WHAT IS THE REDUCER?
The reducers, which are a component of the parallel gearing of the gearbox assemblies together with gearboxes, are composed of components consisting of components such as gears, millers, bearings, etc., placed in the structure. Its academical definition is a closed gear assembly designed to reduce the high rotational speeds of electric motors to the rotational speeds required for machines.
REDUCER TYPES?
Today, reducers are produced in standard sizes by various companies and are launched to the market. Factors such as conversion ratio, efficiency, size and weight must be taken into account when selecting reducer types. Classification of the reducers is done as follows;
1) According to the number of stages; reducers with 1, 2 and more stages,
2) According to used gear type used; gears with bevel gears, cylindrical gears, worm gears and gears with multiple types.
REQUIREMENTS TO BE CONSIDERED IN THE USE OF REDUCERS
1. An upper body should be selected in high inclined lines.
2. An upper body should be selected where a quick take off is necessary.
3. Reducer connection stretcher must be done very well.
4. Reducer connection stretcher must be adjusted and the reducer must be able to stretch while it is operating.
5. Reducer drive pulley must not be operating together with the engine.
6. Since reducer body is alloyed, it must be protected against extreme impact which may come from the outside.
GENERAL PRODUCTION INFORMATION
Gears
Helical forehead gears and helical bevel gears are manufactured of alloyed case hardened steel. After the machining of the gears (lathe, shafting, deburring and slot), the gear module is heat treated to provide adequate cementation depth and surface hardness of 58-60 HRC. After heat treatment, shafted rod's roller bearings, shaft holes and geras profiles of gears are ground. The profile shifts in the gears prevent lower cuts, especially in pinion gears. The grinding of the gear profiles allows the reducer to operate silently.
Shafts
The input shaft of the reducers is usually a pinion gear shafts. In this case, the input gearwheel material 8620 is hardening steel.
Bearings
The bearings of the reducer shaft and the gears conical roller bearings or cylindrical roller bearings are utilized.
Bodies
Reducer bodies are aluminum casting in Etial 160-171 quality.
There are oil fill-emptying plugs, oil level gauges and bleeder plug on the bodies.
Connection of Shafts
Very good adjustment of the shaft axes in connection with the clutches, minimization of the angular and linear deviations between the axes of shaft, as well as extending the life of the shafts, the bearings and the clutches, allows the system to operate without vibrations. It is necessary for the gears to be parallel to each other in the connection, and that the gears need to clutch each other along the entire gear surface. It is adequate to connect reducer inlet shafts to engine; belt-pulley systems, elastic clutches with hydraulic or electromagnetic finned. It is essential to connect shafts coaxial with the clutches (coaxial); in belt-pulley systems, the parallelism of the shafts is provided; in order to maintain long lasting of coupling elements, the engine and reducer shaft bearings, and for the vibration-free operation of the system.
One Way Turn
Reducer can be manufactures locked in one direction, depending on demand.
Efficiency
In principle, there is a power loss of 1.5% in each step of the flat and helical gear reducer. Power loss in Helical bevel gear reducers is between 2.5-3% for each step. Power loss of endless screwdriver reducer; it ranges from 5% to 50% depending on the number of shafts of the screw, the screw elevation angle, the input rotation, the material of the pair of endless screw worm gear, and the quality of the processing.
Efficiency in a helical gear unit according to this rule:
Efficiency of one stage (one gear pair) reducer 98.5%
Efficiency of two stage (two gear pair) reducer 97%
Efficiency of three stage (three gear pair) reducer 95.5%
Efficiency of four stage (four gear pair) reducer 94%
Operation, Quality Control and Shipment
At the end of the assembly of reducers, are operated without load and the following checks are made:
- Whether the reducer works silently and without vibration or not,
- Whether the oil level is sufficient or not,
- Whether there is leakage from oil felts and covers or not..
The gear units which pass through the quality control are delivered with their oil filled and ready to work together with the maintenance instructions.
