5 Tips for Cost Savings
Tip #1: Reduce Your Inventory
When you purchase a reliable gear reducer with a long warranty, you can save on replacement costs. You don&#;t need as many storeroom components because you have a durable solution. Another way to reduce inventory would be to consolidate gear reducer case sizes, ratios, motor inputs, and shaft sizes. Many plants have a variety of reducer sizes and ratios across multiple line locations. By using variable frequency drives and standardizing on sizes, you can simplify your inventory. Imagine reducing storeroom SKU&#;s from 60 down to 10!
Tip #2: Invest in an Efficient Product
Eliminating inefficient motors and worm reducers can save thousands of dollars in electrical power consumption over the course of a year. By using helical bevel reducers, you will have substantially better efficiency than a worm gear reducer. For example, a line location using a 50:1 ratio worm reducer with a 2HP motor could be changed to a 50:1 helical bevel reducer. Your estimated annual savings would be greater than $2K per line location, which will only increase each year.
Tip #3: Be Attentive To Oil
Refilling gear reducers with oil, buying replenishment oil, and discarding oil can cost over $250 per oil change, for every line location. Some units may need this done several times a year. Utilizing a factory filled, no maintenance gear reducer that is lubed for life eliminates the need for oil drip pans and drain lines and reduces harborage risk.
Tip #4: Avoid Labor Expenses
Let&#;s face it, installation to replace a unit bleeds money from your maintenance budget. By using a reliable solution optimized for your specific application, you can steer clear of this cost and extend your reducer&#;s life. When selecting a gear reducer manufacturer, look for any installation fees that might apply. Some will readily assist with installation free of charge.
Tip #5: Eliminate The Worry Of Emergency Breakdowns
Many customers experience extremely costly downtimes and lose thousands of dollars a minute. When a durable solution is chosen, this expense can be avoided altogether. But when the inevitable happens, STOBER has fast, same day shipments with no expediting fees, allowing you to save money with gearboxes.
With competitive price and timely delivery, Huading sincerely hope to be your supplier and partner.
How STOBER Saves You Money
We have been saving our customers money since . Our documented cost savings program allows us to demonstrate the substantial amount of money you can save by using STOBER&#;s highly reliable and efficient helical solutions. Our team can optimize your plant to eliminate gearing misalignment, overloads, water ingress, and lubrication changes to help you avoid these costly failures. To learn more about how you can save money with gearboxes, check out our free download.
A gear reducer is an automated device that links a motor to a driven load. It is also referred to as a gearbox. It enables you to change the speed and torque of a motor in relation to a load. A reduction gear assembly is made up of a number of gears. The transmission ratio is another name for the gear reduction ratio (the number of teeth between the input and output shafts).
There&#;s no doubt that it&#;s crucial to choose the right gear reducer. Hence, in this blog, we&#;ll go over the various factors to consider while choosing a gear reducer.
Requirements For Selecting A Gear Reducer.
Several variables must be considered when purchasing a gear reducer. A gear reducer is often used to modify the properties (torque as well as speed) of a mechanism&#;s input and output axes. This is why you must be aware of the torque plus rotation speed.
As a result, the torque should be the first question you ask yourself. A reducer boosts your motor&#;s torque, allowing a receiving part to spin under the influence of a new torque. Manufacturers of gear reducers may mention the minimum and maximum torque (measured in newton meters, N.m) that each of their devices can sustain. The torque strength varies depending on the gear reducer. Planetary gears, for example, have quite a high torque intensity.
Another function of a gear reducer is to lower motor speed, and we suggest that you consider the optimal reduction ratio for your application. The reduction ratio is utilized to calculate the output rotational speed depending on the speed of rotation of your motor. Manufacturers also provide this information on their product sites. It&#;s measured in rotations per minute.
Finally, consider what type of gear reducer component is most suited to your application. Your gear reducer&#;s input and output shafts might be coaxial, parallel-shaft, as well as orthogonal. This is determined by your intended usage.
The Different Kinds Of Gear Reducers
Planetary gear reducers, worm gear reducers, gear train gear reducers, plus bevel gear reducers are the four primary kinds of gear reducers. Every gear reducer has benefits and drawbacks. You must choose the one that is most suited to your intended usage.
For example, if you want to maximize efficiency, you should pick a planetary gearbox or parallel Helical Gearbox instead of a bevel gear reducer.
When Should A Planetary Gearbox Be Used?
The coaxial assembly is one of the most distinguishing features of a planetary gearbox. Planetary gearboxes are small because of this sort of arrangement.
Planetary gears have many benefits, including their small size, great efficiency, minimal clearance, with high torque to weight ratio. Their intricate and pricey design, on the other hand, need specialist upkeep.
Planetary gears are recommended for applications demanding fast accelerations (robotics) as well as those requiring low-speed yet high torque (industrial rotary furnaces). They are also commonly employed in machining centers as well as other machine tools, as well as mobile gear for public and agricultural operations.
When Should A Worm Gear Reducer Be Used?
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Worm gear reducers feature input and output shafts that are perpendicular to each other. They are often employed in situations that need an extremely high transmission ratio.
Worm gear reducers have a non-reversible mechanism. This indicates that the worm cannot be driven by the worm wheel. The benefit of this non-reversible technique is that it provides the system with a higher degree of security.
Worm gear reducers are far less costly and quieter than planetary gearboxes. Worm gear reducers don&#;t really vibrate, thus they are quieter and more pleasant to operate.
Worm gear reducers also have a varying amount of performance. You may increase the performance of your worm gear reducer by combining it with additional gearboxes as well as gear trains. This sort of technology is recommended for conveyors, winches, and handling.
When Should A Gear Train Gear Reducer Be Used?
Gear train gear reducers having parallel shafts are often utilized in high-power applications such as conveyors. Because of the ease of their technology, you will be able to save money on maintenance. Furthermore, gear train gear reducers have an extremely high-performance level, close to 1. Each gear train has a low reduction ratio.
When Should A Bevel Gear Reducer Be Used?
The fundamental feature of bevel gear reducers is its angular bell crank, which enables the operator to adjust the machine&#;s rotation scheme. This allows you to go from a transversal rotation system to a longitudinal rotation system.
Bevel gear reducers are small in size. They are quite strong and can endure a lot of force. Because of the power of their teeth, they may be used with three-phase asynchronous motors, as well as synchronous or asynchronous servomotors.
Their performance level, however, remains lower than that of planetary gearboxes. Bevel gear reducers are also exceedingly costly and demanding to maintain.
Bevel gear reducers are often found in high-powered conveyors, but they are also found in mobile equipment used in agriculture or public works.
Measuring The Dimensions Of Your Gear Reducer
To determine the size of your gear reducer, you must first choose the proper shaft. There are three shaft orientations to choose from: orthogonal, coaxial, plus parallel.
The input and output shafts of a gear reducer are perpendicular if it has an axial shaft orientation. This is often the case with bevel and worm gear reducers. In addition to industrial applications, orthogonal shaft alignment is employed in differential automobile bridges.
The inlet and outlet shafts of a gear reducer are aligned if it has a coaxial shaft arrangement. This is true, for example, of planetary gearboxes or gear reducers used during aeronautical engines and turboprop engines. The input and output shafts of a gear reducer are parallel if it has a parallel shaft orientation.
Conclusion
A gear reducer plays a crucial role in the efficiency and effectiveness of the overall mechanism. Hence, it&#;s important to not only find the right gear reducer but also find a provider that offers high-quality products. At Premium Transmission, we offer high-quality, precision-engineered power transmission solutions to the global industry. For more information, contact us today!
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