Reduction Gear

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Professional Customization Services
With the continuous development of the automotive industry, there is a growing demand for customization of components. With a strong design team and advanced production equipment, the company is able to customize production according to the specific needs of customers to meet the special requirements of different models and different working conditions.

Perfect supply chain system
A mature automotive gear manufacturer often has a perfect supply chain system, which can ensure the stable supply of raw materials and efficient delivery of finished products. The company has established long-term cooperative relationships with a number of high-quality suppliers, thus ensuring the continuity of production and product stability.

Strong production capacity
Scale production can reduce costs and improve efficiency. The company has a large-scale production base and advanced production lines, which can meet the demand for large-volume orders and provide customers with sufficient supply of goods.

Good market reputation
In the highly competitive auto parts market, good market reputation is an important guarantee for the sustainable development of enterprises. The company has won wide recognition from customers through its high-quality products and services, and established a good brand image and market reputation.

What is Reduction Gear

A reduction gear is a mechanical system of gears in an arrangement such that input speed can be lowered to a slower output speed but have the same or more output torque. The operation of a reduction gear involves a set of rotating gears that are connected to a shaft with a high incoming speed, which is sent to a set of rotating gears where the speed or torque is changed. How many gears are in a reduction gear assembly is dependent on the speed requirements of the application.
The use of a reduction gear occurs when the drive gear is smaller and has fewer teeth than the driven gear. This is unlike the condition where the drive gear is larger with more teeth than the driven gear, which is referred to as overdrive.
reduction gear are an essential component in cars and trucks where the high rotational speed of the engine is converted such that the slower motion of the tires can interpret and use the power safely.

Planetary Gear

Planetary gears are used in applications where space is limited, as they are typically smaller than

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Beval Gear

Bevel gears are gears where the axes of the two shafts intersect and the tooth-bearing faces of the

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Spiral Gear

Spiral gear is the abbreviation of helical cylindrical gear, that is, the cylindrical gear whose

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Sun Gear

The sun gear, together with the planetary gears, internal gears, and planetary carriers that

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Worm Gear

A worm gear is a gear consisting of a shaft with a spiral thread that engages with and drives a

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Annulus Ring Gear

The annulus ring gear is a very important part of the planetary reducer, which provides a rotating

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Electric Drive Gear

The central motor drive system consists of motor, fixed speed ratio reducer and differential. In

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The Types of Reduction Gears and Features of Each

Planetary reduction gear gear
Planetary reduction gear gears have a sun gear in the middle and multiple planetary gears inside a ring gear. There are fixed and movable internal gears. Using gears with different numbers of teeth allows these reducers to produce high gear ratios and large reductions in speed.

Strain wave reduction gear gear
Strain wave reduction gear gears are high-performance reduction gears that use the strain wave gearing principle. They are driven by an elliptical wave generator that is placed inside a thin, cup-shaped elastic metal body. When the wave generator rotates and creates waves in the elastic metal body, the body comes into contact with the external circular gear. As the teeth of the elastic metal body engage the teeth of the external circular gear, the body rotates.
In addition to high torque, low inertia, and compact size, strain wave reduction gear gears have almost no backlash, and have low vibration and noise, allowing for quiet and stable operation.

Parallel shaft reduction gears

Parallel shaft reduction gears combine several stages of spur gears (which have excellent power transmission) and helical gears (which operate quietly) to reduce rotational speed. One notable feature is that the input and output shafts are parallel to each other.
A wide range of reduction gear ratios can be set by combining gears in several stages, making this type of reducer useful in a variety of applications.

Worm reduction gear gear

Worm reduction gear gears combine a worm gear, which is a threaded gear, with a worm wheel, which is a helical gear. The worm gear acts as the input axis and the worm wheel acts as the output.
Move separately. The input gear rotates perpendicular to the output gear and allow worm gears to achieve high reduction ratios in a single stage.
Energy is transmitted from the worm gear to the worm wheel through a sliding motion, which can tend to generate heat, and the duty factor is generally set very low. On the other hand, worm gears tend to be much quieter than planetary gears.

Bevel reduction gear gear

Bevel reduction gear gears use a type of bevel gear known as a hypoid gear to reduce the input speed. The axis of the output is rotated 90 degrees in relation to the input.
Bevel gears have strong teeth, so they perform well even under heavy loads and exhibit high durability. In addition, they feature high duty factors and are less likely to retain heat than worm reduction gears.

How Reduction Gear Work

Gear reducers, or reduction gears, are necessary for high efficiency machinery operating at elevated speeds. For the speed produced by the machinery to be practical, it has to be reduced to a lower speed to meet the needs of the powered application. The basic construction of a gear reducer consists of a large gear that is positioned with a smaller gear with both gears turning together.
In the case of a single gear reducer where a large gear is connected to a single smaller gear, the smaller gear makes two turns for every one turn of the larger gear. With the multiple turns of the smaller gear, there is greater speed but a loss of torque.
The reduction gear process takes place at preset ratios that meet the characteristics of the input and output gears. A gear reducer achieves the change in energy by changing the ratio of the moving gears.

The Process of a Reduction Gear

Gear ratio
The gear ratio is a way of measuring how different sizes of gears interact to transfer energy. The essential aspect of this calculation is the measurement of a circle, which is a major part of gears. The determination of the gear ratio can be understood by examining the circumference of a circle. A gear that makes two rotations to turn a larger gear once has a ratio of 2:1, which means that the output speed has been cut in half.
This example simplifies more complex gear reducers with several gear pairs in a series for converting revolutions per minute (RPMs) to torque. The example below presents a slightly more complex gear reducer with an idler gear between the small gear and the larger.
In determining the gear ratio, the only gears that influence the gear ratio are the drive gear and driven gear. Any gears inserted in between the two are not calculated in the gear ratio. An easy way to calculate the gear ratio is to count the number of teeth in the drive and driven gear. In the example, the drive gear has seven teeth while the driven gear has 30. The drive gear has to turn 4.3 times before the driven gear will turn.

Reduction gear torque
Torque is a rotational force that is received by the gear reducer and changed into a different force and speed with the amount of power remaining the same. Gear reducers are a gear or series of gears designed to reduce the torque of a motor, which increases in direct proportion to the reduction of rotations per unit of time or revolutions per minute. This is accomplished by base mounted or shaft mounted gear reducers.
Gears are used to multiply or divide torque, which is determined by the size of the gears. The ratio of the gear sizes increases or decreases torque, which is the foundational aspect of the operation of a gear box.

Drive gear
Drive gears or gear drives are designed to change the speed, torque, or direction of a rotating shaft. In their simplest form they are a small gear that drives a larger gear connected to the output shaft. They are essential for providing variable output speed from a constant power source.
In the image below, the silver worm shaft with a worm gear is the drive gear for this two gear gear reducer. The driven gear is the brass colored worm wheel of the worm gear set.

Driven gear
The driven gear is connected to the output shaft and transfers the reduced power to the application. They are the larger of the gear set regardless of how many gears there are in the series and come in a variety of shapes. In the compound gear train example below, there are two driven gears connected to different shafts, B and C. The gear ratio for the driver gear for shaft B and the one for shaft C is the same.

Reduction Gear Types

Bevel reduction gear

Bevel gear reducers have an angular bell crank that allows users to change the rotation of the system from transverse to longitudinal. They are compact and can handle a great deal of power from three phase asynchronous motors, synchronous motors, or asynchronous servo motors.
As with helical and hypoid gear reducers, bevel gear reducers operate quietly at a very high performance level with exceptional energy efficiency.

Cycloidal reduction gear

With a cycloidal gear reducer, the input shaft drives a bearing assembly that drives a cycloidal disc that is connected to an output shaft. The cycloidal has teeth that engage with a cam follower that has pin or needle bearings. The cam rotation produces a rotation of an output shaft at a much lower speed and higher torque than the input shaft.
The major benefit of cycloidal gear reducers is the elimination of backlash, which leads to higher precision and accuracy that is needed in robotic applications and machine tools. Additionally, cycloidal gear reducers have rolling contact that leads to less wear.

Gear Train reduction gear

A gear train gear reducer includes a series of gears that transfer power from an input shaft to an output shaft. They are used for applications that require a great deal of power and operate on parallel axes. There are several versions of gear train gear reducers with two gear trains being the simplest with a drive gear and driven gear. In multiple versions of gear trains, there is a drive gear with driven gear with idler gears in between.

Helical reduction gear

Helical gear reducers are another form of space saving gear reducer with durability and high overload capacity. They are used for forward speeds where the gear train is operating at medium to high speeds. The tooth traces of helical gears are slanted creating a higher meshing ratio to produce less noise and make them stronger. Their synchromesh design never disengages and provides more surface area.
The angular cut of the helical cut of helical gears allows for the teeth to be longer but have the same number of teeth as a spur gear.

Hypoid gears

Hypoid gears are cone shaped that send power between non-intersecting shafts. The small hypoid pinion side is offset from the hypoid gear side, which makes them able to pass without interference. The large contact ratio of hypoid gears allows for heavier load transmission with smooth meshing. As with helical gear reducers, the smooth meshing of hypoid gears produces less noise. Hypoid gear reducers are capable of very high speed reduction.
It is common to find hypoid gears being used when the angle is square and the distance between axes is small. Hypoid gears are used as an intermediate between bevel and worm gears.

Magnetic reduction gear

Magnetic gear reducers are a very unique form of gear reducer that uses magnetic attraction instead of physical contact. They do not have gear teeth but use opposing magnets that repel each other, which makes them capable of applying pressure regardless of the angle. Magnetic gears create motion just like traditional gears without touching, making them unaffected by wear.
Additionally, magnetic gears do not require lubrication or sealed barriers. They are manufactured using permanent magnets or electromagnets.

Planetary reduction gear

A planetary gear reducer has a sun gear, planet gears, and large ring gear. The planet gears depend on the support of the output shaft, inner gear ring, and the sun gear. The power drives the sun gear in the middle of the gear configuration, which drives the planetary gears to rotate following the inner gear ring. The rotation of the planet gears drives the output shaft connected to the output power.
A planetary reducer has a long service life, small size, high carrying capacity, low noise, high output torque, and high efficiency. It has power splitting and multiple tooth meshing to produce a reducer with wide versatility.

Spur reduction gear

Spur gear reducers have straight teeth that are parallel to the axis. They are the most common and frequently used type of gear reducer and can include multiple gears with multiple gear ratios. Spur gear gearboxes have exceptionally high efficiency with very low backlash and are very rugged and stable.

Worm reduction gear

A worm gear reducer has a worm pinion input and an output worm gear with a right angle orientation. They are used to take a motor’s speed and produce a lower speed output with a higher torque. Worm gear reducers are ideal for saving space due to their sleek design and the small diameter of their output gear as well as the excellent speed reduction using a small package.

How to Choose a Reduction Gear

There are certain factors that have to be evaluated before deciding to purchase a gear reducer. The main purpose of a gear reducer is to adapt the characteristics of torque and speed of the input and output axis of a mechanism. It is for this reason that it is necessary to understand the torque and rotational speed of the application.

Torque of a motor
A gear reducer increases the torque of a motor and creates a new torque for the receiving application. As an assist to customers, manufacturers express maximum and minimum torque in newton meters (Nm) for their products with the torque density varying between different gear reducers.

Speed of a motor
The second purpose of a gear reducer is to reduce motor speed, which is expressed in terms of the reduction ratio. The rotational speed of a motor is changed by the rotational ratio to produce the output rotational speed, which is described in revolutions per minute.

Reduction gear selection
At this stage of the selection process, an expert, engineer, or designer that is knowledgeable in gear reducers is necessary since there are so many types of gear reducers designed to meet the requirements of a wide assortment of functions and parameters. The configuration of the input and output shafts are the first criteria related to choosing the type of gear reducer.

Reduction gear dimensions
To decide on the dimensions of a gear reducer, it is important to choose the right shaft, which can be orthogonal, coaxial, and parallel. Each of these shaft types have a different orientation in regard to the gear reducer, which are perpendicular, aligned and parallel.

Motor performance
In some applications, motors experience shock or cyclic loads. When choosing a gear reducer, it is important to factor in these conditions in order to allow the gear reducer to be able to deal with the increased torque.

Operational efficiency
Choosing a gear reducer that operates efficiently is necessary regarding its cost. The correct one for an application can be beneficial in regard to long term costs.

Choosing a gearbox
Planetary reduction gear
Planetary gear reducers are used with applications that demand fast acceleration, low speed, and high torque. They are used in machine centers, machine tools, and agricultural operations.

Worm gear
Worm gear gear reducers are used in applications with a high transmission ratio. They are less costly than other gear reducers and operate very quietly. Worm gear gear reducers are used on conveyors, winches, and material handling due to their non-reversibility.

Choosinggear train
Gear train gear reducers are designed for high powered applications and save money on maintenance due to their exceptional performance and low reduction ratio.

Bevel reduction gear
Bevel gear reducers permit operators to change their rotation scheme. They are small, strong, and can endure a great deal of force. The drawbacks to bevel gear reducers is their poor performance, high cost, and constant need for maintenance. Bevel gear reducers are found in farm equipment and heavy duty conveyors.

Choosing the right reduction gear
Gear reducers are critical factors in a wide assortment of machines and are important components for the smooth operation of the machines. The correct selection of a gear reducer ensures the effectiveness and efficiency of a mechanism. A qualified manufacturer with the proper knowledge and tools can guide the perfect solution for any application.

Reduction Gear Maintenance

Lubrication material
Every gear reducer manufacturer sells or recommends the correct lubrication material for their products. The lubricant has to have the right properties to enhance performance. Initially, during the break in period, it may be necessary to filter the lubricant to remove contaminants. The quality of the lubricant should be checked regularly as well as its level.

Reducer contamination
The only thing that is permitted in a gear reducer is the lubricant. Dust and water that can enter through faulty seals can cause extensive damage to the gears.

Storage for reduction gear
Gear reducers are stored in clean, dry, and climate controlled conditions with all of its covers, vents, and drains closed and sealed. Though the gear reducer is not in operation, its lubrication cycle must be maintained. During the process, it should be rotated to ensure the even distribution of the lubricant.

Reducer vibration or noise
The initial indications of problems with a gear reducer are noise. Assessment can be made by operating it without a load. Essentially, noise and vibration are an indication of the need for gear reducer overhaul or replacement.

Reduction gear overheating
Overheating is an indication that the gear reducer is not receiving sufficient lubrication. The harm of overheating can be prevented by regular checks of the surface temperature of the gear reducer. Overheating can be due to friction between the gears caused by a lack of lubricant.

Our Factory

Founded in 1992, JinHua JingGong automotive gear Ltd., Co. was originally established in JinHua, ZheJiang. Major products are transmission gear and gear shaft parts. As a 30-year-old mechanic manufacturing company, the persistency on automotive industry has always driven us to be creative and keep forging ahead. Currently, we have capability to produce 500,000 parts per year and independently develop new transmission gear boxes, and more importantly, we can turn a blueprint into a fact. Holding the IATF 16949 certificate, JingGong is currently a supplier of DFAC. Our products cover full-range of transmission field, including trucks, construction machinery, farm machinery and mining machinery. Also, we have developed transmission parts of first batch EV trucks in China.

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FAQ

Q: What is a reduction gear?

A: A reduction gear is a mechanical transmission device used to convert input high-speed rotational motion into lower-speed rotational motion while increasing torque. It achieves speed reduction and torque increase through meshing between gears.

Q: What is the main function of a reduction gear?

A: The main function of a reduction gear is to adjust the rotational speed of mechanical equipment while increasing torque output to meet different work requirements. In many mechanical equipment, such as automobiles, machine tools, cranes, etc., reduction gears are indispensable key components.

Q: What is the working principle of a reduction gear?

A: The working principle of a reduction gear is based on the meshing transmission of gears. When two gears of different sizes mesh with each other, the speed of the large gear will be lower than that of the small gear, but the large gear will transmit greater torque. By adjusting the number of teeth and module of the gears, different reduction ratios can be achieved.

Q: What are the types of reduction gears?

A: There are various types of reduction gears, including but not limited to planetary reducers, worm gear reducers, helical gear reducers, spur gear reducers, etc. Each type has its unique structural characteristics and application scenarios.

Q: How is the reduction ratio of the reduction gear calculated?

A: The reduction ratio is the ratio of the input speed to the output speed of the reduction gear. It is usually equal to the ratio of the number of teeth of the driving gear (or the number of teeth of the small gear) to the number of teeth of the driven gear (or the number of teeth of the large gear).

Q: In which industries are reduction gears widely used?

A: Reduction gears are widely used in various industrial fields, including automobile manufacturing, machinery manufacturing, aerospace, energy and power, construction engineering, etc. They play an important role in adjusting the speed and transmitting torque in these industries.

Q: What are the precautions for the maintenance and care of reduction gears?

A: The maintenance and care of reduction gears should pay attention to the following points: regularly check the wear of the gears and replace the gears with severe wear in time; keep the gearbox clean and replace the lubricating oil regularly; avoid overload operation to prevent gear damage; pay attention to the lubrication and cooling of the gears to ensure that the gears run in good working condition.

Q: What are the common causes of failure of reduction gears?

A: Common causes of failure of reduction gears include gear wear, fracture, poor lubrication, overload operation, etc. In addition, improper installation, improper use or design defects may also cause failure of reduction gears.

Q: How to choose a suitable reduction gear?

A: Choosing a suitable reduction gear requires considering multiple factors, including the working environment, workload, speed requirements, torque requirements, etc. of the mechanical equipment. At the same time, factors such as the type, accuracy, and reliability of the reduction gear also need to be considered.

Q: What is the impact of the accuracy of the reduction gear on the mechanical equipment?

A: The accuracy of the reduction gear directly affects the operating stability and reliability of the mechanical equipment. High-precision reduction gears can ensure accurate transmission and efficient operation of mechanical equipment, reducing energy loss and wear.

Q: How to solve the noise problem of the reduction gear?

A: Solving the noise problem of the reduction gear can start from many aspects, including optimizing gear design, improving processing accuracy, improving lubrication conditions, and strengthening gearbox sealing. In addition, choosing suitable lubricants and gear materials can also effectively reduce noise.

Q: How to predict and extend the life of the reduction gear?

A: The life of the reduction gear can be predicted by theoretical calculations and experimental tests. In order to extend the life of the reduction gear, a series of measures can be taken, such as selecting high-quality gear materials, improving processing accuracy, optimizing lubrication conditions, and avoiding overload operation.

Q: What is the role of reduction gears in automated production lines?

A: In automated production lines, reduction gears play an important role in adjusting the speed of equipment and transmitting torque. They can ensure that all parts of the production line run at a predetermined speed and sequence, improving production efficiency and product quality.

Q: What are the lubrication methods for reduction gears?

A: The lubrication methods for reduction gears mainly include oil bath lubrication, splash lubrication, pressure lubrication, etc. Different lubrication methods are suitable for different working environments and load conditions. Choosing a suitable lubrication method is essential to ensure the normal operation of reduction gears.

Q: What are the options for gear materials for reduction gears?

A: There are many types of gear materials for reduction gears, including cast steel, alloy steel, stainless steel, etc. When selecting gear materials, factors such as material strength, toughness, wear resistance, and corrosion resistance need to be considered.

Q: What are the key points for installing and adjusting reduction gears?

A: The following points should be noted when installing and adjusting the reduction gear: Ensure that the gearbox and the installation foundation are stable and reliable; Install in accordance with the prescribed installation order and method; Adjust the meshing clearance and side clearance of the gears to ensure that the gears can mesh correctly and transmit torque; Check the rotation flexibility and smoothness of the gears.

Q: How is the reduction ratio of the reduction gear calculated, and what is its importance?

A: Reduction ratio calculation: The reduction ratio is the ratio of the input speed to the output speed of the reduction gear, usually expressed as i = n1/n2, where n1 is the input speed and n2 is the output speed. It can also be calculated by the ratio of the number of teeth of the driving gear to the number of teeth of the driven gear.
Importance: The selection of the reduction ratio is crucial to the performance of mechanical equipment. A suitable reduction ratio can ensure that the equipment operates in an efficient and stable state while meeting specific working requirements. Too large or too small a reduction ratio may cause equipment performance degradation or damage.

Q: What are the common faults of the reduction gear during use, and how to solve them?

A: Common faults: Common faults of the reduction gear during use include abnormal sound, excessive bearing temperature, oil leakage of the oil seal, tooth surface damage or corrosion, etc. These faults may be caused by a variety of reasons, such as excessive lubricating oil residue, damage to the gear meshing part, large bearing gap, oil seal failure, etc.
Solution: For these faults, corresponding solutions can be taken. For example, check and replace damaged parts, adjust bearing clearance, replace lubricating oil and oil seals, etc. At the same time, regular maintenance and maintenance of reduction gears are also important measures to prevent failures.

Q: What are the considerations for the selection and application scenarios of reduction gears?

A: Selection considerations: When selecting reduction gears, multiple factors need to be considered, including the working environment, workload, speed requirements, torque requirements, etc. of the mechanical equipment. In addition, factors such as the type, accuracy, reliability and cost of the reduction gears need to be considered.
Application scenarios: Reduction gears are widely used in various industrial fields, such as machinery manufacturing, automated production lines, food processing, mining, metallurgy, chemical industry, construction, etc. In the field of machinery manufacturing, reduction gears are commonly used in machine tools, conveying equipment, packaging machinery, printing machinery, etc.; in automated production lines, reduction gears are used to drive equipment such as conveyor belts, assembly lines and robots. Different application scenarios have different requirements for reduction gears, so they need to be selected and applied according to specific circumstances.

Q: How efficient is a reduction gearbox?

A: The general characteristics of gear reducers with parallel axes are as follows : For high precision gears, the transmission efficiency is very high. (98 to 95% for one-stage gear reducer) When properly lubricated, it can be used for a long time.

We're professional reduction gear manufacturers and suppliers in China, specialized in providing high quality customized service. We warmly welcome you to buy high-grade reduction gear at competitive price from our factory.

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