FEATURE GEARS & GEARBOXES
WHY PLASTIC IS FANTASTIC for spur gears
Marcus Schneck, CEO of norelem, discusses why plastic spur gears are a viable alternative to their
metal counterparts, and how they can boost productivity
T
he ‘Productivity Puzzle’ is a term that has been bandied around for many
years by statisticians, looking at how to raise the collective productivity of workers to enable long term economic growth. Yet, in the UK, productivity has
slowed to drastic levels in recent years. In 2018, productivity grew by just 0.5%. To put that into perspective, the measure of economic output per hour of work previously rose by about 2% a year, on average, before the 2008 financial crisis. This slowdown isn’t just a ‘so
what?’ situation either. If it is not rectified, there will be implications. Productivity is considered an important driver of improved living standards over the long term, enabling companies to pay higher wages as they can produce higher revenues with the same or fewer resources. For engineers and manufacturers, much
of the focus to driving up output has been about realising new technologies. These include additive manufacturing, IIoT, and Industry 4.0, the trend of automation and data exchange in manufacturing. While these overarching developments
are needed, there are also much more simpler ways where machinery can be improved to create efficiencies and release added value. This includes looking at the standard components used in engineering, and specifically, making good use of plastic spur gears.
GEARED TO PERFECTION Gears are integral to the smooth operation of most machinery equipment, transmitting rotary motion and force as required, depending on the application. This is crucial for machines that require a change in the direction of rotation – for example, where loads must be raised or lowered. To achieve this, most machinery
will use a combination of standard gear components, the most common of which are spur gears,
52 JUNE 2019 | DESIGN SOLUTIONS
“As with all engineering, there needs to be careful consideration around the spur gears’ application, usage, and user benefits,” commented Schneck
Plastic spur gears are rust-proof, low in weight and quieter in operation
which are mainly used for transmission between a rotating mechanism and a mechanism with longitudinal movement. An example of this is in the connection
of a gear wheel with a gear rack. Spur gears are suitable for form-locking and slip-free force transmissions with alternating rotation. Commonly, spur gears are made of
steel and, although these offer high strength and can cope with high transmission forces and temperatures, these components do wear over time – through corrosion and general wear and tear – and must be replaced. This then causes downtime, as well
as incurring capital costs to replace the parts. In addition, spur gears need lubrication while in service, which is another cost to consider, and can cause excessive noise during operation if not fitted correctly.
GOING PLASTIC To alleviate these issues, plastic spur gears are now widely available as standard components. norelem offers these parts in a variety of sizes and in teeth numbers from 12-38. For engineers, these plastic versions
offer a variety of benefits. First and foremost, they are highly cost-effective in comparison to their steel counterparts. This is due to them being rust-proof and therefore requiring no lubrication and minimal maintenance. In turn, they do not need replacing as often, downtime is minimised, capital costs from parts, labour and lubrication is reduced and,
ultimately, productivity increases. Due to their material make-up, they
are also lower in weight, and are much quieter during operation. One of the biggest problems in factory environments is machinery noise, which interferes with production. Not only does excessive noise mean employees cannot communicate effectively, but it can also increase the chances of unnecessary accidents. Indeed, regular exposure to loud noise can permanently damage hearing, which is why there is protection through regulation from The Control of Noise at Work Regulations 2005. By reducing noise in the workplace,
accidents that lay-off workers can be prevented, while employers can provide a better welfare overall. Outputs are then better through a healthy, happier workforce.
HERE TO HELP As with all engineering, there needs to be careful consideration around the spur gears’ application, usage, and user benefits. Temperatures and forces will alter which type and size of spur gear are required, along with the amount of teeth. In general, the more teeth, the higher the degree of accuracy when moving loads. Spur gears can be combined with
gear racks or bevel gears for more complex applications. These are also available from norelem via its complete engineering reference guide, THE BIG GREEN BOOK. CAD data, diagrams and best practice material is also available from norelem, while experts are on hand to help with engineering enquiries.
norelem
www.norelem.co.uk
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