1.

Aims
The purpose of this Guide is to enable the user to determine the attributes
required of a gearbox to meet a specific power transmission need and then to select
an appropriate gearbox from those offered by manufacturers. It has been compiled
as part of a series which covers typical elements of a system. It is not concerned
with the detailed design of a gearbox which will be covered in other Guides in this
series.
SELECTION PROCEDURE Before embarking on the selection procedure it is
necessary to ensure that the need for a gearbox, has been carefully considered. The
Guides at higher levels in the Mechanical Power Transmission Series provide
assistance in this process.
The successful selection of a suitable gearbox is the result of matching the
requirements of the power transmission system with one of the range of boxes
offered by the manufacturers. Thus information about the system and information
about available hardware is necessary.
Gather information about system Decide on influential factors Establish limits of
accept- ability for factors Collate information from manufacturers Select suitable
element based on best match Consult manufacturer of chosen element for advice if
required
Figure 1 Summary of Procedure for Selecting a Gearbox
SEED Guides Unit Selection - Gearbox < >
2. Selection Procedure
Gather information about
system
The most important information is usually related to its purpose, constituent
elements, life, performance, environment and the economic situation for which
it is required. This information is needed in order to understand the total system so
that the gearbox selected is consistent with the rest of that system. The temptation
for the engineer to consider only purpose, performance and perhaps environment
should be strongly resisted. Although this stage is sometimes difficult and time
consuming it must be completed thoroughly if an appropriate unit is to be
identified.
Decide on influential factors
Factors which influence the choice of gearbox must now be identified.A listing of
most of the important and common factors is provided in Figure 6. Not all of these
factors are important on every occasion so careful study of the system is required
to ensure that those considered are actually relevant. Reference must be made to
the Product Design Specification for the system.
Establish limits of accept-
ability for factors
Each factor should then be defined in terms which are as objective as possible.
Thus, where appropriate, numerical information should be given, terms must be
explained and vagueness avoided. Then the boundaries of satisfaction must be
defined for each of the chosen factors. This helps the designer to decide which
gearboxes meet the requirements in each respect. The boundaries must be
numerical whenever possible. When subjective judgements are necessary a means
of comparison must be established.
Collate information from
manufacturers
Manufacturers' data should now be collected and arranged into a suitable format.
There is a finite number of gearboxes available from manufacturers and the
selection process is heavily constrained by the form and content of the information
presented by them and by the range of catalogues available to the designer at the
time.
There is a good case for maintaining a 'rolling' catalogue library, or data on
microfilm/computer, since this stage can be very time consuming if a unique set of
data is collected separately on each occasion. Data on, say, size, performance, cost
can be noted in numerical form, giving a range where appropriate. In the case of
less objective data a rating may be shown based on advice or opinion gathered.
Select suitable element based
on best match
Optimising the choice is now a process of finding the best compromise (in the
opinion of the designer) between the priorities of the system and the availability of
the hardware. As far as the factors involving numerical data are concerned, some
yield a 'go/no-go' situation which will eliminate those boxes which are too costly,
too heavy, too big etc.
Other requirements involving more subjective data should be compared on the
basis of their ability to meet the criteria as laid down in the Product Design
Specification. This may be an iterative process which converges on the best
compromise.
The evaluation technique used here will be similar to that used elsewhere in the
design activity.
Consult manufacturer of chosen
element for advice if required
Further advice on the detail of installation or specifying and ordering will be
required from the manufacturer's information. Normally this would be available
from the catalogue but sometimes it is necessary to communicate directly with a
representative of the company.
SEED Guides Unit Selection - Gearbox < >

3. Types of Gearbox and their Characteristics

In this section a description of the most common types of gearbox available
together with their general characteristics is given. Typical ranges of main
parameters are shown purely for preliminary guidance. It should be noted that it is
possible to obtain composite boxes, which combine the characteristics of two or
more types, or compound boxes, which increase the speed ratio by compounding
two or more stages of the same type. Both these extensions would be at the
expense of simplicity, weight, cost and mechanical efficiency.
The classification of types is usually on the basis of shaft orientation or speed ratio.
Figure 2 shows the shaft orientations available for the gearbox types covered in
this Guide.
PARALLEL SHAFTS PERPENDICULAR SHAFTS SKEWED SHAFTS
SPUR
BEVEL CROSSED HELICAL
HELICAL
WORM
EPICYCLIC
SPIROID
Figure 2 Classification of Gearbox Types according to Shaft Geometry
SEED Guides Unit Selection - Gearbox < >
4. General Characteristics
A gearbox consists of a means of transmitting mechanical torque between two
shafts with structural support between them. Normally it is contained within a
casing which would provide the structural support and also have containment and
safety functions.
Most gearboxes are designed for speed reduction though some may be suitable for
speed increasing duties. Some types are not suitable for reverse driving and the
system may require the prevention of 'over-running'.
Shafts are usually provided with a means of accepting and delivering torque in the
form of a keyway or splines suitable for connecting to a coupling or to another
unit. Shafts will have a limited protrusion from the casing.

Figure 3 Typical Features of a Gearbox Casing

Figure 3 shows typical features of a gearbox CASING which performs several
functions:
 structural support of the shaft bearings and hence the gear loadings;
 transfer of torque reaction to supporting structure or further drive element;
 containment of lubricant and exclusion of foreign matter;
 provision of safety and noise barrier;
 dissipation of heat generated by friction;
 unitisation of assembly, thus aiding testing, installation, and maintenance;
 enhancement of visual qualities;
Casings are generally cast or fabricated in ferrous or light alloys and an important
consideration in casing design is shaft orientation. Although gearboxes are usually
designed to be as compact as possible the overall dimensions and location of
mounting positions will vary widely between manufacturers.
Casings must be accurately located and securely fastened to their foundations in
order to maintain rigidity in support and safety and reliability in operation. They
must also be suitably ventilated to allow dissipation of heat.
The main PERFORMANCE AND GEOMETRICAL factors concerning gearboxes
covered in this Guide are shown in Figure 4.

Spur gearboxes contain spur gears which have teeth cut parallel to the shaft axis
and are only suitable for parallel shaft applications. However they facilitate the
arrangement of a sliding gear ratio change. Input and output shafts may be
arranged on the same side of the casing or opposite sides. For concentric input and
output shafts an internal 'layshaft' is needed.
Spur boxes may have single or compound ratios but for each stage the speed
reduction is limited to about 6A. The highest peripheral speed of a spur gear is also
limited, because of noise generation, to about 20 m/s. This limits the input
rotational speed according to gear size.
Helical gearboxes have many characteristics which are identical to spur boxes, but
as a result of tooth form their performance is enhanced in terms of power, speed
ratio and peripheral speed. Their mechanical efficiency is marginally inferior due
to a greater sliding contact at the gear tooth faces but this is rarely a problem. They
are not suitable for a sliding gear change.
Epicyclic gearboxes are a versatile arrangement of spur or helical gears in which
the input and output shafts are concentric and either shaft or the casing may be
constrained to be the stationary element, the torque being transmitted between the
other two. The three main elements are thus a 'sun' gear, a 'ring' gear and a number
of 'planet' gears meshing with both.
Wide ranges of speed ratio are obtainable from a given set of elements and very
large reductions result from compounding stages. They tend to have high
power/weight and power/bulk ratios and are available for a wide range of powers.
Harmonic drives consist of a gearbox which allows two gears with a large number
of teeth to rotate such that a third element rotates according to the difference
between the numbers of teeth on the gears.
Torque capacity is high in relation to bulk and weight, speed ratios range between
60:1 and 250:1 and mechanical efficiency between 70% and 85%. Backlash is very
small and can be totally eliminated with special units.
Bevel gearboxes are used for drives where shafts are not parallel but whose axes
intersect. The most common intersection angle is 90š but other angles are possible.
A right angle drive with a 1:1 speed ratio is sometimes called a 'mitre' box.
Either straight cut or spiral bevel gears may be specified depending on the power,
speed and speed ratio. It is possible to specify a variety of shaft arrangements with
more than one output shaft if geometry demands and permits.
Worm gearboxes allow high ratios of speed reduction within a single stage
coupled with non-parallel, non-intersecting shafts. Reverse drive is not normally
permissible and under some circumstances positive locking of reverse drive results.
The high proportion of tooth sliding results in heat generated so casings are often
provided with 'fins' to enhance heat dissipation. There is a consequential reduction
in mechanical efficiency.
Spiroid gearboxes perform a similar function to worm boxes but the gears have
characteristics which combine those of the bevel and worm gears. High powers and
speed ratios are possible and mechanical efficiencies higher than worm boxes for
equivalent ratios.
Crossed helical gearboxes are the general case of which worm boxes are a special
case. They contain helical gears which are designed to mesh between shafts which
are skewed but do not intersect. The speed ratio depends on the helix angle of both
gears, which may be different, and within the range 0š to 90š. The sum of the
individual helix angles must be equal to the shaft skew angle.
Power capacity of crossed helical gears is severely limited and they are often found
on auxiliary drive trains. Mechanical efficiency is also significantly inferior to
helical boxes so heat generation can be a problem.

5. Factors Affecting Gearbox Selection

Two factors which have an strong influence on the choice of gearbox for a given
application are:
 purpose for which the gearbox is required in the context of the total system;

 quality of the gearbox, which is a function of purpose and which, in turn,

affects the commercial context. Quality may be 'general purpose', 'precision',
or 'super-precision' affecting the materials used, the manufacturing and
assembly techniques employed and the cost. The quality chosen should be
only be as high as is necessary to satisfy system requirements.
Other factors, many of which are inter-related, may be classified in groups under
the following headings and are summarised in Figure 5.
 Commercial
Commercial factors are both the most significant and the most difficult the
establish. The quantity required will strongly relate to price. The commercial life
of the product may also affect choice since a product known to be old and likely to
be replaced would be an inferior choice for a system requiring a long service life.
Convenience in purchase and manufacturer's reputation are subjective and
difficult to quantify but may have a disproportionate effect on the final choice. The
former relates to the availability of catalogue information, access to
representatives, method of ordering, conditions of purchase etc. The latter involves
the experience of the designer and the advice he receives.
Although most gearboxes do not contribute greatly to the overall visual impact of
the system, the aesthetics of appearance should not be ignored. In many domestic
applications the shape of the box may be a significant factor.
Performance
Performance factors relate to what is normally the primary function of the
gearbox - the transmission of torque. The inter-related factors of power capacity,
torque capacity, and speed limitation will have a strong influence on the choice.
These requirements are related to the system output (i.e.: the demand of the driven
machine). The nominal torque requirement should be increased by applying a
service factor to reflect the duty conditions and the driving and driven machine
types. Figure 6 gives some guidance in choosing a suitable service factor.

Speed ratio with output speed (or both input and output speed) must also be
influential and are controlled by the 'up-stream' elements of the system.
Gearboxes are (nominally) constant power devices so speed is inversely
proportional to torque. Thus high speed and high torque occur at opposite ends of
the unit. The duty cycle in terms of torque and speed should be established since it
will affect maintenance schedules and long term life.
Secondary functional factors involve the requirement to support loads other than
torque. Radial and axial loads on the shafts will be a limiting factor in many
gearboxes. These may arise from other system elements such as belt drives and
couplings as well as the driven machine itself.
Typical duty categories are:
Light Duty: centrifugal fans, blowers, fans, light conveyors;
Medium Duty: conveyors, mixers, machine tools, positive displacement pumps;
Heavy Duty: reciprocating compressors, hammer mills, punches, presses;
Extra Heavy Duty: crushers, hoists, lifts.
The structural integrity of the casing including its rigidity and strength should be
considered. Normally proprietary gearboxes will be adequate for all general
purpose applications and data will be difficult to obtain but in special cases it will
be necessary to consider this factor.
An extension of the casing is the structure on which it is mounted and this must
also be checked to ensure that it will provide the strength and stiffness necessary to
resist torque and withstand radial and axial loads applied to the unit.
Thirdly such concerns as reversibility of drive, the torque required for back-
driving (or over-running) and inertia should be considered. Sometimes it is
important that the system cannot be over-driven by the inertia of the load, while
for other systems such driving results in torques which are much higher than the
nominal system torque. The inertia of the load will affect both these and the
acceleration of the system. In some cases the inertia of the gearbox may be
significant in the system.
Finally energy based factors such as efficiency, related to heat generation, noise
and backlash should be considered. It must be remembered that single stage
gearbox efficiencies may vary between 92% and only 50%. Low efficiencies imply
the generation of large quantities of heat which must be dissipated and could be an
important consideration. Noise is usually associated with speed, power and the
accuracy and form of the gear teeth. Backlash, the torsional flexibility of the
shafting and the circumferential clearance between gear teeth, all of which are
normally very small, are nevertheless significant for some systems. Some gearsets
can be arranged to have zero backlash but all arrangements will exhibit shaft
flexibility and tooth clearance.
lnstallation
Installation requirements include a number of important factors. The general ease
of installation involves the shape, weight and size of the casing including features
which aid lifting, manouvering and securing.
The orientation of shafts, their positions and their directions of rotation are
related to the function of the system and it is necessary to ensure that the
requirements can be met.
The relationship of the gearbox with its supporting structure is an important
consideration. This involves the type of mounting arrangement and its orientation,
the accuracy of location or provision for adjustment and the effect of the gearbox
on the structure itself (e.g.: the transmission of vibration or heat).
The box may also affect other system elements such as couplings used, the space
available and their orientation.
Operation
Operation of gearboxes over a long service life with minimum maintenance,
especially when duties are light, is not uncommon. However provision for in-
service maintenance and/or repair should be considered.
While it is possible to run some non-metallic gears without lubricants all gearsets
benefit from lubrication in terms of efficiency, thus generating less heat, longer
life and lower wear rate. The lubrication system used will depend on the
performance of the unit and its required service life as well as the lubrication
requirements of the rest of the system. It is usually contained within the unit but
may be served by an external system.
Convenience in performing maintenance and repair tasks, involve accessibility,
the need for special tools, schedules for regular maintenance, ease of in-situ
reassembly and the consequences of system shut-down.
In applications where continuous running is critical to safety, or where other
factors justify the cost, condition monitoring equipment may be considered. By
detecting wear, noise or malfunction timely maintenance can be applied thus
avoiding a dangerous or costly failure.
Environment
Environmental factors involve the entire context of the unit in use, relating to
functional, installation and operational requirements.
Firstly the shape and size of the space available for installation should be
considered. This relates to the ease of installation and accessibility as detailed
above- The load capacity of the support may also be important, particularly when
the gearbox is not mounted on a horizontal surface or when the material is weak.
Secondly the ambient air conditions must be considered with regard to both
temperature and humidity. Since heat is generated from even the most
mechanically efficient gearbox there will be a need for heat dissipation which is a
function of both of these. This requirement can be quantified and provision made
so that the maximum permitted temperature is not exceeded.
The maximum permitted temperature will be specified in relation to a standard
ambient temperature. It should be noted that increasing altitude reduces heat
dissipation rates since air density decreases. Significant increases in altitude (>
1000m) should be taken into account.
Humidity could be a factor in heat dissipation but more commonly is associated
with the possibility of corrosion, particularly if the gearbox is left unused for long
periods of time.
Finally the effect of gearbox failure (which may take a variety of forms) on the
system itself, on the immediate environment and on the general environment must
be considered

December 09, 2003

Sizing gear reducers

Base your decision on application torque requirements
By Chris Spees and Keith Taliaferro
September 13, 2002
How do you select a gear reducer for your power transmission application? In recent
years, many purchasers have selected replacement gear reducers simply on a size-to-
size basis. As a result, they are missing opportunities to optimize gear drives and
reduce cost. For example, technological advances have improved gear reducer power
density, making it possible to use smaller, more economical gear units.

Selecting a replacement
Replacement gear reducers can be based on size-for-size, output power or application
requirements.

The size-for-size replacement is the simplest approach. However, it misses the

opportunity to downsize the drive and cut cost. For example, newer worm reducers
have higher power ratings, efficiency and reliability.

Matching output power is also a quite simple approach. It assumes that the same speed
motor and same gear ratio reducer are required. The replacement unit must have an
output power (or torque) rating equal to or greater than the existing unit. The overhung
load capacity of the replacement unit must exceed the actual overhung load. The
approach may result in selecting a gear reducer that's smaller and more economical
than the existing unit.

The application approach is the most rigorous. It requires determining required output
power (torque), output shaft rpm, service factor and overhung load. Although
demanding, it provides the best chance for selecting a smaller, more economical gear
reducer.

Gearbox efficiency
As a gear reducer transmits power from the input to output shaft, it also increases
torque and reduces speed. The power and torque delivered depends on gearbox
efficiency. Some power is lost because of component friction within the gearbox.
Gearbox efficiency is defined:
Efficiency = (output power) / (input power)

Gearbox selection process

Follow four steps when selecting a reducer replacement.
• Determine required output power, or torque.
• Determine required reducer output speed.
• Determine the application service factor.
• Determine the overhung load on reducer output shaft.

Determining output power

Gear applications are classified as either constant or variable torque. Constant torque
applications require a specific torque over a range of speeds. Conveyors fit into this
category. For example, a package handling roller bed conveyor uses a rubber belt
supported by rollers. The weight of the packages creates a force on the belt, which
results in friction between belt and rollers. A force, called belt pull, must overcome this
friction and move the belt. The gear drive provides torque to the drive pulley, to power
the belt. The required torque (lb.inch) to drive the conveyor is equal to the belt pull
(lbs) multiplied by the drive pulley radius (in.).

In variable torque applications, torque increases with speed. A fan is a variable torque
application. When started, the torque must overcome the inertia of the fan blades. As it
accelerates, torque requirements increase. For the fan, the required torque is
proportional to the cube of its speed.
If the actual output torque, or output power of the load, is not known, the existing gear
reducer's output hp or torque ratings may be used to select a new gear reducer.

Determining required output speed

For conveyors drives with direct-coupled or shaft-mounted gearboxes, reducer output
rpm is calculated as:
Rpm = 3.82*S/D
Where RPM = output speed
S = belt speed (ft. per min.)
D = pulley diameter (inches)

When sizing a replacement gear reducer, it's necessary to consider the

required output power, output speed, overhung load and the application service
factor.

Determining service factor

The service factor is a multiplier applied to the drive's motor horsepower that accounts
for the severity of the duty that a gear reducer experiences in a specific application. For
example, if a gear reducer has uniform loads with few stops and starts and runs less
than eight hours, the service factor will be 1 or slighter greater. If it has relatively
uniform loads and runs up to 10 hours per day, such as a conveyor drive, the service
factor may be rated at 1.25. For applications with severe duty, such as shock loads or
frequent stops and starts, a service factor of 2.0 or more may be warranted.

Gearbox manufacturers publish service factor tables that are readily available.

Determining overhung loads

If a belt drive or chain drive is mounted on a gearbox output shaft, an overhung load
(belt pull or chain pull) is imposed on the shaft. It must be calculated and compared to
allowable overhung load published by the gear reducer manufacturer.
Analyzing the application's actual power (torque) requirements may allow users
to deploy smaller, less expensive drive packages.

Applying the guidelines

XYZ Co. produces chemicals packaged in five-gallon pails. A 40-ft. long belt conveyor
feeds a palletizer that packages the pails. The motor and gear reducer are generating
noise and need to be replaced. The existing drive is a three hp motor with a single
reduction worm gear reducer shaft mounted directly to the conveyor head pulley.

The reducer's nameplate information is:

Input hp rating max (@ 1,750 rpm). = 4.6 hp
Output torque rating max. = 2,776 in-lb
Gear ratio 20:1
Gearing center distance = 3.5 inches
Efficiency = 0.83

It could be replaced with an identical 3.5 center distance unit; however, another option
should be considered.

Actual hp requirements can be determined by checking the motor's current draw with
an ammeter and comparing the reading to the motor's nameplate. In this example, the
motor measures 4.6 amps, the same as the nameplate's amperage. Therefore, it's
delivering three hp to the conveyor.

Calculate output torque, or output hp, of the current unit:

Output hp = input hp * reducer efficiency

Output torque = [Input hp * 63,025/ (reducer output rpm)]*efficiency.

(Note that this example will continue using torque as the selection parameter. A
 reducer also could be selected based on an output hp rating that meets the application
requirements.)

Output torque = [3 hp*63,025/ (1,750/20)]*0.83=1,728 in-lb

The original reducer had a 1.5 service factor (2,776 in-lb) / (1,794 in-lb). However, this
application would normally require only a 1.25 service factor. Therefore, the required
output torque is 1.25*1,794=2,243 in-lb.

Because only 2,243 in-lb of output torque is needed, a smaller, more power dense,
single-reduction, worm-gear design, can be selected:

Input hp rating max (@ 1,750 rpm) = 3.74 hp

Output torque rating max = 2,345 in-lb

Gear ratio 20:1

Gearing center distance = 3.0 inches

Efficiency = 0.87

Analyzing the application's actual power (torque) requirements may allow users to
deploy smaller, less expensive drive packages. Beyond purchase cost savings, the
drives are more compact and lighter in weight, making them easier to service. It pays to
examine the actual power or torque required by application.

Chris Spees is an industry engineer with Rockwell Automation; Keith Taliaferro is a

senior development engineer with Rockwell Automation. For more information call
864-281-2289 or e-mail lktaliaferro@powersystems.rockwell.com.

Photos: Rockwell Automation

Plant Services © 2002 Putman Media