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FEATURE GEARS & GEARBOXES


Specifying the wrong gear can result in excessive energy consumption, noise, reduced efficiency, safety issues and more. Here, Marek Lukaszczyk,


Europe and Middle East marketing manager for geared motor manufacturer WEG, explains how to select the right gear unit for your application


TAKING THE CONFUSION OUT OF GEAR SELECTION


M


anufactured in a range of materials, today’s gear units are available in a variety of shapes and sizes, and can


even be designed specifically to meet the demands of industry applications ranging from robotics, automotive and aerospace to industrial machinery.


Choosing the solution depends upon the end goal, however choosing the wrong gear can result in excessive energy consumption, noise, wear and tear, reduced efficiency, breakdowns, and the possibility of safety issues caused by consequences like excessive vibrations. So how do you go about selecting the right gear for your application?


TECHNICAL REQUIREMENTS Defining technical requirements is fundamental for choosing the right gear unit. The more clearly defined, the better. The absolute basics of this technical specification include: the output torque required to complete the task, the speed and power requirements of the motor and the required mounting dimensions. Before a buyer makes a purchasing decision,


the technical specifications must be checked by the company’s own engineers to ensure that the gear units actually deliver the required


54 DESIGN SOLUTIONS JUNE 2023


power, reliability and cost-effectiveness in a specific application. From a technical point of view, two factors


are decisive when selecting a gear unit: the application requirements and the available space, which always depends on the location of the gear unit. Gear drives are the most commonly used type


in industry, but there are other varieties to consider. Helical gear, bevel gear, parallel shaft gear and worm gear units make up the majority of all installed gears, and planetary gears are also used to a lesser extent. Design differs depending on the industry in which the geared motors are to be used. Factors such as power (kW), speed (rpm) and torque (Nm) always influence size and cost. If a geared motor – the combination of motor and gear unit – is incorrectly dimensioned, it will have a negative consequence on the systems performance.


CONSIDERATIONS Following this, an engineer should consider the ambient conditions in which the unit will operate. What installation space or room is available and where will the gear unit be installed? In some industries, like those operating in hazardous areas, considerations


like excess dirt and dust, temperatures and explosive atmospheres should also be assessed. It is also important to consider the


geographical region the unit will ultimately be operating in. Different certifications may be required, so opting for a unit that is CE (Europe), CSA (United States and Canada), UL and EA (both global) certified can be advantageous. WEG’s WG20 range of gear units – the first gear unit designed entirely in-house by WEG – meets this global certification, has standard mounting dimensions and can be switched to different voltages for applications around the world. Efficiency also plays an important role in the selection of gear units. High efficiency can


reduce the operating costs and CO2 emissions of drives. In fact, energy costs account for almost 90% of the total life cycle costs of geared motors, making efficiency a critical matter. Investments in energy-efficient gear units


generally pay for themselves in a relatively short period of time. This is not only important for an engineer or operator, but also for machine builders and OEMs. So, the following applies: the more efficient the entire drive train, the more economical it will be.


WEG www.weg.net


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