Speed Reducers: Their Primary Uses and How to Increase Their Performance

September 8, 2022

In most cases, speed reducers are mechanical devices that serve two different functions. The principal function is to multiply the torque produced by an input power source to raise the total amount of work that may be accomplished. In addition to this, the speed of the input power source is slowed down to reach the necessary output rates. When selecting and integrating speed reducers, there is much more involved than merely selecting one from a catalogue. The maximal torque, speeds, and radial loads that are published cannot be employed simultaneously in the vast majority of situations. The appropriate service factors need to be implemented to account for a diverse selection of dynamic applications. In addition, after the suitable speed reducer has been chosen, the keys to optimising the life of the reducer are careful installation and maintenance.

Its Categories

Pulleys, sprockets, gears, and friction drives are examples of mechanical speed-decreasing devices. Other electrical gadgets may vary the speed of the motor. This article will concentrate on enclosed-drive speed reducers, also known as gear drives and gearboxes, which are classified into two types: in-line and right angle. Different forms of gearing can be used to achieve each. Helical or spur gears, planetary gears, cycloidal mechanisms, or harmonic wave generators are frequent components of in-line models. Planetary designs often offer the most torque in the smallest compact. Cycloidal and harmonic drives provide compact designs with greater ratios, although helical and spur reducers are often the most cost-effective. All are reasonably efficient. Right angle designs are normally constructed with worm or bevel gearing; however, hybrid drives are also available. Worm gears are possibly the most cost-effective reduction method, although they typically have a minimum 5:1 ratio and lose significant efficiency as ratios increase. Bevel reducers are extremely efficient, but their effective speed reduction limit is 6:1. The kind of application determines which speed reducer design will best meet the needs. To properly size and instal a reducer, the following characteristics must be collected: torque, speed, horsepower, reducer efficiency, service factor, mounting position, connection variables, and life necessary. Backlash, transmission error, torsional stiffness, and moment of inertia are all relevant in specific applications.

Considerations When Choosing Speed Reducers

A reducer increases the torque of your motor, allowing a receiving part to rotate under the influence of a new torque. Gear reducer manufacturers specify the minimum and maximum torque that their devices can handle. The torque density varies depending on the gear reducer. Torque density is high in planetary gears, for example. Operational factors such as the required number of running hours and if the equipment will be subjected to extreme chemical, thermal, shock, or vibration conditions should also be considered. For example, a gear reducer in an aggregate conveyor may be subjected to severe shock, vibration, and temperature strains while working in a filthy environment for extended periods. A gear reducer’s other role is to lower motor speed, and we propose you consider the appropriate reduction ratio for your application. Based on the rotational speed of your motor, the reduction ratio is used to compute the output rotational speed. RPM is the unit of measurement (revolutions per minute).

Maximising Efficiency of Speed Reducers

Despite well-engineered designs and extensive selection studies, speed reducers deteriorate and eventually fail. Proper maintenance methods should be adopted to enhance longevity. The routine oil change is the most critical component. Under the severe pressure of mating gear teeth under load, oil and grease molecules degrade. High temperatures inside the box and the shearing impact of gears cutting through the oil contribute to oil breakdown. Reducer wear occurs quickly when oil and grease lose their lubricating capabilities. If it appears that a larger reducer is needed to accommodate additional overhang weight, try altering the pulley size. Radial forces can be lowered in direct proportion to pulley, sprocket, or gear diameter increases. When accelerating and decelerating inertial loads, the torque required is proportional to the time necessary to reach the desired speeds. Changing the acceleration profiles might result in lower torque needs. Install brakes to help in deceleration and torque limiters to guard against excessive shocks instead of sizing reducers to manage all torque coming from estops or machine jams. Savings of up to 50% are possible.

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