing and quenching, the grinding teeth are finely processed, the transmission is stable, the noise is low, the bearing capacity is large, the temperature rise is low, and the service life is long.

Our Coaxial helical inline gearbox is a heavy-duty, low-cost, gearhead that works with any of the three-inch diameter AmpFlow motors. Our Coaxial helical inline gearbox uses a unique three-stage chain-and-sprocket mechanism that reduces cost while still maintaining high torque capacity.

Applications

R series helical inline Coaxial helical inline gearbox is widely used in metallurgy, sewage treatment, chemical, pharmaceutical and other industries. 

4. Planetary Gearbox

A simple planetary gear set is made up of three main components:1. The sun gear that sits in the centre (central gear). 2. Multiple planet gears..3. The ring gear (outer gear). The load from the sun gear is distributed to several planetary gears which can either be used to drive an outer ring or a shaft or spindle. The central sun gear takes a high-speed, low-torque input. It drives several rotating external gears which increases the torque.

Working

The alignment of the gears can be compared to our solar system where the planets revolve around the sun, hence the name “Planetary Gearbox”.

In the middle of the planetary gearbox, there is a “sun” gear –also known as a central gear. This is often the input gear. Around the outside, there are 2 or more “planet” gears – or outer gears. Surrounding the planet gears there is a ring gear which holds the formation together. The planet gears are connected by a carrier which in turn is connected to the output shaft.

5. Direct Shift Gearbox(DSG)

It is a  type of automatic  gearbox with two clutches,  in one, connected to the engine by two drive shafts . In order to do this, an electronic control unit for the transmission uses information such as engine speed, road speed, accelerator position and driving mode to select the optimum gear and to determine the ideal shift point.

This the gearbox is  always organized on your subsequent move, so the gear shifts are particularly short and   smooth. It’s once in a while additionally known as a dual-clutch gearbox, twin-clutch or DCT.

Working

A DSG gearbox is effectively two gearboxes in one, connected to  the engine by two drive shafts. In order to do this, an electronic     control unit for the transmissionuses information such as engine   speed, road speed, accelerator position and driving mode to select the optimum  gear and to determine the ideal shift point.

Smooth gear-shift operations , No loss of torque through the transmission from the engine to the driving wheels during up-shifts.  with DSG 'boxes will increase fuel economy over manual, whereas others will lower it Combined with the DSGs ultra-efficient gearchanges, this will mean better fuel economy and lower CO2 emissions than the manual car and safe for environment.

Applications

• High end Cars like Audi, Skoda. etc.
• a floor-mounted transmission shift lever
• The DSG can be driven in drive or for more performance it can be shifted to sport mode by pulling