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In this how to video, we cover the basics of selecting an IronHorse gearbox for your application. Currently AutomationDirect offers Cast Iron and Aluminum Worm Gearboxes as well as Cast Iron Helical Gearboxes.
In this How To video, we will discuss the differences and give information on how to select the PROPER Gearbox for YOUR application. As you can see, we have three types of gearboxes in front of me that AutomationDirect currently offers. First the: General Purpose Aluminum Worm Gearboxes, next the General Purpose Cast Iron Worm Gearboxes and last: the General Purpose Cast Iron HELICAL Inline Gearboxes. What does a gearbox do and why would someone need one? Gearboxes, also known as enclosed gear drives or speed reducers, are mechanical drive components that can control a load at a reduced fixed ratio of the motor speed. The output torque is also increased by the same ratio, while the horsepower remains the same. Typical applications are used with electric motors for reducing the output speed and increasing torque. Gearboxes are used on conveyors, packaging machines, rotary tables and more! Searching the web, there are many informative articles that help explain which gear style is best for certain applications. You can also find info on AGMA or AMERICAN GEAR MANUFACTURES ASSOCIATION. In this video we will briefly discuss why someone would choose one gearbox over the other. Studies state that Helical Gearboxes are the most commonly used gear in transmissions. Helical gearboxes offer less vibration, wear, noise and tend to have a longer life. Helical Gearboxes are the most expensive, so the question is: what is the trade-off between the price and cost savings through efficiency and is less vibration, wear, noise and longevity important in your application? We offer straight-through helical gearboxes with cast-iron frames. The output shaft is parallel to the input. Our gearboxes utilize C-face mounting interfaces for C-face motors. These gearboxes use helical gears to provide quiet startup and smooth operation. Our IronHorse Helical Gearboxes are filled with mineral oil and do require maintenance oil changes. Our IronHorse Helical Gearboxes are typically a drop in replacement for our competitors and is offered at a fraction of the cost of our competitors. Worm gearboxes are more commonly used where large gear reductions are required. The design allows the worm to turn the gear, but the gear cannot turn the worm giving a braking or locking style feature. These next two models are both Worm Gearboxes and contain a worm (gear type) on the input shaft, and a mating gear on the output shaft. Worm Gearboxes also change the drive direction by 90 degrees. Our IronHorse CAST-IRON Worm Gearboxes are offered with right hand and dual (both right and left) output shafts, and with hollow-bore outputs (all the way through from one side to the other). We also offer optional gearbox mounting bases for ease of installation of these cast-iron gearboxes. Our IronHorse ALUMINUM Gearboxes feature hollow-bore outputs (hollow all the way through from one side to the other). These gearboxes also utilize C-face mounting interfaces for trouble-free connections to C-face motors. We also offer optional single and double output shafts, output flanges, torque arms, and output covers. Keep in mind, these Aluminum Gearboxes are the lowest cost and the lightest weight, but are not designed to be operated 24/7 under stressful loads. It is important to determine your application needs by specs and not by price! Both of our IronHorse Cast Iron and Aluminum Worm Gearboxes are filled with Synthetic oil and typically only require maintenance checks but not require regular oil changes. Now the big question: How do I select the correct gearbox? You will need to look at: Usage, Power, Environment and Mounting. AutomationDirect has a great selection guide that can be found on our website here: 1) Determine the torque and speed required for the load. 2) Determine the overall speed ratio of motor speed to load speed. 3) Determine the gearbox ratio as well as any reduction outside the gearbox (pulleys, gears, etc.). 4) Determine the applicable service factor and overhung load K factor. 5) Determine the gearbox real output torque required, and select a gearbox with a higher Maximum Thermal output Torque rating . 6) Determine the gearbox design output torque required and select a gearbox with a higher Maximum Mechanical Output Torque rating. 7) Determine the required sizes of pulleys, gears, etc., and determine the overhung load force. Select a gearbox with a higher Overhung Load rating. 8) Confirm that the selected gearbox meets the applicable system requirements. 9) Select a compatible motor. One of the most overlooked selection criteria is frequency of starting and stopping and what loads the gearbox will be controlling. Stopping and starting a gearbox increases stress and wear. If your application runs continuous without stopping and starting, then a lighter duty gearbox may work for your application. If your application requires stopping and starting throughout the workday, then a heavier duty gearbox should be considered. Keep in mind: Loads play a huge factor in selection as well. You may only have light uniform loads to move, or you may have moderate loads. Heavy loads can create shock to the mechanical driveline causing more stress and wear. A great example is: Think about the stress of a baggage conveyor at an international airport. If the line stops while loaded with baggage, startup can stress the drivetrain compared to an empty conveyor that baggage is added to after it is running. What is your application? You can find the specs for AutomationDirects IronHorse Gearboxes on our website at: www.automationdirect.com Don't forget: we sell gearbox accessories, motors, motor controls and more. If you need any help with selecting a gearbox or have questions, please contact Automation Direct's free, award winning Technical support team during regular business hours, they will be happy to help. And don't forget the forums. There are lots of folks there that love to share their years of experience. Just don't post questions directed at Automation Direct's Technical support staff there, they do not monitor the forums on a regular basis. Thanks for watching and we hope to see you again soon.