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Ge n e ra l In fo rma t io n Me ch a n ica l Da t a Typ e o f Drive s Ge a rb o x Se le ct io n E xa mp le s o f Ge a rb o x Se le ct io n

P ow er Nre ( kW ) transmitted by the gearbox

Th e p o w e r o f t h e g e a rb o x Nre , is ca lcu la t e d b y mu lt ip lyin g t h e p o w e r re q u ire d fo r t h e d rive n ma ch in e , Nd (kW ), w it h t h e

o p e ra t io n s a fe t y fa ct o r F.
Nre = F . Nd (kW )
O p e ra t io n s a fe t y fa ct o r ca lcu la t io n is e xp la in e d in a s e p a ra t e s e ct io n a n d t h e fa ct o r ca n b e t a ke n fro m t h e t a b le o n p a g e 1 9 .

G earbox input speed n1 ( rpm)

G earbox output speed n2 ( rpm)

Ge a rb o xe s a re g e n e ra lly u s e d fo r s p e e d re d u ct io n . Hig h e r s p e e d o f t h e mo t o r is re d u ce d t o lo w e r s p e e d re q u ire d fo r t h e

d rive n ma ch in e . Ge a rb o x in p u t s p e e d is h ig h e r t h a n o u t p u t s p e e d : n 1 >n 2
Th e s h a ft o f t h e g e a rb o x co n n e ct e d t o t h e mo t o r is in p u t s h a ft a n d t h e s h a ft co n n e ct e d t o t h e d rive n ma ch in e is o u t p u t
s h a ft .
If t h e g e a rb o x is co n n e ct e d t o t h e mo t o r w it h a co u p lin g , t h e in p u t s p e e d is e q u a l t o t h e mo t o r s p e e d .
If t h e g e a rb o x is co n n e ct e d t o t h e mo t o r via a b e lt s ys t e m, t h e in p u t s p e e d o f t h e g e a rb o x ch a n g e s a cco rd in g t o t h e ra t io o f
t h e p u lle ys .

Reduction ratio i = n1 : n2

Th e ra t io o f t h e in p u t s p e e d t o t h e o u t p u t s p e e d is t h e re d u ct io n ra t io .

G earbox type

Th e g e a rb o x t yp e s u it a b le fo r t h e p ro je ct ca n b e ch o s e n fro m o u r p ro d u ct ra n g e s h o w n o n p a g e s 2 1 - 2 6 . Th e re ca n b e mo re
t h a n o n e t yp e o f g e a rb o x s u it a b le fo r t h e s a me jo b . Th e p rice , d e live ry t ime , e a s e o f a s s e mb ly, s p a ce a va ila b le fo r t h e
g e a rb o x a n d o p e ra t in g co n d it io n s p la y a n imp o rt a n t ro le fo r t h e s e le ct io n p ro ce s s . P ro je ct e n g in e e rs s h o u ld s e le ct t h e t yp e
o f g e a rb o x in t h e p ro je ct p h a s e .
At lo w p o w e r ra n g e s , mo t o r g e a rs a re p re fe rre d fo r e co n o mica l a n d e a s y mo u n t in g re a s o n s .

G earbox mounting positions ( O peration positions) :

Th e o p e ra t in g p o s it io n s o f mo t o r g e a rs a re la b e le d a cco rd in g t o DIN 4 2 9 5 0 a n d a re s h o w n o n p a g e 2 0 .
Th e o p e ra t in g p o s it io n s o f fo o t mo u n t e d g e a rb o xe s w it h mo t o r a re B3 - B6 - B7 - B8 - V5 a n d V6 . Th e o p e ra t in g p o s it io n s o f
fla n g e mo u n t e d g e a rb o xe s w it h mo t o r a re B5 - V1 a n d V3 .

Ge a rb o xe s w it h o u t mo t o r a re p ro d u ce d fo r s p e cific o p e ra t in g p o s it io n s . Th e o p e ra t in g p o s it io n s a re s p e cifie d in d ime n s io n

pages.
Sp e cia l o p e ra t in g p o s it io n s s h o u ld b e s t a t e d d u rin g t h e o rd e r.

Mounting positions of shafts

Th e in p u t a n d o u t p u t s h a ft s o f g e a rb o xe s ca n b e a rra n g e d in d iffe re n t p o s it io n s . Th e mo u n t in g p o s it io n s o f t h e s h a ft s a re
s h o w n in d ime n s io n p a g e s fo r e a ch g e a rb o x t yp e .
Fo r e xa mp le , t h e in p u t a n d o u t p u t s h a ft s o f DA2 mo d e l p a ra lle l s h a ft g e a rb o x ca n b e a rra n g e d in fo u r d iffe re n t p o s it io n s .
Th e s e a re re s p e ct ive ly; w it h rig h t in p u t – le ft o u t p u t , w it h le ft in p u t – rig h t o u t p u t , w it h rig h t in p u t – rig h t o u t p u t , a n d w it h
le ft in p u t – le ft o u t p u t .
Th e re q u e s t e d mo u n t in g p o s it io n s fo r t h e s h a ft s o f g e a rb o x w it h o u t mo t o r s h o u ld b e s t a t e d d u rin g o rd e r a cco rd in g t o t h e
d e s crip t io n s o n d ime n s io n p a g e s .

S pecial requirements

Th e g e a rb o x ca n b e e q u ip p e d w it h b a cks t o p , e le ct ro ma g n e t ic b ra ke o r e le ct ro ma g n e t ic co u p lin g .
Th e d ia me t e rs a n d le n g t h s o f in p u t a n d o u t p u t s h a ft s o f g e a rb o x ca n b e in d iffe re n t d ime n s io n s t h a n g ive n va lu e s o n
d ime n s io n p a g e s . In s o me g e a rb o x t yp e s t h e re ’s a ls o t h e p o s s ib ilit y t o p u t d o u b le in p u t s h a ft s a n d d o u b le o u t p u t s h a ft s . All
s p e cia l re q u ire me n t s s h o u ld b e s t a t e d d u rin g o rd e r.

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Ba ck
Ho me P a g e C o rp o ra t e Ge a rb o x C o u p lin g Ba cks t o p Te ch n ica l In fo rma t io n Re fe re n ce s O rd e r C o n t a ct

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Type of Motor

All t yp e s o f e le ct ric mo t o rs , t u rb in e s , h yd ra u lic mo t o rs , d ie s e l a n d g a s o lin e mo t o rs ca n b e u s e d a s d rive ma ch in e .

Th e e le ct ric mo t o r fo r t h e mo t o r g e a r ca n b e s u p p lie d e it h e r b y u s o r b y t h e cu s t o me r.

The pow er Nm ( kW ) and speed of the motor that w ill driv e the gearbox nm ( rpm)

Th e p o w e r o f t h e mo t o r t o b e co n n e ct e d t o t h e g e a rb o x s h o u ld b e s e le ct e d a s g re a t e r t h a n t h e p o w e r Nd re q u ire d fo r t h e
d rive n ma ch in e . As in g e a rb o x s e le ct io n , t h e mo t o r p o w e r is ca lcu la t e d b y mu lt ip lyin g t h e re q u ire d p o w e r fo r t h e d rive n
ma ch in e b y a ce rt a in s a fe t y fa ct o r. Th is s a fe t y fa ct o r a n d t h e s a fe t y fa ct o r fo r g e a rb o x s e le ct io n d o n o t h a ve t o b e t h e s a me .
It is n o t e co n o mica l t o ch o o s e t h e mo t o r p o w e r g re a t e r t h a n n e ce s s a ry s in ce o p e ra t in g co s t s mig h t in cre a s e d u e t o
e xce s s ive u s e o f e le ct ricit y.

Acco rd in g t o t yp e o f p la n t a n d d a ily w o rkin g h o u rs , t h e mo t o r s a fe t y fa ct o r ca n b e t a ke n b e t w e e n 1 .2 5 a n d 1 .8 .

At t h e t ime o f o rd e r, t h e mo t o r s a fe t y fa ct o r t a ke n o r t h e a ct u a l p o w e r re q u ire d (Nd ) fo r t h e d rive n ma ch in e s h o u ld b e
s ta te d.
Th e id e a l mo t o r s p e e d t o ru n t h e g e a rb o x is 1 5 0 0 a n d 1 0 0 0 rp m. It is n o t re co mme n d e d t o u s e h ig h s p e e d mo t o rs w it h t h e
g e a rb o x. Hig h s p e e d in cre a s e s t h e n o is e le ve l o f t h e g e a rb o x a s w e ll a s d e cre a s e s t h e life t ime o f t h e b e a rin g s a n d g e a rs . If
it is n e ce s s a ry t o u s e a 3 0 0 0 rp m mo t o r, it is re co mme n d e d t o d e cre a s e t h e g e a rb o x in p u t s p e e d t o 1 5 0 0 o r 1 0 0 0 rp m b y
p la cin g a V-b e lt p u lle y b e t w e e n t h e mo t o r a n d t h e g e a rb o x.

Type of coupling connecting motor to gearbox

E la s t ic co u p lin g s , h yd ra u lic co u p lin g s a n d o t h e r s p e cia l co u p lin g t yp e s a n d V-b e lt p u lle ys ca n b e u s e d a s co n n e ct in g
e le me n t s . U s in g rig id co u p lin g s a t g e a rb o x in p u t s h o u ld b e a vo id e d .

External forces on the input shaft of the gearbox from coupling or motor
Th e t yp e (ra d ia l o r a xia l), ma g n it u d e , p o s it io n a n d d ire ct io n o f t h e fo rce s s h o u ld b e s t a t e d .

NEC ES S ARY INFO RMATIO N ABO U T THE DRIVEN MAC HINE

Type of driv en machine
It is ve ry imp o rt a n t t o kn o w t h e t yp e o f d rive n ma ch in e in g e a rb o x s e le ct io n . Th e re a re fo u r ma in g ro u p s :
1 . U n ifo rmly o p e ra t in g ma ch in e s w it h o u t s h o ck lo a d s
2 . Ma ch in e s w it h mo d e ra t e s h o ck lo a d s
3 . Ma ch in e s w it h h e a vy s h o ck lo a d s a n d h ig h mo me n t o f in e rt ia
4 . Ma ch in e s w it h ve ry h e a vy s h o ck lo a d s a n d ve ry h ig h mo me n t o f in e rt ia .

Required pow er Nd ( kW ) to run the machine at full load or torque Td ( N.m) , the speed nd ( rpm) of the machine
Th e re q u ire d p o w e r Nd a n d t h e s p e e d fo r t h e ma ch in e is ca lcu la t e d b y t h e t e ch n ica l s t a ff. Simila r ma ch in e s ca n a ls o b e
t a ke n a s re fe re n ce .

Type of the coupling connecting the gearbox to the driv en machine

E la s t ic co u p lin g s , rig id co u p lin g s , g e a r co u p lin g a n d o t h e r s p e cia l co u p lin g t yp e s , ch a in me ch a n is ms , s p u r g e a rs a n d b e ve l
g e a rs ca n b e u s e d a s co n n e ct in g e le me n t .

External forces on the output shaft of the gearbox from coupling system or driv en machine

Typ e (ra d ia l o r a xia l), ma g n it u d e , p o s it io n a n d d ire ct io n o f t h e fo rce s s h o u ld b e s t a t e d .

O P ERATING C O NDITIO NS

Th e imp o rt a n t fa ct o rs a re : a ve ra g e d a ily o p e ra t io n h o u rs , n u mb e r o f s t o p -s t a rt s w it h in a n h o u r, o p e ra t io n t ime (a s

p e rce n t a g e ) u n d e r lo a d in a n h o u r, w h e t h e r t h e d rive n ma ch in e is lo a d e d u n ifo rmly o r va ria b ly a n d t h e e xt e n t o f s h o ck
lo a d in g (lo w , me d iu m, h ig h ) if t h e ma ch in e is s u b je ct t o s h o ck lo a d in g .

It s h o u ld b e s t a t e d w h e t h e r a flyw h e e l w ill b e p u t t o d e cre a s e t h e e ffe ct o f va ria b le lo a d s a n d s h o ck lo a d in g . If a flyw h e e l

w ill b e a d d e d , t h e ma s s mo me n t u m o f t h e flyw h e e l a n d o t h e r t e ch n ica l s p e cifica t io n s s h o u ld b e co n s id e re d .

ENVIRO NMENTAL C O NDITIO NS

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Th e imp o rt a n t fa ct o rs a re : lo w e s t a n d h ig h e s t a ve ra g e t e mp e ra t u re s o f t h e p la ce w h e re t h e g e a rb o x w ill o p e ra t e , w h e t h e r
t h e g e a rb o x w ill w o rk in a co ve re d p la ce o r o p e n a ir, w h e t h e r t h e re is e xce s s ive d u s t , mo is t u re , w a t e r o r a h e a t s o u rce t o
e ffe ct t h e g e a rb o x a t t h e o p e ra t io n p la ce .

C O O L ING P O S S IBIL ITIES

Th e imp o rt a n t fa ct o rs a re : if a fo rce d co o lin g s ys t e m is n e e d e d , w h e t h e r t h e re is t a p w a t e r, w e ll w a t e r o r o t h e r s o u rce o f

w a t e r a n d t h e t e mp e ra t u re o f t h e w a t e r t o b e u s e d .

Ba ck
Ho me P a g e C o rp o ra t e Ge a rb o x C o u p lin g Ba cks t o p Te ch n ica l In fo rma t io n Re fe re n ce s O rd e r C o n t a ct

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G ears

He lica l s p u r g e a rs a n d h e lica l b e ve l g e a rs a re p ro d u ce d fro m ca s e h a rd e n e d s t e e l. Aft e r t h e ma ch in in g o p e ra t io n s o f t h e

g e a rs (la t h in g , t h re a d cu t t in g , b u rrin g a n d ke yw a y cu t t in g ), h e a t t re a t me n t o p e ra t io n is p e rfo rme d in o rd e r t o a t t a in t h e
re q u ire d ce me n t a t io n d e p t h a n d a 5 8 -6 0 HRC s u rfa ce h a rd n e s s . Aft e r t h e h e a t t re a t me n t p ro ce s s , t h e b e a rin g s u rfa ce s o f
t h e g e a r s h a ft s , g e a r b o re s a n d t e e t h p ro file s a re g rin d e d . W it h p ro file s h ift in g o n t h e g e a rs , t h e u n d e rcu t t in g o n t h e p in io n
g e a rs a re p re ve n t e d . Te e t h p ro file g rin d in g p ro ce s s e n s u re s q u ie t o p e ra t io n o f t h e g e a rb o x.

S hafts

Th e in p u t s h a ft s o f t h e g e a rb o xe s a re u s u a lly p in io n g e a r s h a ft s . In t h is ca s e , in p u t g e a r s h a ft ma t e ria l is ca s e h a rd e n e d
s t e e l. If t h e p in io n g e a r o n t h e in p u t s h a ft is s h a ft mo u n t e d , t h e in p u t s h a ft ma t e ria l is C 4 5 q u a lit y s t e e l.

Th e o u t p u t s h a ft s o f t h e g e a rb o xe s a re p ro d u ce d fro m C 4 5 ma t e ria l a s w e ll. Th e in p u t a n d o u t p u t s h a ft s a re g rin d e d w it h k6

t o le ra n ce u n t il Ø 5 0 mm d ia me t e r a n d w it h m6 t o le ra n ce fo r d ia me t e rs g re a t e r t h a n Ø 5 0 mm. Th re a d e d ce n t e rin g a n d
d is ma n t lin g h o le s a re b o re d in t o t h e s h a ft e n d s a cco rd in g t o DIN 3 3 2 . Th e ke ys a n d ke yw a ys o n t h e in p u t a n d o u t p u t s h a ft s
a re ma ch in e d a cco rd in g t o DIN 6 8 8 5 /1 . Th e ke ys o f t h e in p u t a n d o u t p u t s h a ft s a re s u p p lie d w it h t h e g e a rb o x.

Bearings

Ta p e re d ro lle r o r cylin d rica l ro lle r b e a rin g s a re u s e d in s h a ft s a n d g e a r b e d s . Th e b e a rin g s e le ct io n is ma d e t o e n s u re a

life t ime o f a t le a s t 5 0 ,0 0 0 h o u rs .

Housing

Ho u s in g is GG 2 0 q u a lit y g re y ca s t iro n . Ho u s in g ca n b e p ro d u ce d w it h GGG-4 2 q u a lit y s p h e ro ca s t iro n u p o n re q u e s t . Sp e cia l

d e s ig n g e a rb o x h o u s in g s a re p ro d u ce d w it h w e ld e d co n s t ru ct io n s t e e l.

O il fillin g a n d d ra in in g p lu g s a n d o il le ve l in d ica t o rs a re p re s e n t o n t h e h o u s in g . So me mo d e ls h a ve in s p e ct io n lid s t o s e e t h e

g e a rs in s id e . Fo r h e a vy g e a rb o xe s , lift in g rin g s a re p la ce d t o e a s e h a n d lin g . Th e o il fillin g p lu g s o f t h e g e a rb o x a ls o fu n ct io n
a s ve n t ila t io n h o le s .

S ealing

Th e s e a lin g b e t w e e n t h e h o u s in g a n d co ve rs a re a t t a in e d w it h liq u id g a s ke t s a n d t h e s e a lin g o f t h e in p u t a n d o u t p u t s h a ft s

is a t t a in e d w it h ru b b e r o il s e a ls .

S haft C onnections

Th e g e a rb o x o u t p u t s h a ft s ca n b e co n n e ct e d t o t h e d rive n ma ch in e w it h e la s t ic o r rig id co u p lin g s , s p u r g e a rs o r s p ro cke t

s ys t e ms .
In ca s e o f co n n e ct in g w it h co u p lin g s , fin e a d ju s t me n t o f t h e s h a ft a xis a n d t h e min imiz a t io n o f t h e a n g u la r a n d lin e a r
mis a lig n me n t b e t w e e n t h e s h a ft a xis a re n e ce s s a ry t o e n s u re a n o p e ra t io n w it h o u t vib ra t io n a n d t o p ro lo n g t h e life t ime o f
t h e s h a ft s , b e a rin g s a n d co u p lin g s . In ca s e o f co n n e ct in g w it h g e a rs , t h e s h a ft s s h o u ld b e p a ra lle l a n d t h e g e a rs s h o u ld
co n t a ct e a ch o t h e r a lo n g t h e t e e t h s u rfa ce .
It is co n ve n ie n t t o co n n e ct t h e in p u t s h a ft s t o t h e mo t o r w it h b e lt s , e la s t ic, h yd ra u lic o r e le ct ro ma g n e t ic la me lle d co u p lin g s .
In ca s e o f co n n e ct in g w it h co u p lin g s , t h e s h a ft s s h o u ld b e co a xia l. In ca s e o f co n n e ct in g w it h b e lt s , t h e s h a ft s s h o u ld b e
p a ra lle l t o s e cu re a n o p e ra t io n w it h o u t vib ra t io n a n d a lo n g life t ime fo r t h e co n n e ct in g e le me n t s , t h e mo t o r a n d g e a rb o x
s h a ft b e a rin g s .

L ubrication
O il b a t h s p la s h lu b rica t io n is a p p lie d fo r g e a rb o xe s w o rkin g in h o riz o n t a l p o s it io n . If t h e t ra n s mis s io n p o w e r is clo s e t o t h e
t h e rma l p o w e r limit s o r a b o ve it ; fo rce d lu b rica t io n s ys t e m is a p p lie d . In ca s e s w h e re n e ce s s a ry, fo rce d a ir-co o le d lu b rica t io n
s ys t e m is u t iliz e d .
Ve rt ica l o p e ra t in g g e a rb o xe s a re lu b rica t e d w it h o il b a t h me t h o d a s w e ll; h o w e ve r, s in ce s p la s h me t h o d is n o t p o s s ib le , t h e
o il le ve l s h o u ld b e a lmo s t o r co mp le t e ly fu ll.

Fo r t h e ve rt ica l o p e ra t in g g e a rb o xe s , a n a lt e rn a t ive me t h o d o f lu b rica t io n is fo rce d lu b rica t io n . Th e g e a rs a n d b e a rin g s a t

t h e h ig h e s t le ve l o f t h e g e a rb o x a re lu b rica t e d d ire ct ly b y s p ra yin g o il, e limin a t in g t h e n e e d t o lo a d t h e g e a rb o x fu lly w it h
o il. Th is p re ve n t s p ro b le ms re g a rd in g h e a t in g o r s p illin g o ve r o f t h e o il.

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Efficiency

A p o w e r lo s s o f 1 .5 % o ccu rs a t e a ch re d u ct io n s t a g e o f a g e a rb o x u n it w it h h e lica l s p u r g e a rs . Fo r a g e a rb o x u n it w it h
h e lica l b e ve l g e a rs , t h e p o w e r lo s s is b e t w e e n 2 .5 -3 % a t e a ch s t a g e .

Fo r w o rm g e a re d u n it s , p o w e r lo s s ra n g e s b e t w e e n 5 % - 5 0 % d e p e n d in g o n t h e t h re a d n u mb e r, t h re a d a n g le , in p u t s p e e d
a n d t h e q u a lit y o f t h e ma t e ria l a n d ma ch in in g o f t h e w o rm g e a r p a ir.

Acco rd in g ly, e fficie n cy fa ct o r fo r h e lica l s p u r g e a r u n it s ca n b e t a ke n a s fo llo w s :

Sin g le re d u ct io n (1 g e a r p a ir) g e a rb o x: 9 8 .5 %
Do u b le re d u ct io n (2 g e a r p a irs ) g e a rb o x: 9 7 %
Trip le re d u ct io n (3 g e a r p a irs ) g e a rb o x: 9 5 .5 %
Q u a d ru p le re d u ct io n (4 g e a r p a irs ) g e a rb o x: 9 4 %.

Dyeing

Th e in n e r s u rfa ce s a re d ye d w it h g ro u n d co a t s , t h e o u t e r s u rfa ce s a re d ye d w it h g ro u n d co a t a n d t w o fin is h in g co a t s .

Q uality control

U p o n a s s e mb ly, t h e g e a rb o x is o p e ra t e d w it h o u t lo a d a n d fo llo w in g in s p e ct io n s a re d o n e t o e n s u re ;
• Th e g e a rb o x o p e ra t e s w it h o u t n o is e a n d vib ra t io n ,
• Th e o il le ve l is s u fficie n t ,
• Th e re is n o o il le a ka g e fro m o il s e a ls a n d co ve rs .
Aft e r q u a lit y in s p e ct io n , t h e g e a rb o x is d e live re d re a d y t o o p e ra t e t o g e t h e r w it h ma in t e n a n ce in s t ru ct io n s .

G earbox selection

Firs t o f a ll, g e a rb o x s e le ct io n is ve ry imp o rt a n t t o e n s u re a fla w le s s o p e ra t io n a n d a lo n g life t ime . To ma ke t h e rig h t

s e le ct io n , re q u ire d t e ch n ica l in fo rma t io n a n d o p e ra t in g co n d it io n s fo r t h e g e a rb o x s h o u ld b e p ro vid e d d u rin g t h e o rd e r
p ro ce s s .

Th e mo s t a p p ro p ria t e g e a rb o x is s e le ct e d t a kin g in t o co n s id e ra t io n t h e t e ch n ica l in fo rma t io n a n d o p e ra t in g co n d it io n s s t a t e d

b e lo w . Th e s e le ct io n ca n b e ma d e e it h e r b y t h e t e ch n ica l s t a ff o f t h e co mp a n y w h ich w ill b e u s in g t h e g e a rb o x o r b y o u r
t e ch n ica l s t a ff u p o n t h e s u b mis s io n o f t h e n e ce s s a ry in fo rma t io n . If t h e re is mo re t h a n o n e g e a rb o x mo d e l a d e q u a t e fo r t h e
jo b o r p ro je ct , t h e mo s t e co n o mica l o p t io n is s e le ct e d .

Ge a rb o x s e le ct io n is b a s e d o n t h e fo llo w in g crit e ria :

• Me ch a n ica l d a t a o f t h e g e a rb o x
• Typ e a n d s p e cifica t io n s o f t h e d rivin g mo t o r
• Typ e a n d s p e cifica t io n s o f t h e d rive n ma ch in e
• O p e ra t in g co n d it io n s
• E n viro n me n t a l co n d it io n s
• C o o lin g p o s s ib ilit ie s

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Ge n e ra l In fo rma t io n Me ch a n ica l Da t a Typ e o f Drive s Ge a rb o x Se le ct io n E xa mp le s o f Ge a rb o x Se le ct io n

G EARBO X S EL EC TIO N

Aft e r a b o ve me n t io n e d crit e ria a re co n s id e re d , g e a rb o x s e le ct io n w ill b e d o n e in t w o s t a g e s :

1 ) Se le ct io n o f g e a rb o x t yp e
2 ) De t e rmin in g t h e s iz e o f t h e s e le ct e d g e a rb o x t yp e

S election of G earbox Type

Th e g e a rb o x t yp e s u it a b le fo r t h e d rive n ma ch in e is d e t e rmin e d d u rin g p ro je ct p h a s e . Th e t e ch n ica l s t a ff d e s ig n in g t h e

p ro je ct d e cid e s o n t h e t yp e o f g e a rb o x a cco rd in g t o h is p a s t e xp e rie n ce s o r e xa min in g a p p lica t io n s d o n e b e fo re .

Fo r s ys t e ms re q u irin g le s s p o w e r, mo t o r g e a rs a re t h e re co mme n d e d s o lu t io n . Mo t o r g e a rs a re le s s e xp e n s ive a n d a re e a s ily

mo u n t e d . Sh a ft mo u n t e d g e a rb o xe s a re a ls o p re fe rre d d u e t o s a me re a s o n s .

Th e g e a rb o x t yp e s p ro d u ce d b y o u r co mp a n y a re lis t e d s ch e ma t ica lly o n p a g e s 2 1 - 2 6 . O n t h e s e t a b le s , g e a rb o x

t ra n s mis s io n ra t io s , p o w e rs a n d s u mma ry in fo rma t io n o n g e a r s ys t e ms a re g ive n .

Determining the size of the selected gearbox

Ge a rb o x s iz e ca n b e d e t e rmin e d w it h t h e h e lp o f t h e g e a rb o x p o w e r t a b le s . Fo r e a ch g e a rb o x t yp e a s e p a ra t e p o w e r t a b le
is la id o u t . Th e t a b le s h o w s t h e ma ximu m p o w e r (kW ) a g ive n g e a rb o x s iz e ca n t ra n s mit a cco rd in g t o t h e in p u t s p e e d a n d
t ra n s mis s io n ra t io . Th e o u t p u t t o rq u e t h e g e a rb o x ca n t ra n s mit is a ls o g ive n in a s e p a ra t e t a b le .

Th e p o w e r a n d t o rq u e va lu e s g ive n in t a b le s a re n o min a l va lu e s . Th e p o w e r a n d t o rq u e n e e d e d fo r t h e d rive n ma ch in e

s h o u ld b e le s s t h a n t h e n o min a l p o w e r a n d t o rq u e t h e g e a rb o x ca n t ra n s mit s o t h a t t h e g e a rb o x ca n o p e ra t e a t a ce rt a in
s a fe t y.

Th e p o w e r Nre , t h e g e a rb o x s h o u ld t ra n s mit , is d e t e rmin e d b y mu lt ip lyin g t h e p o w e r Nd n e e d e d fo r t h e d rive n ma ch in e b y

t h e o p e ra t io n s a fe t y fa ct o r. Th e n o min a l p o w e r o f t h e s e le ct e d g e a rb o x s h o u ld b e e q u a l t o o r mo re t h a n t h e Nre va lu e .

P le a s e fin d b e lo w t h e me t h o d t o ca lcu la t e t h e o p e ra t io n s a fe t y fa ct o r.

O peration safety factor ( F) :

C o e fficie n t s d e t e rmin in g t h e fa ct o r:

1) Th e co e fficie n t fo r the d rive n ma ch in e , fd

2) Th e co e fficie n t fo r the d rivin g mo t o r, fm
3) Th e co e fficie n t fo r the d a ily o p e ra t io n t ime , ft
4) Th e co e fficie n t fo r the s t a rt -u p n u mb e r, fs

O p e ra t io n s a fe t y fa ct o r F is a t t a in e d b y mu lt ip lyin g t h e fo u r co e fficie n t s :
F = fd . fm . ft . fs

The driv en machine coefficient ( fd)

Th is co e fficie n t d e p e n d s o n t h e t yp e o f d rive n ma ch in e . Drive n ma ch in e s ca n b e cla s s ifie d in fo u r ma in g ro u p s a cco rd in g t o

t h e ir le ve l o f s h o ck lo a d in g a n d mo me n t o f in e rt ia .

U niformly operating machines w ithout shock loading: Fo r ma ch in e s w it h co n s t a n t p o w e r d e ma n d , w h ich o p e ra t e w it h o u t

s h o ck lo a d in g a n d w it h o u t s u d d e n mo me n t in cre a s e , t h e co e fficie n t fd is t a ke n a s 1 .

Machines w ith medium shock loading: Fo r ma ch in e s w h ich o p e ra t e w it h me d iu m s h o ck lo a d in g a n d w h e re lo a d in cre a s e s o r

d e cre a s e s b y a t mo s t 5 0 % , t h e co e fficie n t fd is t a ke n a s 1 .5 .

Machines w ith heav y shock loading and high moment of inertia: Fo r ma ch in e s w it h h ig h in e rt ia w h ich o p e ra t e w it h h e a vy

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s h o ck lo a d in g a n d w h e re lo a d in cre a s e s o r d e cre a s e s b y a t mo s t 1 0 0 % , t h e co e fficie n t fd is t a ke n a s 2 .

Machines w ith v ery heav y shock loading and v ery high moment of inertia: Th e co e fficie n t fd is t a ke n a s 2 .5 -3 fo r t h is
g ro u p .

Th e t yp e s o f ma ch in e s w it h in t h e s e fo u r ma in g ro u p s a re g ive n in o p e ra t io n s a fe t y fa ct o r t a b le .

Driv ing motor coefficient ( fm )

Th is co e fficie n t is d e t e rmin e d a cco rd in g t o t h e t yp e o f mo t o r d rivin g t h e s ys t e m. Th e re a re t h re e ma in g ro u p s :

1 .Gro u p : E le ct ric mo t o rs (As yn ch ro n o u s , s yn ch ro n o u s , d ire ct cu rre n t mo t o rs ), s t e a m t u rb in e s , h yd ra u lic mo t o rs . Th e fm fo r

t h is g ro u p is t a ke n a s 1 .

2 .Gro u p : In t e rn a l co mb u s t io n , 4 - 6 cylin d e r e n g in e s (g a s o lin e o r d ie s e l), w a t e r t u rb in e s . Th e fm fo r t h is g ro u p is t a ke n a s

1 .2 5 .

3 .Gro u p : In t e rn a l co mb u s t io n , 1 - 3 cylin d e r e n g in e s (g a s o lin e o r d ie s e l.) Th e fm fo r t h is g ro u p is t a ke n a s 1 .5 .

Daily operation time coefficient ( ft )

If t h e d a ily o p e ra t io n t ime is b e t w e e n 3 - 1 0 h o u rs , t h e ft co e fficie n t is t a ke n a s 1 .

If t h e d a ily o p e ra t io n t ime is le s s t h a n 3 h o u rs , t h e ft co e fficie n t is t a ke n a s 0 .8 .
If t h e d a ily o p e ra t io n t ime is b e t w e e n 1 0 - 2 4 h o u rs , t h e ft co e fficie n t is t a ke n a s 1 .2 5 .

S tart- up number coefficient ( fs )

If t h e s ys t e m ma ke s a t mo s t five s t a rt -u p s in a n h o u r, t h e co e fficie n t fs is t a ke n a s 1 .

If t h e s ys t e m ma ke s mo re t h a n five s t a rt -u p s in a n h o u r, t h e co e fficie n t fs is t a ke n b e t w e e n 1 .2 5 – 2 . In t h is ca s e , s p e cia l

p re ca u t io n s mig h t b e n e e d e d . C o n n e ct in g t h e g e a rb o x t o t h e mo t o r w it h h yd ra u lic o r e le ct ro -me ch a n ica l co u p lin g w ill re d u ce
t h e e ffe ct o f s h o cks d u rin g s t o p -s t a rt s .

An example for operation safety factor calculation

Th e s a fe t y fa ct o r (F) fo r a s ys t e m o p e ra t in g 2 4 h o u rs d a ily w it h a n e le ct ric mo t o r, ma kin g a t mo s t five s t a rt -u p s in a n h o u r,

w it h mo d e ra t e s h o cks :
F = fm . fd . ft . fs = 1 . 1 .5 . 1 .2 5 . 1 = 1 .8 7 5 .
F ca n b e t a ke n a s 1 .8 o r 2 .
O p e ra t io n s a fe t y fa ct o rs (F) a re g ive n in t h e t a b le o n p a g e 1 9 . In t h is t a b le , d rive n ma ch in e s a re cla s s ifie d in t o fo u r g ro u p s ;
w it h o u t s h o ck lo a d in g , me d iu m s h o ck lo a d in g , w it h h e a vy s h o ck lo a d in g , a n d w it h ve ry h e a vy s h o ck lo a d in g a n d h ig h mo me n t
o f in e rt ia . Th is cla s s ifica t io n is a g u id a n ce b a s e d o n p a s t e xp e rie n ce s . C o n s id e rin g e co n o mica l a n d s a fe t y fa ct o rs t o g e t h e r,
t h e o p e ra t io n s a fe t y fa ct o r ca n b e t a ke n lo w e r o r h ig h e r t h a n t h e va lu e in t h e t a b le .

Thermal P ow er ( Nt)

Th is is t h e p o w e r t h e g e a rb o x ca n t ra n s mit w it h o u t h e a t in g u p . Th e rma l p o w e r o f g e a rb o x d e p e n d s o n t h e s iz e o f e xt e rn a l
s u rfa ce o f t h e g e a rb o x h o u s in g , a mb ie n t t e mp e ra t u re , o p e ra t io n a re a (co ve re d p la ce o r o p e n a ir) a n d t h e o p e ra t io n t ime in
a n h o u r (FD).
Th e rma l p o w e r va lu e s e a ch g e a rb o x s iz e ca n t ra n s mit a re g ive n in g e a rb o x p o w e r t a b le s . Th e rma l p o w e r va lu e s (Nt ) g ive n in
t a b le s a re va lid fo r g e a rb o xe s o p e ra t in g in a clo s e d a re a , w it h 2 0 - 3 0 C a mb ie n t t e mp e ra t u re a n d fo r co n t in u o u s o p e ra t io n
(FD = 1 0 0 % ).
Fo r 4 0 C a mb ie n t t e mp e ra t u re , 7 5 % o f t h e va lu e g ive n ; fo r 5 0 C a mb ie n t t e mp e ra t u re , 6 0 % o f t h e va lu e g ive n in t h e t a b le
s h o u ld b e t a ke n .
If t h e g e a rb o x is o p e ra t in g 3 0 min u t e s in a n h o u r (FD = 5 0 % ), Nt ca n b e in cre a s e d b y 2 5 % . Fo r a n o p e ra t io n o f 1 5 min u t e s
in a n h o u r (FD = 2 5 % ), Nt ca n b e in cre a s e d b y 5 0 % .
If t h e g e a rb o x is co o le d w it h a ir o r t h e g e a rb o x o il is co o le d , t h e rma l p o w e r ca n b e in cre a s e d b y 1 0 % - 5 0 % d e p e n d in g o n
t h e e ffe ct o f t h e co o lin g .

Determination of gearbox size

To rq u e re q u ire d fo r t h e d rive n ma ch in e is d e t e rmin e d e it h e r b y ca lcu la t io n o r b y p a s t e xp e rie n ce . Sp e e d s u it a b le fo r d rive n

ma ch in e is a g a in fo u n d e it h e r b y e xp e rie n ce o r b y t ria l a n d e rro r me t h o d .
Th e p o w e r re q u ire d t o o b t a in t h e re q u ire d t o rq u e fo r t h e d rive n ma ch in e a t t h e s e le ct e d s p e e d is ca lcu la t e d in (kW ) a s :

Td (N.m) . n d (rp m)
Nd = ____________________
9550

P ro vid e d t h a t t o rq u e re q u ire d fo r t h e d rive n ma ch in e s t a ys co n s t a n t , if t h e ma ch in e w ill o p e ra t e a t va ria b le s p e e d , p o w e r

re q u ire d s h o u ld b e ca lcu la t e d co n s id e rin g t h e h ig h e s t s p e e d .

O p e ra t io n s a fe t y fa ct o r F ca n b e t a ke n fro m t h e t a b le t a kin g in t o co n s id e ra t io n t yp e o f d rive n ma ch in e , mo t o r a n d d a ily

o p e ra t io n t ime .

Th e p o w e r g e a rb o x s h o u ld t ra n s mit (Nre ) is o b t a in e d b y mu lt ip lyin g p o w e r re q u ire d fo r d rive n ma ch in e (Nd ) a n d o p e ra t io n

s a fe t y fa ct o r. Th e Nre va lu e is t h e ke y fo r g e a rb o x s e le ct io n .
Nre = F . Nd

Th e p o w e r t a b le fo r s e le ct e d g e a rb o x t yp e s h o w s t h e n o min a l p o w e r Nn (kW ) a g ive n g e a rb o x s iz e ca n t ra n s mit a cco rd in g t o

t h e in p u t a n d o u t p u t s p e e d . Th e g e a rb o x s iz e h a vin g a n o min a l p o w e r g re a t e r t h a n o r e q u a l t o t h e Nre s h o u ld b e s e le ct e d
fro m t h e t a b le .

Th e Nre va lu e ca lcu la t e d s h o u ld b e le s s t h a n t h e t h e rma l p o w e r (Nt ). ( Nre < Nt ).

If Nre is clo s e t o o r g re a t e r t h a n t h e rma l p o w e r, g e a rb o x s h o u ld b e fo rce d co o le d . If t h e re is n o co o lin g p o s s ib ilit y, a g re a t e r

s iz e s h o u ld b e s e le ct e d .

He n ce , g e a rb o x s e le ct io n is co mp le t e d .

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Ge n e ra l In fo rma t io n Me ch a n ica l Da t a Typ e o f Drive s Ge a rb o x Se le ct io n E xa mp le s o f Ge a rb o x Se le ct io n

E x a m p l e 1 f o r G e a r b o x S e l e c ti o n

G e a r b o x s e l e c ti o n f o r a n e l e v a to r

A v a i l a b l e d a ta a b o u t th e a p p l i c a ti o n :

D r iv e n m a c h ine ty p e : Ele v a to r
D r iv e ty p e : Ele c tr ic m o to r
Mo to r s p e e d : 1460 r p m
D r iv e n m a c h ine s p e e d nd : 23 r p m
T o r q ue r e q uir e d f o r d r iv e n m a c hine T d : 900 k p .m
D a ily o p e r a tio n tim e : 24 ho u r s
No o f s ta r t-up s p e r ho ur : C o n tinuo us
O p e r a tio n tim e with in a n ho ur : 60 m inute s (FD = 100% )
T h e g e a r b o x is c o nne c te d b y h y d r a ulic c o u p ling to th e m o to r a nd b y e la s tic c o up ling to the d r iv e n m a c hine .
G e a r b o x is to o p e r a te in a c lo s e d a r e a (A m b ie nt te m p e r a tur e 20-25o C )
G e a r b o x inp ut s p e e d e q ua ls m o to r s p e e d : n 1 = nm = 1460 r p m
G e a r b o x o u tp ut s p e e d e q ua ls d r iv e n m a c hine s p e e d n2 = n d = 23 r p m .

G e a r b o x ty p e s , whic h a r e s uita b le fo r this a p p lic a tio n, a r e D A 3 a nd D K 3 m o d e ls .

C a l c u l a ti o n s :

P o we r Nd r e q u ir e d f o r d r iv e n m a c hin e is c a lc ula te d with b e lo w fo r m ula .

Nd = T d (k p .m ) n d (r p m ) = 900 . 23 = 22.2 k w
974 974
G e a r b o x tr a ns m is s io n r a tio : i = n1/n 2 = 1460/23 = 63/1

Lo a d f a c to r c a l c u l a ti o n
Lo a d fa c to r is c a lc ula te d b y F = f m . f d . f s . f t

D r iv e c o e ff ic ie nt f m is ta k e n a s f m = 1 f o r a m a c hine d r iv e n with e le c tr ic m o to r .
D r iv e n m a c h ine c o e ff ic ie nt f d is ta k e n a s fd = 1.5 f o r a m e d iu m s ho c k lo a d ing m a c h ine e le v a to r .
S ta r t-up c o e f f ic ie n t f s is ta k e n a s f s = 1 f o r a m a c hine o p e r a ting c o n tinuo u s ly witho u t s ta r t-up .
D a ily o p e r a tio n tim e c o e f f ic ie n t f t is ta k e n a s f t = 1.25 f o r a m a c hine o p e r a ting 24 ho ur s d a ily .
T h us F = 1 . 1.5 . 1 . 1.25 = 1.875

Lo a d fa c to r c a n a ls o b e ta k e n f r o m th e ta b le .
I n the ta b le , it is g iv e n th a t lo a d f a c to r fo r a n e le v a to r tha t is d r iv e n b y a n e le c tr ic m o to r , o p e r a ting 24 ho ur s d a ily a nd with m e d ium
s ho c k lo a d ing is 1.9.

P o we r g e a r b o x s ho uld tr a ns m it: Nr e = F . Nd = 1.9 . 22.2 = 42.2 k w

No m ina l p o we r Nn fo r s e le c te d g e a r b o x s ho uld b e g r e a te r tha n Nr e . Nn > Nr e

I n p o we r ta b le o f D A 3 m o d e l g e a r b o x ; it is f o u nd th a t f o r ninp ut = 1460, no utp ut = 23 r p m .

No m ina l p o we r D A 3-560 m o d e l g e a r b o x c a n tr a ns m it is 45 k w. D A 3-560 m o d e l g e a r b o x is s uita b le f o r th is a p p lic a tio n .

C he c k ing the the r m a l p o we r :

T h e r m a l p o we r o f D A 3-560 m o d e l g e a r b o x is f r o m the r m a l p o we r ta b le Nt = 240 k w. Nt > Nr e th e r e f o r e D A 3-560 m o d e l g e a r b o x c a n

tr a ns m it p o we r Nr e witho ut c o o lin g .

I n ta b le s it is g iv e n tha t no m ina l p o we r o f D K 3-450 m o d e l g e a r b o x is 45 k w und e r s a m e o p e r a ting c o nd itio ns . Nn > Nr e the r e fo r e D K 3-

450 c a n a ls o b e u s e d f o r this a p p lic a tio n.

E x a m p l e 2 f o r G e a r b o x S e l e c ti o n

G e a r b o x s e l e c ti o n f o r d r i v i n g a c o n v e y o r b e l t.

A v a ila b le d a ta a b o ut the a p p lic a tio n:

D r iv e n m a c h ine ty p e : C o nv e y o r b e lt
D r iv e ty p e : Ele c tr ic m o to r
Mo to r s p e e d : 1450 r p m
 p p
D r iv e n m a c hin e s p e e d nd : 60 r p m
T o r q u e r e q uir e d f o r d r iv e n m a c hin e : T d = 180 k p .m
D a ily o p e r a tio n tim e : 10 ho ur s
S ta r t-up s in a n ho ur : a t m o s t 5
O p e r a tio n tim e in a n ho u r : 50 m inu te s (FD = 80% )
T he r e is a V -b e lt p ulle y s y s te m b e twe e n g e a r b o x a nd m o to r . P ulle y r a tio : 1.5/1
G e a r b o x inp u t s p e e d : n1 = 1450/1.5 = 960 r p m
G e a r b o x is m o unte d o n c o nv e y o r s ha f t.
G e a r b o x o u tp ut s p e e d = D r iv e n m a c hine s p e e d ; n2 = nd = 60 r p m
G e a r b o x will b e o p e r a te d in o p e n a ir (a m b ie nt te m p e r a tu r e 25o -30o C ).

D G 2 m o d e l s ha f t m o unte d g e a r b o x is s u ita b le f o r this a p p lic a tio n

Ca l c u l a ti o n s :
P o we r r e q uir e d f o r d r iv e n m a c hine Nd is c a lc ula te d b y b e lo w f o r m ula :

Nd = T d (k p .m ) . nd (r p m ) = 180 . 60 = 11 k w
974 974

G e a r b o x tr a ns m is s io n r a tio : i = n1/n2 = 960/60 = 16/1

Lo a d f a c to r is ta k e n f r o m the ta b le . Lo a d f a c to r is g iv e n a s 1.5 fo r a c o nv e y o r whic h is a m a c hine d r iv e n with e le c tr ic m o to r , o p e r a tin g

10 ho u r s d a ily , with m e d ium s ho c k lo a d ing .

P o we r g e a r b o x s ho uld tr a n s m it: Nr e = F . Nd = 1.5 . 11 = 16.6 k w

No m ina l p o we r Nn f o r s e le c te d g e a r b o x s ho u ld b e g r e a te r tha n p o we r Nr e . Nn > Nr e .

I n p o we r ta b le o f D G 2 m o d e l g e a r b o x it is s e e n tha t f o r ninp u t = 140, no utp ut = 60 r p m .

No m ina l p o we r D G 2-250 m o d e l g e a r b o x c a n tr a n s m it is 19 k w.

D G 2-250 m o d e l g e a r b o x is s u ita b le f o r this p la nt.

Ch e c k th e r m a l p o we r :
T he r m a l p o we r o f D G 2-250 m o d e l g e a r b o x is Nt = 36 k w (f r o m th e r m a l p o we r ta b le .)

S inc e Nt > Nr e D G 2-250 m o d e l g e a r b o x c a n tr a n s m it p o we r Nr e with o ut c o o ling .

E x a m p l e 3 f o r Ge a r b o x S e l e c ti o n

Ge a r b o x s e l e c ti o n f o r a d r y i n g p l a n t.
A v a ila b le d a ta a b o ut the a p p lic a tio n:
D r iv e n m a c hin e ty p e : D r y in g m ills
Mo to r p o we r to b e c o nne c te d to g e a r b o x : 15 k w
Mo to r s p e e d : 1460 r p m
D r iv e n m a c hin e s p e e d nd : 24 r p m
T o r q u e r e q uir e d f o r d r iv e n m a c hin e T d = 465 (k p .m )
D a ily o p e r a tio n tim e : 10 ho ur s
S ta r t-up s in a n ho ur : a t m o s t 5
O p e r a tio n tim e in a n ho u r : 60 m inu te s (FD = 100% )
Mo to r is d ir e c tly c o nne c te d to g e a r b o x .
G e a r b o x inp u t s p e e d = m o to r s p e e d = 1460 r p m .
G e a r b o x is c o nn e c te d to d r y ing m ill with c ha in s p r o c k e t.
C ha in s p r o c k e t r a tio = 2.5/1
G e a r b o x o u tp ut s p e e d = 24 . 2.5 = 60 r p m
G e a r b o x o p e r a te s in o p e n a ir (a m b ie n t te m p e r a tur e 25o -30o C ).

2D MA m o d e l, he a v y ind u s tr y m o to r g e a r , is s u ita b le f o r this a p p lic a tio n

Ca l c u l a ti o n s :
P o we r r e q uir e d f o r d r iv e n m a c hine Nd is c a lc ula te d with b e lo w f o r m ula :

Nd = T d (k p .m ) .n d (r p m ) = 465 . 24 = 11.5 k w
974 974

Lo a d f a c to r is ta k e n f r o m ta b le . Lo a d f a c to r is g iv e n a s 1.5 in the ta b le f o r a d r y ing m ill whic h is

a m a c hine d r iv e n b y e le c tr ic m o to r , o p e r a tin g 10 ho u r s d a ily a nd with m e d ium s ho c k lo a d ing .

T he p o we r g e a r b o x s ho uld tr a ns m it: Nr e = F . Nd = 1.5 . 11.5 = 17.25 k w

S inc e a m o to r with 15 k w p o we r is c o nne c te d to g e a r b o x , s a f e ty f a c to r in m o to r s e le c tio n is a s Nm /Nd = 15/11.5 = 1.3

I n th e p o we r ta b le o f 2D MA m o d e l m o to r g e a r b o x f o r 15 k w p o we r a n d 60 r p m g e a r b o x o utp ut s p e e d ; it is c o nc lud e d tha t 2D MA 6

m o d e l g e a r b o x s ho uld b e s e le c te d .

T he p o we r ta b le o f 2D MA m o d e l m o to r g e a r b o x is c a lc ula te d s o tha t lo a d f a c to r is a t le a s t 1.5.

2D MA 6 m o d e l g e a r b o x tr a ns m its 15 k w p o we r a t 60 r p m with a lo a d f a c to r o f 1.5 tha t is no m ina l p o we r Nn o f g e a r b o x is Nn = 15 . 1.5

= 22.5

A c tua l lo a d f a c to r b a s e d o n p o we r r e q uir e d f o r d r iv e n m a c h ine Nd is Nn/Nd = 22.5/11.5 = 1.95

Mo to r g e a r is s e le c te d with the s a f e ty f a c to r g r e a te r th a n s uf f ic ie nt.

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