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Posted on Aug 10, 2020
A speed reducer is a mechanical device used to double the torque generated by the input power source to increase the available work, and to reduce the input power source speed to achieve the desired output speed. The gearbox or reducer can be set in the opposite direction and the speed of the shaft can be increased by reducing the torque. In this post, we 're going to break down the advantages of a speed reducer, talk about different forms, and tell you why you should also find a speed reducer for your applications.
So, what are the main advantages you can benefit from by using a speed reducer? Let’s talk about them one by one:
• You can save costs
Using speed reducers to multiply torque and reduce speed helps reduce the overall cost of the operating system. You get increased efficiency and reliability with all your motor applications. Many gear motors are inexpensive to install and require little maintenance, which means less unplanned downtime for gear repairs.
• Increase your Environmental Friendliness
High-efficiency speed reducers can achieve significant savings in energy and drive component costs. Besides, gear motors can also help the environment and operators. Industrial electric motor systems account for approximately 1/12 of all greenhouse gas emissions from fossil fuel power plants. By using high-efficiency reducers such as gear reducers to reduce motor power consumption, the generation of greenhouse gases can be significantly reduced.
• Get a Torque Boost
Gear motors have advantages when they are directly connected to the motor output shaft. This creates a mechanical advantage based on the ratio of the number of gears to the number of teeth on each gear. For example, if the motor produces 17.5 N/mm of torque, installing a 5:1 reducer will produce 87.5 N/mm of output torque.
• Achieve reliable Speed reduction
Speed reducers are also called gear reducers because as they increase output torque, they reduce output speed. A motor with a speed of 1,000 rpm equipped with a 5:1 reducer outputs 200 rpm. Since many motors cannot operate efficiently at low speeds, this speed reduction improves system performance.
:: Read more : What is the selection criteria for choosing a gear reducer?
It is relatively easy to realize the reduction mechanism by combining spur gears with different numbers of teeth. However, a reducer that has become a device is generally used. We use the following system as a typical reducer. However, the gears given below are usually combined to realize a reducer to ensure the required reduction ratio.
• Parallel Axis Gear Speed Reducer
Depending on the reduction ratio, it can be divided into one to four stages. The power is transmitted in a rolling manner. Therefore, transmission efficiency of approximately 98% per stage can be ensured. The reduction ratio is about 1/5 to 1/2500, which can cover various reduction ratios. The combination of gear stages and reduction ratio is different. This means that the size of the reducer changes according to the output of the adaptive motor.
• Helical Speed Reducer
This is the same as a parallel shaft gear reducer, but it uses helical gears as gears. Helical gears usually have twisted tooth shapes. As a result, the tooth meshing ratio increases. This means that a highly smooth and quiet power transmission can be obtained. However, they have a weakness. The thrust they generate is proportional to the size of the power transmission. This is because the marks on the teeth are smooth. This weakness can be overcome by double-helical gears equipped with opposite helical gears to counteract the thrust.
• Bevel Gear Speed Reducer
This is a reducer combined with a bevel gear at an angle of normally 90 degrees.The combination of large and small gears will reduce speed. However, these are often used for output with a 90° swing. For this reason, if the reduction ratio in the bevel gear reducer is 1:1, it is also called a miter gear. Gears that increase the meshing ratio by twisting the tooth traces of bevel gears such as helical gears are called spiral bevel gears.
• Hypoid Speed Reducer
The gear is designed to offset the center of the pinion axis relative to the center of the gear axis by a certain amount. These increase the power transmission of spiral bevel gears, such as the worm reducer we will introduce later. This makes a smoother power transmission possible. The hypoid reducer can obtain a larger reduction ratio. This is because the gear ratio is as large as a worm reducer. However, participation is complicated. Therefore, it is necessary to accurately adjust the engagement position.
• Worm Speed Reducer
This is a reducer that combines a worm wheel and a worm wheel. Only through this combination, it is possible to obtain a large reduction ratio of about 1/10 to 1/60. If the lead angle of the worm wheel becomes smaller (the reduction ratio is higher), it is called self-locking. By taking advantage of the fact that it is difficult to rotate from the worm wheel side (output side), the lifting device can be prevented from falling. Also, reducing the thrust recoil of the input shaft makes it possible to suppress recoil. Therefore, this is a reducer with various advantages. However, compared with spur gears, power is transmitted according to the sliding of the tooth surface. Therefore, heat is easily generated, and the transfer efficiency is not very good, about 50%.
The magnetic speed reducer could replace the traditional gear reducer to ensure speed and torque multiplication by magnetic attraction instead of physical contact between moving parts. To date, complicated materials, high weight, and low torque have hindered the success of this magnetic technology. Electromagnetic gears, however, eliminate the need for lubrication, thus minimizing maintenance costs. Failure to lubricate also ensures that the device can work at high temperatures. Such benefits are especially desirable for applications that are costly to maintain or run in extreme environments.
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