Also referred to as speed reducers, gear reducers are mechanical devices that is primarily use to multiply the amount of torque at input power source for the desired amount of work. Also, they are used to reduce the input power source speed for the required output. While gear reducers are proven to be very effective in achieving higher gear efficiency, their integration involves much more than just selecting one out of a manufacturer’s catalogue. Though specifications like torque, speed, and radial load are readily published, you should not rely on them as is. Instead, you have to consider proper service factors, too, for a number of dynamic applications.
Apart from gear reducers, there are other similar mechanical speed reducing devices available, including friction drives, pulleys, and sprockets. They are also capable of changing the motor speed, but the most commonly used in various applications are the enclosed-drive reducers. They are also popularly known as gear drives and gearboxes and come in two major configurations: right angle and in-line reducers.
The right angle configurations are usually made with bevel or worm gearing. Bevel gear reducers offer high efficiency with an effective speed reduction at a maximum of 6:1. Worm gears, on the other hand, provides the most cost effective reduction ratio with at least 5:1 but has the tendency to lose efficiency when ratios become bigger. In-line designs are typically made with spur or helical gears, cycloidal mechanisms, and planetary gears. Among them, the spur and helical gears are the most economical solution. Cycloidal drives provide compact design even in higher ratios while planetary gears offer the highest torque even in the smallest unit.
Despite of their differences, all of these gear reducers are efficient in their own way and it’s the type of your application that determines which design is best suited for your requirements. Just don’t forget to always consider the right specifications to properly size and install your new unit.