What is the Gearbox?
A gearbox, sometimes called a speed reducer or increaser, is a mechanical transmission device, which is usually used in conjunction with an engine or motor to change the rotational speed and torque of the power source through the meshing of the gears, thus realizing the transmission of the power and the reduction or increase of the speed.
Why do We Need a Gearbox?
Gearboxes can increase or decrease the input speed and torque of power sources such as engines or electric motors according to people’s needs, thus realizing the control of speed and torque of vehicles or machinery and equipment, and thus maximizing efficiency and performance. At the same time, the use of gearboxes also provides overload protection against damage to more expensive components of vehicles or machinery and equipment, which can help to reduce maintenance costs and prolong the service life of the vehicle or equipment.
Different Types of Industrial Gearboxes
Planetary Gearbox
Planetary gearbox or reducer is a kind of widely used industrial product, which can reduce the speed of the motor and increase the output torque at the same time.
The main transmission structures include bearing, planetary wheel, sun wheel and internal gear ring, which can achieve power transmission and conversion. Planetary gear reducers are widely used in metallurgy, mining, lifting and transportation, electric power, energy, construction and building materials, light industry, transportation, aerospace, medical and health care, industrial robots, production automation, CNC machine tools, automobile manufacturing, textile, printing, food, metallurgy, warehousing and logistics and other fields.
Three kinds of planetary gearboxes are available on the market.
High Power High Ratio High Torque Planetary Gearbox
P series planetary gearbox adopts involute planetary gear transmission and reasonablely uses the internal and external meshing and power shunt. And modular design has been adapted to achieve different ways of conbination according to customer requirements. In addition, the box body is made of ductile iron, which has greatly increased the rigidity and shock resistance of the box, and all the gears are carburized and quenched to obtain a high-hardness and wear-resistant surface. The gears are all ground after heat treatment, which not only reduces the noise, but also has improved the efficiency and service life of the main machine. P series planetary gear reducer has the characteristics of light weight, small size, large transmission ratio range, high efficiency, smooth operation, low noise, strong adaptability, etc. Input methods include concentric shaft input, helical gear input, bevel gear-helical gear input and bevel gear input. The output modes include internal spline type, hollow shaft shrink disc type, external spline type and solid shaft flat key. Installation methods include horizontal installation, vertical installation, and torque arm installation. There are specifications of 9-34 type, 2-stage and 3-stage transmission stages to choose from. They are widely used in metallurgy, mining, hoisting and transportation, electric power, energy, construction and building materials, light industry, transportation and other industrial sectors.
High Precision Low Backlash Planetary Gearbox
This type of gearbox reducer is a precision planetary gearbox with relatively high accuracy. The backlash of single-stage gearbox can reach within 3 arcmin, and the backlash of two-stage gearbox can reach within 5 arcmin. The noise can be as low as 65 decibels, and the efficiency can reach 92%~95% according to different speed ratios. The precision planetary gearbox is made of high-strength alloy steel, and the entire gear is hardened instead of simply surface hardened, which greatly extends the service life while still maintaining the original accuracy. In addition, the use of modular design allows planetary gearboxes to be connected to each other, and the speed ratio can reach more than 1/1000. The input end adopts a flange connection method, and the input sizes can be customized according to the customer’s motor, so that it can be installed on any brand of servo motor or stepper motor in the market. The use of high-viscosity grease that is not easy to separate effectively prevents grease leakage, and there is no need to replace the grease during the service life of the product. This type of precision planetary gearbox can be installed on servo motors or stepper motors with a power range of 100w~15kw, achieving a rated output torque of up to 2000NM.
There are German brands of planetary gearboxes like Wittenstain, Japanese brands like Shimpo planetary gearbox, Chinese Taiwan brands of gearboxes like Liming, Apex, sesame, and Chinese brands of gearboxes like MKD, TransDyna, ZD, Kofon, etc. Chinese gearboxes can replace all other brands of precision gearboxes. Their sizes are all in line with that of overseas brands of gearboxes. Meanwhile, the prices are much cheaper.
Micro Planetary Gearbox
Micro planetary gearbox mainly refers to planetary gear reducer with a body diameter between 8mm and 62mm. Stainless steel shell material, all-steel, hard-tooth surface gear material, Swiss gear hobbing machine precision hobbing processing, overall carburizing and quenching gear processing technology, and the output adopts rolling bearings, making the miniature planetary reducer have a compact size and optimal Power to weight ratio, low noise, high efficiency, low backlash and long service life. The micro planetary gearboxes are widely used in fields of robotics, medical equipment, smart home, optics, oil, natural gas, aerospace and heavy industry.
Voltage range: 3-12V
Compatible motor types: stepper motor, DC brush motor, coreless motor
Harmonic Gearbox
What is a Harmonic Gearbox?
A harmonic gearbox or reducer, also called harmonic drive gear or strain wave gearbox, is a high-precision transmission component with a compact structure, lightweight, no backlash, and can both decelerate and accelerate. Invented by American inventor C.W. Musser in 1955, it is widely used in industrial robots, spacecraft, precision machinery, and other fields.
The Structure of Harmonic Gearbox
The harmonic gear reducer mainly consists of three basic components including a fixed internal tooth rigid gear, a flexible gear, and a wave generator that causes radial deformation of the flex spline.
Wave Generator
Thin-walled ball bearings are embedded on the periphery of the oval cam, and the entire component is oval. The inner wheel of the bearing is fixed on the oval outer wheel, and the outer wheel can be elastically deformed through balls. It is installed on the motor shaft.
Circular Spline
Circular spline is an internal gear of the rigid body. There are gears the same size as the flexspline embedded inside, and the number of gears is two more than that of the flexspline. It is usually fixed inside the gearbox.
Flexspline
Thin-walled, cup-shaped metal elastomer components. There are gears engraved around the opening of the cup. Output is usually performed from here.
Transmission principle of harmonic gearbox
The transmission principle of the harmonic gear reducer is the cycloid pinwheel planetary gear transmission principle proposed by German Lorenz Baraen in 1926. The wave generator changes the shape of the flex spline into an elliptical shape. Therefore, in the long-axis part of the oval, the flex spline meshes with the gear of the rigid spline, and in the short-axis part, the gear is completely disengaged. Fix the rigid wheel and rotate the wave generator clockwise. The flex spline will elastically deform and the gear meshing parts of the rigid wheel will move sequentially. Rotate the wave generator 180 degrees clockwise, and the flex spline will move counterclockwise with a difference of 1 tooth. When the wave generator rotates once (360 degrees), the number of gears of the flex spline is two less than that of the rigid spline, and it moves counterclockwise with a difference of 2 teeth. This action is generally performed as output.
Advantages of harmonic drive reducer
- The transmission speed ratio is large.
The single-stage harmonic gear transmission speed ratio range is 70~320, which can reach ratio 1,000 in some devices, and the multi-stage transmission speed ratio can reach more than 30,000. It can be used not only for deceleration but also for speed increase.
- Strong load capacity.
This is because the number of teeth meshing simultaneously in harmonic gear transmission is large, and the number of teeth meshing simultaneously in double-wave transmission can reach more than 30% of the total number of teeth. Moreover, the flex spline uses high-strength materials, and the teeth are in surface contact.
- High transmission accuracy.
This is because the number of teeth meshing simultaneously in harmonic gear transmission is large, and the errors are averaged. That is, the multi-tooth meshing has a mutual compensation effect on the errors, so the transmission accuracy is high. When the gear accuracy level is the same, the transmission error is only about 1/4 of that of ordinary cylindrical gear transmission. At the same time, the radius of the wave generator can be slightly changed to increase the deformation of the flex spline so that the backlash is very small, and even backlash-free meshing can be achieved. Therefore, the harmonic gear reducer has a small transmission gap and is suitable for reverse rotation.
- High transmission efficiency.
Since the flex spline gear teeth move uniformly radially during the transmission process, even if the input speed is very high, the relative slip speed of the gear teeth is still extremely low (so it is 1% of that of ordinary involute gear transmission), so the gear teeth wear is small and the efficiency is high (up to 69%~96%). And because both sides of the gear are involved in the work when meshing in and out, there is no impact and the movement is smooth.
- Simple structure
There are only three basic components, and the input and output shafts are coaxial, so the structure is simple and easy to install.
- Small size and lightweight.
Compared with ordinary reducers, when the output torque is the same, the volume of the harmonic gear reducer can be reduced by 2/3 and the weight can be reduced by 1/2.
- Low noise
The harmonic reducer has low noise because its motion is harmonic vibration rather than ordinary shaft transmission.
- Long service life
A harmonic gearbox lasts longer than other reducers because it moves in a way that reduces wear and damage to the gears.
- Good reversibility
The harmonic reducer has good reversibility and can achieve forward and reverse rotation and rapid speed change.
- High reliability
The harmonic drive gearbox uses non-contact transmission, which reduces wear and friction between parts, thereby improving the reliability and stability of the machine.
Application of harmonic reducer
Harmonic reducers are widely used in end shafts of robots under 10kg and industrial robots between 10~20kg.
90 Degree Servo Gearbox
The 90-degree servo gearbox is also called a right-angle spiral bevel gearbox, and people also call it a steering gearbox. It is mainly used in conditions where the installation space is limited and the direction needs to be changed. Their shells can be designed in different materials, including stainless steel and cast iron. This series of reducers provides a variety of output shaft options, including single-shaft output like right or left shaft output, and dual-shaft output which means both left and right shafts output at the same time. According to different usage conditions, some customers also require hollow output, which can be single-hole output or double-hole output. The input method of the gearbox can be shaft input or flange input. Flange output is more commonly used and easier to install. We only need to customize the input size of the flange according to your motor input sizes.
Advantages of 90-degree servo bevel gearbox
- High rigidity.
The integrated stainless steel body ensures maximum rigidity and corrosion resistance, and multiple precision machined surfaces allow for easy assembly.
- High torque
Using the top-grade worm bevel gear design software, the optimized design allows uniform load on the contact tooth surface to allow high torque output.
- High precision
The gears are made of high-strength carburized alloy steel, and the grinding precision meets DIN level 5 standards.
- High ratio.
The high-precision ground worm bevel gear set combined with the optimally designed planetary gear set can achieve a reduction ratio of 500:1.
- Simple Structure.
The streamlined structure design of high torque and low backlash is suitable for precision servo applications.
- Maintenance free.
Patented oil seal design, maintenance-free thus no need to change the lubricating oil, long operating life.
- High strength.
The high-precision spiral bevel gear is made of nickel-chromium alloy steel SCM415HRC60, which ensures the high strength of the reducer.
- High efficiency
The combination of a high-precision planetary gearbox and precision spiral bevel gear structure ensures the high efficiency of the reducer.
- High load capacity
The gearbox has an excellent rigid structure and is supported by double-conical bearings. It is particularly suitable for situations where the load at the output end changes greatly.
- Diverse input and output shaft options.
Inputs include flange input and shaft input. The output shaft has single output shaft type, double output shaft type, hollow shaft type, hollow flange type, hollow shaft tapered pressing type, screw linear type, and thread linear type. Can be applied to various industrial application needs.
Parameter usage range of 90-degree right angle spiral bevel gear servo gearbox
Reduction ratio: single stage 1:3~1:10; double stage 1:12~1:100
Small size, space-saving: frame size 55MM-220M
Output torque: 15Nm~1600Nm, spiral bevel gear module M1.0 ~ M6.0
Easy to install: can be installed in 5 directions
Applicable power: 50W~15KW
Robotic RV Gearbox (reducer)
Introduction to RV reducer
RV reducer is a newly popular transmission speed reducer. It is developed based on the traditional pin-pendulum planetary gearbox. It not only overcomes the shortcomings of general pin-pendulum transmission but also has the advantages of small size, lightweight and high transmission ratio. With a series of advantages such as large range, long life, high precision and stability, high efficiency, and smooth transmission, it has attracted widespread attention at home and abroad.
Structure of RV reducer
The transmission device of the RV reducer is composed of the first-stage planetary reducer mechanism and the second-stage cycloidal pinwheel reduction mechanism. The input shaft is connected to the driving sun gear. If the sun gear rotates clockwise, the three planet wheels revolve around the sun. While the wheel revolves, it also rotates counterclockwise. The three crankshafts are connected to the planet wheels and rotate at the same speed. Two cycloid wheels with a phase difference of 180° are hinged on the three crankshafts and mesh with the fixed needle wheel. The output mechanism is driven by three pairs of crankshaft support bearings mounted on it. The rotation vector on the cycloidal wheel is transmitted at a speed ratio of 1:1.
The working principle of RV-E reducer
RV-E type reducer is a 2-stage reduction type of gearbox.
1st reduction part…spur gear reduction mechanism
- The rotation of the input shaft of the deceleration mechanism is transmitted from the input gear to the spur gear and is reduced according to the tooth count ratio. This is the first reduction section. The second reduction section is a differential gear reduction mechanism.
- The spur gear of the deceleration mechanism is connected to the crankshaft, becoming the input of the second reduction section. In the eccentric part of the crankshaft, an RV gear is installed through a rolling bearing. In addition, on the inner side of the housing, there are needle teeth arranged at an equal tooth spacing, which is only one more than the number of teeth on the RV gear. If the housing is fixed and the spur gear rotates, the RV gear will also undergo eccentric motion due to the eccentric motion of the crankshaft. At this time, if the crankshaft rotates one revolution, the RV gear will rotate one tooth in the opposite direction to the crankshaft. This rotation is output to the shaft of the second reduction section.
- When the shaft is fixed, the housing side becomes the output side.
The Working principle of RV-C reducer
RV-C type reducer is a 2-stage reduction type of gearbox.
1st reduction unit…spur gear
The rotation of the input shaft of the reduction mechanism is transmitted from the input gear to the spur gear and is reduced according to the ratio of teeth number. This is the first deceleration section.
2nd reduction part…differential gear
The spur gear of the deceleration mechanism is connected to the crankshaft, becoming the input of the second reduction section. In the eccentric part of the crankshaft, an RV gear is installed through a rolling bearing. In addition, on the inner side of the housing, there are needle teeth arranged at an equal tooth spacing, which is only one more than the number of teeth on the RV gear. If the housing is fixed and the spur gear rotates, the RV gear will also undergo eccentric motion due to the eccentric motion of the crankshaft. At this time, if the crankshaft rotates one revolution, the RV gear will rotate one tooth in the opposite direction to the crankshaft. This rotation is output to the shaft of the second reduction section. When the shaft is fixed, the housing side becomes the output side. There are many ways to use the RV-E reducer. Please choose the best practical method for the rotation direction and speed ratio. The reduction ratio i obtained by adding the first reduction section and the second reduction section varies depending on the method of use, and it can be calculated based on the speed ratio value shown in the following formula.
Shaft rotation situation
R: Speed ratio value
Z1: Number of teeth of input gear
Z2: Number of teeth of spur gear
Z3: Number of teeth for RV gears
Z4: Number of needle teeth
i: Reduction ratio
Advantages of RV reducer
The RV reducer is driven by a solid rigid wheel, so the RV reducer has higher fatigue strength, high rigidity, long service life, large torque, impact resistance, large transmission ratio range, high positioning accuracy, and low vibration.
Disadvantages of RV reducers
The vast majority of transmission mechanisms in RV reducers are rolling transmission, but the exception is between the needle teeth and the needle gear housing. Its actual manifestation is mainly sliding friction, and the force wear situation is similar to that of sliding bearings. Sliding bearings are mainly suitable for high-speed light loads, which limits their bearing capacity.
In actual working conditions, RV reducers require repeated precise positioning, that is, continuous starting and braking. In order to maintain a certain degree of accuracy without attenuation and extend the service life, there are quite high requirements for the machining accuracy, materials, and technology of the needle teeth, needle gear shells, and needle gear pins. This is also one of the important reasons why precision RV reducers are difficult to produce.
Application of RV reducer
The RV-E and RV-C series were initially widely used in the joint axes of heavy-duty robots weighing over 10kg, such as six-axis industrial robots, palletizing robots, welding robots in the welding field, heavy-duty displacement machines, stamping robots in the stamping field, as well as machine tools, medical testing equipment, satellite receiving systems, and other fields.
Parallel shaft helical Gearbox
What is a parallel shaft helical gearbox?
A parallel shaft gearbox refers to a gearbox where the gear shafts are parallel to each other, and the input and output shafts are also parallel. It is commonly used in situations where variable speed and reverse rotation are required. There are multiple motor combinations, installation positions, and structural forms for parallel axis helical gear reducers. This series adopts a serialized and modular design, and you can choose the corresponding speed and structural form according to your needs. This series of boxes uses high-quality rigid cast iron, greatly improving the performance of the box’s resistance to impact, and ensuring the parallelism and positioning accuracy of the shaft through precision machining. The surface of his internal transmission gears has undergone high-frequency heat treatment, which greatly enhances the hardness and wear resistance of the gears. In addition, the adoption of planetary design principles allows this series of gearboxes to be combined with MB series continuously variable transmissions to form a continuously variable speed reduction motor, thereby achieving speed adjustment within an extremely low output range. Due to the combination of international technology requirements in the manufacturing of this series of parallel shaft gearboxes, it has high technological content, saves space, and is reliable and durable. His overload capacity is also very high, with a power of over 90KW, superior performance, and an efficiency of over 95%.
Advantages of parallel shaft helical gearbox
- Modular design.
A highly modular design can be easily installed on various forms and powers of motors or other power input devices.
- High Transmission Ratio
The range of transmission ratios for this series of gear reducers is wide, with detailed division, making it easy to find the gear ratio and speed you want. And the combination model can form a large transmission ratio and output extremely low rotational speed.
- Easy to install.
The installation position of the gearbox in this series is not restricted and there are multiple styles available.
- High load-bearing capacity and small size.
The box of this series of gearboxes is made of high-strength cast iron, and the gears and gear shafts are treated with gas carburization quenching and precision grinding technology, resulting in high load-bearing capacity per unit volume.
- Long service life
Under the conditions of correct selection and normal maintenance, the main components of the gearbox, except for vulnerable parts, have a lifespan of up to 20000 hours or even longer.
- Low noise
The main components of the gearbox are precision machined and assembled and tested to ensure low noise levels.
- High efficient
The efficiency of a single machine shall not be less than 95%.
- Ability to withstand large radial loads.
- Can withstand axial loads not exceeding 15% of radial force
Technical data of parallel shaft helical gearbox
Power usage range: 0.12KW~200KW
Torque of reducer: 3N.m ~ 22500N.m
Output speed of reducer: 0.06-374r/min
Models of parallel shaft helical gearbox
- F-type
– Ordinary shaft extension parallel shaft helical gear reducer;
- FA type
– Shaft mounted parallel shaft helical gear reducer;
- FF type
- Flange type parallel shaft helical gear reducer;
- FAF type
– Shaft mounted flange parallel shaft helical gear reducer.
Application of parallel shaft helical gearbox
This series of gear reducers are widely used in the light industry, food, beer and beverage, chemical industry, escalators, automated storage equipment, construction and building materials machinery, steel metallurgy, environmental protection, power plants, coal, mining, papermaking, artificial boards, automobiles, ports (airports, docks), tobacco machinery and other fields
Mounting ways of parallel shaft helical gearbox
Installation methods include base installation, hollow shaft installation, flange installation, torque arm installation, and small flange installation. The basic type has the same rotation direction for the second-level input and output, but the opposite rotation direction for the third level. Please consult us when combining F/R
Output ways of parallel shaft helical gearbox
The output method is hollow shaft output or solid shaft output.
Average efficiency of parallel shaft helical gearbox
The working efficiency of the 2-stage gearbox can reach 96%, the working efficiency of the 3-stage gearbox can reach 94%, and the working efficiency of the F and R combination gearbox can reach an average efficiency of 85%.
Orthogonal Shaft Gearbox
Orthogonal shaft gearbox refers to a gear transmission structure in which the input shaft and output shaft are arranged vertically. This type of reducer transmits power at 90 degrees. It is often used in situations where steering or speed changes are required. It has certain requirements for space, but the entire gear The mechanical design of the box allows for great flexibility.
Concentric Gearbox
A concentric gearbox, also known as an inline gear transmission device, is a parallel shaft gearbox where the input shaft (high-speed shaft) and output shaft (low-speed shaft) are located in the same straight line and vertical plane. Single or multi-stage gear units are arranged in a row, and their shafts are aligned in a straight line. For example, a planetary gearbox is a type of concentric inline gear transmission device, which is typically used in applications that require higher torque due to its sturdy design.
Our concentric gearbox transmission device is designed to be sturdy and durable enough, with superior quality. After long-term application in industrial equipment and machinery by our company, it has been verified multiple times that it can meet various challenges. The careful design and careful use of materials in the concentric inline gear reduction transmission device can minimize wear and prolong the service life of the reducer.
Coaxial Helical Inline Gearbox
What is Coaxial Helical Inline Gearbox?
The R series coaxial helical gear reducer is a hard tooth surface reducer designed and manufactured on the basis of a modular combination system, with input and output shafts in a straight line. Its structural forms are diverse, and the transmission ratio classification is fine. You can always find the model you need. This series of helical gear reducers have the characteristics of small volume, lightweight, high load-bearing capacity, high efficiency, long service life, and convenient installation. They are widely used in various industries that require deceleration equipment, such as metallurgy, sewage treatment, chemical, pharmaceutical, and other industries.
Types of Structure
R: Axis extension foot installation
RF: flange installation
R… F: Installation of foot flange
RM: flange installation with extended bearing housing
RX: Single-stage foot installation
RXF: Single-stage flange installation
Technical data
Power range: 0.18KW~132KW
Torque range: 1.4Nm~23200Nm
Output speed: 0.06-1090r/min
Input methods: direct motor, shaft input, and connecting flange input
Output method: Solid shaft output
Reduction ratio: Level 2: 5-24.8, Level 3: 27.2-264, R/R combination can reach 18125
Average efficiency: Level 2 96%, Level 3 94%, R/R combination 85%
The R series, designed specifically for mixing, can withstand large axial and radial forces
Advantages of parallel shaft helical gearbox
- Space saving, reliable and durable, with high overload capacity, and a power of up to 132KW
- Low energy consumption, superior performance, and transmission efficiency of over 95%
- Low vibration, low noise, high energy efficiency
- High-quality forged steel material is selected, with a rigid integral cast iron casing. The gear surface is subjected to high-frequency heat treatment
- After precision machining to ensure the parallelism of the shaft and the requirements for positioning bearings, the gearbox that forms the helical gear transmission assembly is equipped with various types of motors, combined into electromechanical integration, fully ensuring the quality characteristics of the helical gear transmission assembly.
Bevel Helical Gearbox
What is a bevel helical gearbox?
The K series bevel gearbox is an external involute helical cylindrical gear reducer that uses bevel gear transmission for vertical output. It has the characteristics of high precision, high efficiency, fine transmission classification, high transmission torque, low vibration, low noise, flexible installation, and convenient use and maintenance. It is widely used in various low-speed and high torque right angle transmissions and is a universal basic component of mechanical transmission.
Advantages of bevel helical gearbox
- Small space occupation, durable and reliable, able to withstand high overload capacity, with a power of over 200KW.
- The reducer has high efficiency, low energy consumption, and superior performance.
- Low noise, and low vibration, can save you a lot of energy
- High-quality forged steel material has been selected, and the casing is made of steel cast iron. The surface of the gears has undergone high-frequency heat treatment.
- The transmission assembly of helical gears, bevel gears, and bevel gears has undergone precision machining, and the reducer is equipped with various types of motors, forming a high-quality electromechanical integrated product.
- There are many models to choose from. Mainly including K37, K47, K57, K67, K77, K87, K97, K107, K127, K157, K167, K187
- Multiple transmission ratios and diverse installation forms。
Ways of Installation
Base type, flange type, small flange type, torque arm type installation
Output Ways
Solid and hollow shaft outputs
Input ways
Direct connected motor, shaft input and connecting flange input
Structure Style
Shaft mounted type A, shaft extended flange type F, shaft mounted flange type AF, shaft mounted small flange type AZ, ordinary shaft extended type
Application
Bevel helical gearboxes are widely used in metallurgical, mining, lifting, transportation, cement, construction, chemical, textile, printing and dyeing, pharmaceutical and other fields.
Skew Bevel Helical Gearbox
The internal gears of the gearbox of this type of reducer are designed to be skew bevel helical, and the worm gear reducer is one of them. Its casing is sturdy and suitable for heavy-duty and other occasions. Once installed on various types of motors, these industrial gearboxes can provide efficient operation. There are multiple numbers of teeth and gears to choose from, and different configurations can be made to meet your application requirements.
Worm Reduction Gearboxes
What is a Worm Reduction Gearbox?
A worm gear reducer is a power transmission mechanism with a compact structure, high transmission ratio, and self-locking function under certain conditions. The internal structural unit is mainly composed of a turbine and a worm gear. It uses the speed converter of gears to reduce the motor speed to the desired output speed through a certain speed ratio and obtain a larger torque as a reduction gearbox. Adding a helical gear reducer at the input end of the worm gear reducer can result in a multi-stage reducer with very low output speed, higher efficiency than a single-stage worm gear reducer, and lower vibration and noise. Widely used in mechanisms for transmitting power and motion to meet your needs for lower speeds and greater torque.
Technical Data
Power: 0.06KW ~ 7.5KW
Torque: 2.6N.m ~ 2379N.m
Transmission ratio: 7.5-100
The structure of the worm gearbox
This series of worm gearboxes, also known as RV worm gear reducers, are made of aluminum. Its basic structure mainly consists of transmission components such as worm gears, shafts, bearings, housing, and its accessories. Among them, the box, worm gear, and shaft combination are its three basic structural components. The box is the base of all accessories in the worm gear reducer, which is an important component that supports and fixes the shaft system components, ensures the correct relative position of transmission accessories, and supports the load acting on the reducer.
Shell: aluminum alloy (base: 025-090)
Cast iron (base: 110-150)
Worm: 20Cr steel. Carbon and nitrogen co-infiltration treatment (maintain tooth surface hardness HRC60 after precision grinding, with a hardness thickness greater than 0.5mm).
Worm gear: specially configured wear-resistant nickel bronze.
Oil cap/breather: mainly used to exhaust the gas inside the casing of the turbine worm reducer.
End caps: divided into large end caps and small end caps. End caps fix the axial position of shaft components and bear axial loads. Both ends of the bearing seat holes are closed with bearing caps.
Oil seal: mainly to prevent the leakage of lubricating oil inside the chassis and improve the service life of lubricating oil.
Oil drain plug: mainly used for draining dirty oil and cleaning when replacing lubricating oil.
Oil gauge cover/oil gauge: mainly used to observe whether the oil level inside the turbine worm reducer case meets the standard.
Types of Worm Gear Reducer
WP Series
Including WPA/WPS/WPW/WPE/WPZ/WPD
WH Series
Including WHT/WHX/WHS/WHC
CW Series
Including CWU/CWS/CWO
RV Series
Including RV/NMRV/NRV
Brief Introduction of RV worm gear reducer
The RV series worm gear reducer is designed and manufactured according to technical quality standards. Based on the parameters of the cylindrical worm gear in accordance with the national standard GB10085-88, and drawing on advanced domestic and foreign technology, it has a unique “square box” shape structure. The box has a beautiful appearance and is made of high-quality aluminum alloy die-casting. The mechanical reduction device, which has been widely used in various industries for production process equipment, is the best choice for modern industrial equipment to achieve high torque, high speed ratio, low noise, and high stability mechanical reduction transmission control devices.
Advantages
- Compact mechanical structure, lightweight appearance, small and efficient
- Good heat exchange performance and fast heat dissipation
- Easy installation, flexible and lightweight, superior performance, and easy maintenance and repair
- Smooth operation, low noise, and durability
- Strong usability, high safety and reliability
Models
| RV25 | RV30 | RV40 | RV50 | RV63 | RV75 | RV90 | RV110 | RV130 | RV150 |
| NMRV25 | NMRV30 | NMRV40 | NMRV50 | NMRV63 | NMRV75 | NMRV90 | NMRV110 | NMRV130 | NMRV150 |
| NRV25 | NRV30 | NRV40 | NRV50 | NRV63 | NRV75 | NRV90 | NRV110 | NRV130 | NRV150 |
Maintenance
Please do not apply pressure to the output components and casing of the reducer during installation. When connecting, please meet the corresponding requirements for coaxiality and verticality between the machinery and the reducer.
The initial operation of the gearbox should be replaced with lubricating oil after 400 hours, and the subsequent oil change cycle is about 4000 hours.
Sufficient lubricating oil should be retained inside the gearbox and checked regularly.
Pay attention to keeping the appearance of the gearbox clean, and promptly remove dust and dirt to facilitate heat dissipation
Application
Worm gear reducers are widely used in various types of mechanical transmission systems, such as ships, cars, locomotives for transportation, heavy-duty machinery for construction, processing tools and automated production equipment used in the mechanical industry, as well as common household appliances, clocks, etc. in daily life. The application of reducers can be seen from the transmission of large power to small loads and precise angle transmission. In industrial applications, reducers have functions of reducing speed and increasing torque.
XB Series Cycloidal Pin-wheel Gearbox
What is a Cycloidal Pin-wheel Gearbox?
The X/B cycloidal pinwheel reducer is a novel transmission device that applies the principle of planetary transmission and adopts cycloidal pinwheel meshing.
Working Principle of Cycloidal Pin-wheel Gearbox
The cycloidal pinwheel reducer is a novel transmission device that applies the principle of planetary transmission and adopts cycloidal pinwheel meshing. The entire transmission device of the cycloidal pinwheel reducer can be divided into three parts: input part, deceleration part, and output part. There is a 180 ° offset double eccentric sleeve installed on the input shaft, and two roller bearings called the rotating arm are installed on the eccentric sleeve, forming the H mechanism. The center holes of the two cycloidal gears are the raceways of the rotating arm bearings on the eccentric sleeve, and the cycloidal gears mesh with a group of circular arranged needle teeth on the needle gear to form an internal meshing reduction mechanism with a tooth difference of one tooth. (To reduce friction, in reducers with small speed ratios, the needle teeth are equipped with needle sleeves.) When the input shaft rotates with the eccentric sleeve for one revolution, due to the characteristics of the tooth profile curve on the cycloidal wheel and its limitation by the needle teeth on the needle gear, the cycloidal wheel is used. The motion of the cycloidal gear becomes a planar motion with both revolution and rotation. When the input shaft rotates in the forward direction, the eccentric sleeve also rotates once, and the cycloidal gear rotates in the opposite direction by one tooth to achieve deceleration. Then, with the help of the L output mechanism, the low-speed self transfer motion of the cycloidal gear is transmitted to the output shaft through the pin shaft, thereby obtaining a lower output speed.
Brif Introduction of Structure of Cycloidal Pin-wheel Gearbox
When the input shaft rotates with an eccentric sleeve for one revolution, due to the characteristics of the tooth profile curve on the cycloidal gear and its limitation by the needle teeth on the needle gear, the motion of the cycloidal gear becomes a plane motion with both revolution and rotation. When the input shaft rotates forward for one revolution, the eccentric sleeve also rotates for one revolution, and the cycloidal gear rotates in the opposite direction by one tooth to achieve deceleration. Then, with the help of the W output mechanism, the low-speed rotation motion of the cycloidal gear is transmitted to the output shaft through the pin shaft, thereby obtaining a lower output speed.
Shaft-Mounted Gearbox
The outer shell of this type of gear reducer is made of high-strength cast iron precision manufacturing, and the steel gears and shafts have been hardened. The outer circle of the input shaft is precisely ground, which can withstand the maximum radial load and torque, greatly improving the impact resistance of the entire machine. Grinding process, involute tooth profile modification, with a gear transmission efficiency of up to 98% for each level, stable transmission, and low noise. Precision machining of bearing aperture, accurate positioning of locating pins, ensuring smooth meshing of gears, high-strength alloy steel input gear shaft. The included box support angle can support the torque arm bolts to prevent them from being too tight and damaging the box, and control the installation position of the standard torque arm within the recommended range In addition, the backstop is an optional accessory used when your gearbox cannot reverse. However, it is only used for gearboxes with a speed ratio of 13:1 and 20:1, and it is not recommended to use a backstop for gearboxes with a speed ratio of 5:1. The use of ball bearings and skeleton double lip oil seals greatly improves the efficiency of the gearbox. Attachment torque arm refers to the use of a torque arm to install and adjust the spatial position of the reducer and the tightness of the belt.
Spiral Bevel Steering Gearbox
The housing of the spiral bevel gear reducer is a regular hexahedron, which can adapt to installation in different directions. Its design has a large load-bearing capacity, long service life, low noise, smooth transmission, and a gear line speed of up to 40 meters excitation, with a transmission efficiency of up to 94%. The spiral bevel gears of the reduction gearbox are made of high-quality low-carbon alloy structural steel, which has undergone carburizing, quenching, heat treatment, and grinding to achieve high-precision hard tooth surfaces. The HD series commutator has a variety of specifications to choose from, including shaft input and flange input. The output shaft also comes in various forms, which can meet the needs of different occasions. In addition, the gearbox commutator can also achieve two transmission modes of deceleration and acceleration.
Stepless Gearbox
The continuously variable transmission (CVT), also known as the stepless transmission, is mainly composed of the following types: friction-based, chain-based, belt-based, and pulsating-type CVTs. Its purpose is to change or adjust the variation of equipment and energy. The stepless transmission belongs to a gear transmission device that can fix or change the transmission ratio between the output shaft and the input shaft. It mainly consists of a clamped drive pulley device, a friction transmission mechanism, and a speed control mechanism. You can choose from a variety of complex operating procedures such as speed change, braking, reversing, slow-speed starting, and slow-speed deceleration according to your needs.
CVTs are usually used in conjunction with gear reducers, double-flange electromagnetic clutch brake units, and worm gear reducers to achieve the effect of low speed and high torque. It is widely used due to its characteristics of high strength, large speed range, high-speed regulation accuracy, small size, lightweight, smooth operation, low noise, long life, strong combination ability, and suitability for various harsh working environments. Currently, it is widely used in various fields such as production lines, textile machinery, printing and dyeing machinery, wire and cable machinery, food machinery, leather machinery, woodworking machinery, packaging machinery, electronic equipment manufacturing plants, and other fields.
PC Pre-stage Helical Gearbox
What is PC Pre-stage Helical Gearbox?
The PC front helical gear reducer is a modular structure product, which has a modern appearance and can be combined with any reducer with a PAM input flange to increase its speed ratio. This device cannot be used alone and can only be used in conjunction with a gearbox. The aluminum alloy shell not only reduces its own weight but also improves heat dissipation performance. The material of the gear is 40Cr gear, based on involute precision manufacturing. Compact in structure, compact in size, and combined with various reducers, the deceleration range can be greatly expanded.
The common speed ratios are 5, 7.5, 10, 15, 20, 25, 30, 40, 50, 60, 80, and 100.
Models of PC Pre-stage Helical Gearbox
The main models of PC front gear reducers include PC063, PC071, PC080, and PC090.
PC063 can be paired with NMRV040/NMRV050/NMRV063
PC071 can be paired with NMRV050/NMRV063/NMRV075/NMRV090
PC080 can be paired with NMRV075/NMRV090/NMRV110/NMRV130
PC090 can be paired with NMRV110/NMRV130
Advantages of PC Pre-stage Helical Gearbox
Characteristics of PC front helical gear reducer and its combination reducer
- Large transmission ratio
The transmission ratio of the first stage reducer is 1/6-1/87. The transmission ratio during two-stage deceleration is 1/99-1/7569
The transmission ratio is 1/2057-1/658503 during the third level reduction. You can use more level combinations as needed.
- High transmission efficiency
Due to the use of rolling meshing in the meshing part of the PC front helical gear reducer, its average efficiency can reach over 90%.
- Small volume and light weight
Due to the use of the planetary transmission principle, the input and output shafts are on the same axis, and the unique feature of being directly connected to the electric motor, this machine has the characteristics of a compact structure, small volume, and lightweight.
Different Types Of Automobile Gearbox
From industrial machinery, and turbines to automobiles, gearboxes are widely used. In addition to the aforementioned industrial machinery, gearboxes are also used in automobiles, or you can call them transmission boxes. Below are different types of automotive gearboxes.
Manual transmission
In a car with a manual gearbox, the driver can fully control the gears by changing different gears and combining them with the use of the clutch, selecting the appropriate gear to help him start quickly and save fuel. Due to the excellent quality and affordability of manual transmission gearboxes, most vehicles adopt this type of gearbox.
Sliding-Gear Transmission
Sliding gear transmission is actually a type of manual gearbox. Nowadays, vehicles no longer use this type of gearbox, and sliding gear transmission devices can only be found in older models of cars. When the gearbox is in neutral, the only movement inside the gearbox is the main drive gear and cluster gear. In order to send power to the drive wheels, the clutch pedal must be pressed in order to move the shift lever. Moving the shift lever can change the position of the shift linkage and fork, and cause the gears to slide along the main shaft directly above the cluster gears.
Once these two gears mesh, the clutch can be released. To shift gears again, the driver needs to first cancel the engagement of the current gear and then synchronize the two new gears. For this type of transmission device, not all gears have the same diameter and number of teeth. Different diameters cause gears to rotate at different speeds, which may lead to gear collisions. This issue is one of the main reasons why this type is no longer in use.
Constant-Mesh Transmission
A constant mesh transmission, also known as a synchronous transmission, ensures that the group gears, driving gears, and main shaft gears maintain constant motion. Gears can rotate freely around the spindle. The claw clutch is used to lock these gears in place when needed. When the shift linkage moves, the teeth on the dog clutch and main shaft gear lock with each other and keep the gear stationary. The synchronizer is used for constant engagement transmissions to prevent any collisions or friction during gear shifting.
Pre-selector Transmission
The preselector transmission system uses a planetary gear system, which pre-determines the transmission ratio through a small lever on the steering column. Then, the driver uses the foot pedal to adjust to the preset gear, and when the new gear is engaged, the process will disengage from the previous gear.
With the development of the automotive manufacturing industry, manual transmissions have slowly undergone a series of evolution. A type of manual transmission developed before the introduction of automatic transmissions is called the Wilson preselector.
This transmission was launched in 1930 and adopts a planetary gear system, which pre selects the gear ratio through a small lever on the steering column. If a gear shift is required, the driver Ziyao can adjust one of the pre-selected gears by pressing the foot pedal. When this situation occurs, the previous gear will disengage and the new gear will engage.
Automatic transmission
Compared to manual transmissions, automatic transmissions follow different basic principles. On the surface, any gear change operation is easy for the driver because the gear lever on the automatic transmission is just an electronic switch (such as a button, paddle, or dial), which sends commands to the software that manages the transmission, allowing the gearbox to perform different mechanical operations.
Torque Converter
The most common type of automatic transmission is to use a torque converter to transfer the rotational force of the engine to the wheels. A hydraulic torque converter is a type of hydraulic coupling that allows a car to start and stop without stalling the engine. However, due to the curved shape of the turbine blades inside the torque converter, it can cause some efficiency loss when absorbing driving force. The advantages of this type of gearbox are smooth acceleration at low speeds and good engine responsiveness at low speeds.
Automated-Manual Transmission
Automatic manual transmission is a type of automatic transmission that uses a conventional clutch and gear configuration, but utilizes sensors, actuators, processors, and pneumatic devices to simulate the use of manual gears. However, a common problem with this type of vehicle is the unstable performance of the engine during low speeds and rapid acceleration.
Dual-clutch transmissions (DCT)
This type of transmission is rapidly becoming the most common automatic transmission for gasoline and diesel vehicles. Most Volkswagen Group brands; Volkswagen, SEAT, and Skoda refer to it as a DSG (Direct Shift Transmission), although Audi refers to it as an S-Tronic, while Porsche prefers to use PDK, which makes things even more chaotic, but they are all the same.
As the name suggests, these transmissions have two clutches working together. In the most basic form, there will be two independent clutch systems; One for odd numbered gears and the other for even numbered gears.
Therefore, the gearbox can pre select the next gear before shifting, which means the shifting speed is much faster than other types of transmissions. In high-performance cars, this technology has developed to a point where gear shifts are almost imperceptible.
This type of gearbox provides the same direct feel as the single clutch version, but typically drives more smoothly and efficiently. It can usually provide better fuel economy and performance than manual transmissions. At low speeds, there may still be some shaking, and moving between first and reverse gears may be a bit clumsy.
Continuously variable transmission (CVT)
CVT has no gears at all. On the contrary, it uses a conical shape with a strip around the cone and another axis. The belt can move up and down on the cone to change its length, thereby changing the transmission ratio. In theory, it provides an infinitely variable ratio between the upper and lower limits, which means it can perfectly optimize fuel efficiency or performance at any given time. This is particularly helpful for hybrid vehicles, as they can use CVT to balance the workload between gasoline engines and electric motors.
The disadvantage is that the driving experience often feels strange and unpleasant. When accelerating, it feels like a car is pulling a rubber band. At the same time, the accompanying noise has a terrifying buzzing sound, as the RPM directly reaches the peak power point and remains there during car acceleration, rather than rising and falling as you work through multiple gears. The latest transmission is constantly being improved, so CVT will soon shine brightly.
