What is Gearbox?
A gearbox is like a traffic cop for the power in machine and vehicle. Playing the fundamental role in the transmission of power and torque between the wheels and engine or other machinery. It is first function is to alter the speed and torque of the vehicle by providing different gear ratios, those toothy wheels, inside a protective box.
One cool thing about gearboxes is their ability to multiply power. This means that the input torque from the engine can be modified through the gear ratio to generate high or low output torque. In conditions where extra force is required
Types of gearbox
Here are some different types of gearboxes:
1-Manual Transmission
2-Automatic Transmission
3-Continuously Variable Transmission(CVT)
4-Semi Automatic or Automated Manual (AMT)
5-Double clutch transgression (DCT)
6-Manual sequential Transmission
7-Planetary Gearbox
8-Worm Gearbox
9-Bevel gearbox
10-Helical gearbox
Manual Transmission:
A manual gearbox also known as standard transmission, requires the driver to manually engage and disengage gear using a clutch pedal. These transmissions are commonly found in cars and trucks.
The manual transmission comes in various configurations, including synchronized, unsynchronized, and sequential.
Automatic Transmission:
Automatic transmissions use a torque converter to automatically change gear without the need for manual shifting by the driver. They are commonly found in most modern cars and provide smooth, convenient shifting. Automatic transmissions often have multiple modes. like drive (D), Reverse (R), and park (P).
Continuously Variable Transmission(CVT):
AVTs use a belt and pully system or a chain to provide an infinite number of gear ratios, allowing for seamless and continuous acceleration without distinct gear shifts. Continuously Variable Transmission (CVTs) are found in many modern cars and some smaller vehicles.
Semi-Automatic or Automated Manual (AMT):
These gearboxes combine the convenience of automatic transmission with the ability for manual control by the driver. They lack a clutch pedal but can be manually shifted using paddle shifters or buttons.
Double Clutch Transgression (DCT):
Double-clutch transmission have two separate clutches, one for odd-numbered gears and one for even-numbered gears. This design enables rapid gear changes and improved efficiency. Double clutch transgression (DTCs) are often used in high-performance and sports cars.
Manual Sequential Transmission:
These transmissions are commonly encountered in racing cars and motorcycles. They enable sequential shifting without the need to operate a clutch pedal. Gears are selected in sequence with a lever or paddle shifter.
Planetary Gearbox:
Planetary gearboxes use a group of gears arranged in a planetary or epicyclic configuration. They are compact and efficient, making them suitable for various applications, including automatic transmissions, industrial machinery, and robotics.
Worm Gearbox:
Worm gearboxes comprise a worm (a screw-like gear) and a worm wheel. They deliver high torque and are commonly used in applications where precise and slow-speed control is required, like in conveyor systems and elevators.
Bevel Gearbox:
Bevel gearboxes have bevel gears that transmit motion between shifts at an angle. They are often used in applications where the input shaft and output shafts are not parallel, such as in differential gears in vehicles.
Helical Gearbox:
Helical gearboxes utilize helical gears with slanted teeth to transmit power. They offer high efficiency and smooth operation making them suitable for various industrial and automotive applications.
Gearbox Parts
There are many different parts in a gearbox, We have discussed some common gearbox parts names:
Output shaft: The output shaft sends the mechanical power to the rest of the drivetrain.
Input shaft: The output shaft gets the mechanical power from the engine and motor.
Clutch: Clutch joint with the gearbox from the engine to facilitate gear changes.
Bearings: Bearing supports and facilitates to the rotating parts, reducing friction.
Gear shift lever: That helps to change different gears.
Seals and Gaskets: Seal and gaskets that help to prevent leaks of lubricating oil and maintain gearboxes’ life.
Selected Forks: Helps to components that move gear engagement.
Oil pumps: properly lubrication of gearbox components.
Idler Gear: A gear placed between two other gears to change their route of rotation.
Synchromesh: That helps smooth shifting the speed of the gears.
Necessity of Gearbox
The engine gives its full horse power at a fairly high speed and it is not reversible in the direction of rotation. The tractive force required by road wheels to propel the car varies according to the condition of use. It means-
- On a flat rod moderate torque is required at rod wheels but at high wheel speed.
- When the car starts from rest high torque is required at a low wheel speed.
- When climbing a steep hill a high torque is required.
- It helps the engine to disconnect from the driving wheels.
- It provides the leverage between the engine and driving wheel to be varied
Function of Gearbox
- It provides a neutral position so that the engine and road wheels are disconnected even with the clutch in the engaged position.
- It provides a variable torque ratio between the engine and road wheels depending upon the different conditions and demands.
- It also provides a reverse direction to the vehicle by using a reverse gear mechanism.
- It provides a neutral position to the vehicle.
- it provides forwarding direction to the vehicle.
- It generates high torque at starting and high speed while running.
- It helps the running engine connect to the drive wheels smoothly and without shock.
Gearbox Overheating Reasons
- Excess fill-up in the gearbox above the oil level
- A low oil level in the gearbox results in improper lubrication and increased friction as a result heat is generated and your gearbox gets overheated
- Un-cleaned fins and cooling fan cover
- If your gear oil condition is bad ( low viscosity ) it is life cycle completed, or it is contaminated. Then improper lubrication results in increased friction and high heat generation.
Gearbox Abnormal Sounds Reasons
Here are few main common reason of gearbox abnormal sounds.
1-Gear misalignment: Misalignmenet of gears can lead to improper meshing, causing excessive noise and wear. This misalignment can occur due to manufacturing defects, improper installation, or thermal expansion/contractions.
2-Gear tooth damage: Damage to gear teeth, such as chipping, pitting, or excessive wear, can result in noise during operation. This damage can be caused by overloading, poor lubricated, or foreign particles in the gearbox.
3-Lubrication issuse: Inadequate or contaminated lubrication can lead to increased friction, overheating, and excessive wear on gear teeth, resulting in noise. Daily maintenance and monitoring of lubrication system.
4-Bearing problem: Damaged or worn-out bearing can produce nise. These issues can arise due to poor maintenance, misalignment, overloading, or contamination.
5-Overloading: Applying excessive loads or torque beyond the gearox is design capacity can lead to noise and accelerated wear. This can be due to improper applocation or changes in operational requirements.
6-Vibration: Excessive vibration, whether from misalignmenet, imblance, or other sources, can create noise in a gearbox. Vibration can be transferred to the gearbox, causing damage and noise.
7-Worn seals: Seals, which are essential for keeping contamunants out and lubricant in, can degrade over time. If they fail, foreign particles can enter the gearbox, leading to damage and noise.
8-Operational conditions: Environmental factor such as temperature, humidity, and load fluctuations can influence gearbox noise. Extreme conditions may cause expansion/contraction issue, leading to noise.
9-Aging and wear: Over time, even well maintained gearboxes will experience wear and degradation. Components can become less effective and noisier as they age.
FAQs
Why we are use gearbox?
Answer: 1-Reduce rotational speed 2- Transmit high torque
Where is the application of the worm wheel gearbox?
Answer: Worm wheel is used in the conveyor belt and lift rotary valve
Is the worm wheel gearbox rotated in a reversible direction?
Answer: The output shaft does not rotate in the reversible direction
What is the reason for gearbox failures?
Answer: Lack of lubrication
Which gearbox is easy for assembly and dismantling?
Answer: 1-Planetary gearbox 2-Worm wheel gearbox
How to find the gearbox ratio without a nameplate?
Answer: If you rotate the input shaft 10 times and your output shaft rotates one time it means the gear ratio is 10:1
Conclusion
We hope that we have cleared all yours questions about gearbox. If you have any queries about the “GEARBOX“ you can contact directly in my contact us page. Thanks for reading.
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