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GEARS AND GEAR REDUCERS

Introduction:
Function of Gears
The Function of Gears is to transmit rotary motion and torque from one shaft of equipment to
another.

Types of Gears
1. Spur Gears
The spur gear is the most basic mechanical power transmission gear. A spur gear is cylindrical in
shape, with teeth on the outer circumference that are straight and parallel to the axis (hole).

Figure 1 spur gears

2. Helical Gears
A helical gear is similar to a spur gear except that the teeth of a helical gear are cut at an angle
(known as the helix angle) to the axis (or hole). Helical gears are made in both right and left hand
configurations

Figure 2 helical gears

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3. Bevel Gears
A bevel gear is shaped like a section of a cone and usually operates on shafts at 90-degrees. The
teeth of a bevel gear may be straight or spiral.

Figure 3 Bevel gears

4. Worms & Worm Gears

Worm
Worms are a type of gear with one or more cylindrical threads or starts (that resemble screw
threads) and a face that is usually wider than its diameter. A worm gear has a center hole (bore)
for mounting the worm on a shaft.
Worm Gears
Like worms also are usually cylindrical and have a center hole for mounting on a shaft. The
diameter of a worm gear, however, is usually much greater than the width of its face.

Figure 4 worm gearing

5. Herringbone Gear
Has teeth that are V-shaped, like a double helical gear. The shafts rotate in opposite directions
as in an ordinary spur gear.

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Figure 5 herringbone gears

Figure 6 Summaries of Types of Gears

GEAR TRAINS

Gear trains are several gear pairs are placed in series.

1. Gear Boxes
A typical commercial gearbox is shown with its cover removed. It demonstrates
that it is usually more attractive economically to split a larger speed ratio into a
number of stages (pairs of gears) rather than to affect it with a single pair. There
are three stages here - the first spiral bevel pair is followed by two helical pairs.
A couple of features of the box are immediately apparent :
compactness - shafts are short and simply supported where practicable, with gears
located as close as possible to bearings in order to minimize shaft bending
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Sturdiness increasing from input through output - the sizes of input & output
shafts, and second & third stage gear teeth, should be compared.

Figure 7 typical gear box

2. Speed Reducers
Speed reducers are much more common than speed -up drives not so much because they reduce
speed, but rather because they amplify torque.

What is a Gear Reducer?

A Gear Reducer is a set of gears, shafts, and bearings that are enclosed in housing and are
arranged in a way that resembles a solar system, with one or more planet gears orbiting
around a sun gear.

Gearboxes are known as speed reducers. They convert input speed (typically provided by an
electric motor) into a lower output speed while correspondingly creating higher torque. In other
words, gear-boxes reduce RPM, turning it into power for use in low-RPM high-torque
applications. Gearboxes come in different arrangements including planetary, bevel, cycloid,
helical, harmonic, spur, and worm. Our focus here is on the planetary arrangement.

Gear Reducers come in many sizes and capacities, and vary in speed ratios depending upon
configuration. The gearboxes pictured to the right are approximately 60 mm to 2.4 inches in size,
and produce output torque ranging roughly from 2,000 to 36,000 ounces per square inch.

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Much larger Gear Reducers exist for industrial processes, providing output torque in excess of
6,000,000 pounds per square inch. The focus of this website, however, is on these smaller Gear
Reducers.

The input power to these small Gear Reducers comes from small electric motors (either a stepper
motor, DC motor, or servo motor). Small motors are found in many household devices such as
fans, clocks, timers, cassette players, printers, computer disc drives, etc.

How Does a Gear Reducer Work?

The planetary system has 3 main components: a central sun gear, a planet carrier (carrying one or
more planet gears), and an annulus (an outer ring). The central sun gear is orbited by planet gears
(of the same size) that are mounted to the planet carrier. The planet gears are meshed with the
sun gear. An outer ring (the annulus) has teeth facing inward that also mesh with the planet
gears.

Figure 8 a typical gear reducer

There are several configurations for planetary systems. Typical configurations require that out of
the 3 components:

Input
Output
Stationary
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For example, one configuration is where the sun gear is the input, the annulus is the output,
and the planet carrier is stationary. In this configuration, the input shaft rotates the sun gear.
The planet gears rotate on their own axes, simultaneously applying a torque to the rotating
planet carrier that in turn applies torque to the output shaft (which in this case is the annulus).

The rate at which the gears rotate (gear ratio) is determined by the number of teeth in each
gear. The torque (power output) is determined by both the number of teeth and by which
component in the planetary system is stationary.

Train Value for a gear train (TV)

TV = in / out TV = (VR)1 (VR)2 (VR)3

Example
The gear train shown is used with an input speed of 1200 rpm, cw. Given the following
properties:

N1=24, N2= 48 & Pd = 16

N3=24, N4= 48 & Pd=12
N5=15, N6= 35 & Pd = 10
Determine the output velocity and center
distance of the gear train.

Example
The gear train shown is used with an input speed of 1200 rpm, cw. Given the following
properties:
N1=24 N2= 36 & Pd = 12
D3=2.0 in. & Pd=10 N4= 40
N5=16 & Pd=8 D6= 6.0 in
Determine the output velocity and center
distance of the gear train.

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Worm Gears:
Able to obtain high ratios in limited space.
Shafts are perpendicular and non-intersecting
Self-locking
40-50% efficien

Figure 9 Worm gear reducer

Example:
Determine the output speed of the gear drive, when the worm is driven at 1200 rpm.

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Figure 10 Component of worm gear reducer

Construction Features:

A. Rugged housing of cast iron to provide maximum strength and durability.

B. Housings are straddle-milled top and bottom for precise alignment.
C. Multi-position mounting flexibility.
D. Internal baffle assures positive leak-free venting.
E. Oil reservoir to provide highly efficient heat dissipation and lubrication.
F. High pressure angle on worm provides greater operating efficiency.
G. Integral input worm and shaft design made of steel alloy.
H. Tapered roller bearings. Double lip oil seals are standard.
I. Super-finished oil seal diameters on both input and output.
J. High strength steel output shaft assures capacity for high torque and overhung loads.
K. Worm gear is mounted between tapered roller bearings to increase thrust and overhung load
capacities.

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OVERHAUL AND REPAIR PROCEDURES AND PRACTICES

I. Follow Maintenance Manual

Manufacturers operations and maintenance manual be referred to during the overhaul
process. This will ensure that the technician will have access to critical information
concerning gearbox specifications. Good O & M manuals will have pertinent information
like parts numbers, drawings, disassembly and re-assembly instructions, tolerance
specifications and the like.
II. Safety Precaution
Safety precautions should always be strictly adhered to when preparing to take a gearbox
down for overhaul. Proper notifications should be made. Lock-out, tag-out, block-out
procedures must be performed. Whether the machine is worked on in the shop or on site,
special considerations should be made to keep the area safe, clean and well organized.
III. Inspection ,Cleaning And Storage
During the overhaul process all parts need to be inspected, cleaned and carefully stored
until re-assembly. Care should be taken when removing bearings, seals, gears, shafts and
housings. The correct pullers and or presses should be used to prevent damage to any of
the components and that all the parts are removed carefully.
IV. Take Measurements
Follow all recommended safety precautions when using presses and pullers. All internal
components need to be measured using precision measurement tools. Check for run-out on
shafts and gear assemblies. Micrometer and dial indicator readings should be logged and
the information checked against manufacturers specifications. Any component not within
specified tolerances should be reworked or replaced.
V. Correct Installation
It is imperative that mating surfaces be thoroughly cleaned and checked for high spots. A
fine mill file or a stone can be used to ensure flat surfaces. Another indication of good
mechanical skill is the effort put toward installing components on shafting. Press fits are
critical when assembling gears against shaft shoulders. If parts are to be heated before
assembly, pressure should be kept on the part until cool to prevent shrinkage separation.

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VI. Take Care While Fixing Bearings, Shims And Spacers

Use a light machine oil on shafts and bearings that are pressed together instead of anti-
seize compounds. The metallic solids in anti-seize compounds may cause distortion to the
inner race of a bearing and lead to premature bearing failure. Bearings, shims, spacers and
gears need to be installed squarely and firmly on the shaft and properly secured in place
by locking nuts and retaining rings.
VII. Maintaining Correct Measurements
Mounting distances and gear back lash should be carefully measured and set before
running the machine in. Blueing is recommended to check the gear tooth contact pattern.
Clean oil sumps completely.
VIII. Correct Torque And Lubrication
Torque all fasteners to manufacturers specifications. Lubrication of the unit is absolutely
critical. If the gearbox is oil filled, use the right oil at the right level. If grease lubricated,
use the right grease and most importantly the right amount. The leading cause of (grease
lubricated) anti-friction bearing failure is over greasing.
IX. Monitoring The Unit
After the unit has been re-installed, aligned and run-in. It is always a good practice to
monitor the unit for a period of time checking for high temperature, vibration, unusual
noises, or anything out of the ordinary. Excellent machine performance is a great reward
to the mechanic after a job well done.
Lubrication
I. Before starting the unit it must be filled to the level indicated and with the grade of oil
called for by the application. Any supplier of industrial oil can meet these specifications
with a standard product.
II. Synthetic lubricants are very common. Synthetic lubricants are more viscosity
temperature stable than mineral oils.
III. This allows one lubricant to provide adequate service over a broader temperature range.

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Oil Level

The oil level in a reducer can be checked only when it is at rest and it must be maintained at the
proper level.

Oil Changes
I. Oil in a new unit should be drained out at the end of two weeks and the case thoroughly
flushed with a light oil to remove any foreign substances that may be detrimental to good
operation.
II. The original oil may be reused if good filtering facilities are available; otherwise, new oil
should be used to refill the housing.
III. After this, a change of oil every six months or 2,500 hours.

Speed

High speeds above 1800 RPM usually require a change in oil level.

Lube Oil System

Provide lubrication and remove heat generated by bearings in overcoming friction

Major components:

Sump

Pump

Strainer

Cooler

Bearings

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Figure 11 Lubrication system

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GERBOX TROUBLE SHOOTING

TROUBLE WHAT TO INSPECT ACTION

Reduce loading or replace with drive of sufficient

1. Unit overload
capacity.
Check coolant and oil flow. Vent system of air. Oil
temperatures into unit should be approximately 110F
2.Oil Cooler operation
(43C). Check cooler internally for build-up of deposits
from coolant water.
Check oil level indicator to see that housing is accurately
3. Oil level
filled with lubricant to the specified level.
Bearings must not be pinched. Adjustable tapered
bearings must be set at proper bearing lateral clearance.
4.Bearings adjustment
All shafts should spin freely when disconnected from
load.
Oil seals should be greased on those units having grease
fitting for this purpose. Otherwise, apply small quantity
5. Oil seals or stuffing of oil externally at the lip until seal is run in. Stuffing box
box should be gradually tightened to avoid overheating .
1. Packing should be self-lubricating braided. Asbestos
Overheating type.
Breather should be open and clean. Clean breather
6.Breather
regularly in a solvent.
Oil must be of grade specified in lubrication instructions.
7. Grade of oil
If not, clean unit and refill with correct grade.
Check to see if oil is oxidized, dirty, or of high sludge
8. Condition of oil
content, change oil and clean filter.
Make sure oil pump is functioning. Check that oil
passages are clear and permit free flow of lubricant.
9.Forced feed
Inspect oil line pressure regulators, nozzles, and filters to
lubrication system
be sure they are free of obstructions. Make sure pump
suction is not sucking air.
Disconnect couplings and check alignment. Realign as
10.Coupling alignment
required.
Adjust spacing between drive motor, etc., to eliminate end
11.Coupling lateral float pressure on shafts. Replace flexible coupling with type
allowing required lateral float.
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12. Speed of unit Reduce speed or replace with drive suitable for speed.

WHAT TO INSPECT ACTION

TROUBLE

1.Type of coupling Rigid couplings can cause shaft failure. Replace with coupling that
used provides required flexibility and lateral float.
2. Coupling alignment Realign equipment as required.
3. Overhung load Reduce overhung load. Use outboard bearing or replace with unit having
sufficient capacity.
4. Unit overload Reduce loading or replace with drive of sufficient capacity.
2.Shaft failure

5. Presence of high Apply couplings capable of absorbing shocks and, if necessary, replace
energy loads or extreme with drive of sufficient capacity to withstand shock loads.
repetitive shocks
6. Torsional or lateral These vibrations can occur through a particular speed range. Reduce
vibration condition speed to at least 25% below critical speed. System mass elastic
characteristics can be adjusted to control critical speed location. If
necessary, adjust coupling weight, as well as shaft stiffness, length, and
diameter. For specific recommendations, contact factory.
7. Alignment of Realign bearing as required.
outboard bearing.
1. Unit overload See Overheating (item 1). Abnormal loading results in flaking, cracks,
and fractures of the bearing.
2. Overhung load See shaft failures (item 3)
3.Bearing failure

3. Bearing speed See overheating (item 12)

4. Coupling alignment
5. Coupling lateral float
6. Bearings adjustment
7. Bearing lubrication
See Overheating (item 10)
See Overheating (item 11)
See Overheating (item 4). If bearing is too free or not square with axis,
erratic wear pattern will appear in bearing races.
See Overheating (items 2,3,7,8,9) Improper lubrication cause excessive
wear and discoloration of bearing.

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8. Rust formation due to Make necessary provision to prevent entrance of water. Use lubricant with
entrance of water or good rust-inhibiting properties. Make sure bearings are covered with
humidity sufficient lubricant. Turn over gear unit more frequently during prolonged
shutdown periods.
9. Bearing exposure to Abrasive substance will cause excessive wear, evidenced by dulled balls,
abrasive substance rollers, and raceways. Make necessary provision to prevent entrance of
abrasive substance. Clean and flush drive thoroughly and add new oil.
10.Damage due to Prolonged periods of storage in moist air and at ambient temperatures will
improper storage or cause destructive rusting of bearings and gears. When these conditions are
prolonged shutdown found to have existed, the unit must be disassembled and inspected and
damaged parts either thoroughly cleaned of rust or rust or replaced.

TROUBLE WHAT TO INSPECT ACTION

1. Oil
2. Open breather
3. Open oil drains.
4. Oil seals
5. Stuffing boxes
4. Oil Leakage
6. Force-feed
lubrication to bearing
7. Plugs at drains,
levels, etc., and standard
pipe fittings.
8. Compression-type
pipe fittings.
9. Housing and caps
Check through level indicator that oil level is precisely
at level indicated on housing.
Breather should be open and clean.
Check that all oil drain locations are clean and permit
free flow. Drains are normally drilled in the housing
between bearings and bearing cap where shafts extend
through caps.
Check oil seals and replace if worn. Check condition of
shaft under seal and polish if necessary. Slight leakage
normal, required to minimize friction and heat.
Adjust or replace packing. Tighten packing gradually
to break in. Check condition of shaft and polish if
necessary.
Reduce flow of lubricant to bearing by adjusting
orifices. Refer to factory.
Apply pipe joint sealant and tighten fittings.
Tighten fitting or disassemble and check that collar is
properly gripping tube.
Tighten cap screws or bolts. If not entirely effective,
remove housing cover and caps. Clean mating surfaces
and apply new sealing compound (Permatex # 2 or
equal). Reassemble. Check compression joints by
tightening fasteners firmly.

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TROUBLE WHAT TO INSPECT ACTION

Gear set must be adjusted to give proper
1.Backlash
backlash. Refer to factory.
Make sure that contact pattern is above
2.Misalignment of gears approximately 75% of face, preferably in
center area. Check condition of bearings.
3.Twisted or distorted
Check shimming and stiffness of foundation.
housing
4. Unit overload See Overheating (item 1)
5. Oil level See Overheating (Item 3)
6.Bearings adjustment See Overheating (item 4)
7. Grade of oil See Overheating (item 7)
5. Gear Wear 8. Condition of oil See Overheating (item 8
9.Forced-feed lubrication See Overheating (item 9)
10.Coupling alignment See Overheating (item 10)
11. Coupling lateral float See Overheating (item 11)
12.Excessive speeds See Overheating (item 12)
13.Torsional or lateral
See Shaft failure (item 6)
vibration
14. Rust formation due to
entrance of water or See Bearing failure (item 8)
humidity
15. Gears exposure to
See Bearing failure (item 9)
abrasive substance

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