Industrial Application of Gear Box

1. Sr. No. Roll No. Name PRN NO.
1 58 Younis Giri 12010378
2 69 Aniruddha Thakur 12120191
3 72 Rameshwari Ramesh Ugale 12120241
4 75 Sagar Yadav 12120251
5 76 Dhiraj Zope 12120161
MECH-D: Batch 3 - Group 3
Industrial Application of Gear Box
Guide – Prof. M.R.Khodke

2. Introduction
● A gearbox is a mechanical device that transmits power from one
component to another by changing the speed, torque, or direction
of rotation.
● Gearboxes are commonly used in various industrial applications
that require power transmission and control, such as machinery,
vehicles, and equipment.
● The industrial applications of gearbox include automotive,
aerospace, marine, construction, mining, energy, and many others.
● In automotive applications, gearbox is used to transmit power
from the engine to the wheels, allowing the vehicle to move at
different speeds and handle different driving conditions.
Figure. 1

3. History Of Gearbox And Its Evolution Over Time
➔ Gearbox dates back to ancient times, where simple
mechanisms were used to transmit power.
➔ The first documented use of gears can be traced back to
ancient Greece.
➔ In the Middle Ages, gears were used in the
development of complex machines such as watermills
and windmills.
➔ The first modern gearbox was developed in the early
19th century by François Isaac de Rivaz.
➔ During World War II, gearbox technology advanced
rapidly.
➔ In the post-war era, new gearbox designs, such as
helical, bevel, and planetary gears, were introduced.
➔ Today, gearbox plays a vital role in various industries
and continues to evolve with the advancement of
technology and engineering.
Figure. 2

4. Evolution of Gear Tooth Profile
Gear tooth profile refers to the shape of the teeth
on a gear. It is an important aspect of gear design
as it affects the performance, durability, and
noise level of the gear.
The evolution of gear tooth profile can be traced
back to ancient times when gears were used in
simple machines such as water wheels and
windmills.

5. Involute gear profile
● Tooth shape is based on the curve traced by a point on a taut string
unwinding from a base circle.
● Tooth engagement: When two involute gears mesh, the contact
between the teeth occurs along a line, rather than a point or area. This
provides a larger contact area and distributes the load more evenly
between the teeth.
● Advantages - smooth and efficient power transmission, low wear, and
consistent performance across a range of gear sizes.
● Applications: The involute gear profile is commonly used in a wide
range of applications, including automotive transmissions, industrial
machinery, and power generation equipment.
Figure. 3
Figure. 4

6. ● Cycloidal Profile: The cycloidal profile was developed
in the early 20th century and was used in early
automotive transmissions.
● It is a curve that is traced by a point on the
circumference of a circle as it rolls along a straight line.
● This profile provides a smoother transfer of power than
the involute profile and can handle higher speeds and
loads.
● Cycloidal gears are commonly used in high-speed and
high-torque applications, such as in industrial
machinery and power transmission systems. They can
also be found in some automotive applications, such as
in automatic transmissions.
Cycloidal Profile

7. Epicycloidal Profile
Epicycloidal Profile: The epicycloidal profile was developed in the mid-
20th century and is used in high-precision applications, such as
watchmaking.
It is a curve that is traced by a point on the circumference of a smaller
circle that rolls around the outside of a larger circle.
This profile provides a very smooth transfer of power and allows for
precise positioning of the gears.
Figure. 5

8. Construction of Gearbox
Gearbox consists of following Main Parts and that are:
● Clutch Shaft- It utilizes force engine supplies other parts. The driving shaft
is attached to them via a clutch, and when the clutch is engaged the driving shaft
starts to rotate.
● Counter Shaft- It is provided gears in variant sizes which can produce a level of
torque.Its rotation is different but contributes consecutive speed just like the clutch
shaft.
● Main Shaft- Also known as output shafts. It revolves at a different speed and also
gives mandatory torque to the vehicles.The main shaft is splined so gears could
move; both engage and disengage in a better way.
● Bearings - It promotes support and Delivers maximum power with less frictional
losses.
● Gears
Figure. 6

9. Benefits of using gearboxes in industrial applications
Power
Transmission
Versatility Efficiency Safety
Speed
Reduction or
Increase
Torque
Multiplication

10. Types Of Gear Box According Shaft Arrangement
Type of
Gearbox
Shaft Arrangement Mounting
Concentric High and low-speed shafts are
on the same horizontal and
vertical plane
Foot mounted
Parallel High and low-speed shafts are
on the same horizontal plane
and parallel to each other
Foot mounted
Right Angle High and low speed shaft have a
90-degree relationship
Foot mounted
Shaft
Mount
The gearbox is mounted directly
onto and supported by the
driven shaft
Shaft mounted
Fig. 6. Concentric Fig.7. Parallel
Fig.8. Right angle Fig.9. Shaft Mount

11. Gear Boxes Industries Application
Concentric Agriculture,Cement, Mining Heavy duty bulk material handling, & construction equipment,
Parallel Agriculture,, Cement & Mining, Conveying, Crushers, Feeders.
Right Angle Automotive, Food & Beverage, Feeders, Pumps, Dryers, Mixers/blenders, Agitators, Elevators
Shaft Mount Package Handling, Metal Processing Belt conveyors, classifiers, Separators

12. Types Of Gearboxes Commonly Used In Industrial Applications
Spur Gearboxes
Bevel Gearboxes
Cycloidal
Gearboxes
Planetary
Gearboxes
Helical Gearboxes Worm Gearboxes
Harmonic
Gearboxes

13. Agitators
● An agitator is a shaft mounted with impellers which is inserted into a tank. On rotating the shaft using a geared
motor or a gearbox, the fluids inside the tank undergo a mixing process.
● The profile of the blades, the number of blades, the mounting of the shaft and the shaft dimensions are determined
by the properties of the fluid to be mixed inside the tank and the batch capacity.
Figure. 10
Figure. 11
Figure.12

14. Road Roller
In a road roller, a set of spur gears changes the fast rotational speed of the
engine into a slow rotational speed for the wheels. This change makes it possible
for a road roller to be able to move its heavy roller.
The gears, pinions and shafts of these Diesel Road Compactors are housed in a
mild steel fabricated gearbox and are manufactured out of special and
recommended alloy steels. A differential locking arrangement is provided and is
operated from the driver’s seat.
Figure. 13
Figure. 14

15. Conveyor System
➔ Purpose- Gearboxes are used in conveyor systems to control the
speed of the conveyor belt and to provide the required torque to
move heavy loads.
➔ Speed control: By changing the gear ratio, the gearbox can
increase or decrease the speed of the output shaft, which is
connected to the conveyor belt.
➔ Torque multiplication: Gearboxes also provide the required
torque to move heavy loads on the conveyor belt. By reducing
the speed of the input shaft and increasing the torque.
➔ Gear ratio: The gearbox typically consists of multiple stages of
gears, each with a different gear ratio, to achieve the desired
output speed and torque.
➔ Types of gears: Helical gears are commonly used for their
efficiency and low noise, while bevel gears are used for high-
speed applications. Worm gears are used for high-torque
applications where space is limited.
Figure. 18

16. ❖ Epicyclic Gearbox
Working of Epicyclic Gearbox
➔ The working principle of the epicyclic gearbox is based on the fact
the fixing any of the gears
➔ As fixing any of the above causes the variation in gear ratios from
high torque to high speed. So let’s see how these ratios are
obtained
1. First gear ratio
2. Second gear ratio
3. Reverse gear ratio
Application
● The epicyclic gearbox is used in the automatic model of Audi A4
● It is used in Lamborghini Gallardo.
● It is also used in power transmission between I.C engine and
electric motor, so it also has its uses in hybrid cars.
Figure. 15
Figure. 16

17. Wind Turbine
➔ Purpose of gearbox: to increase the rotational speed of
the rotor shaft, to the speed needed by the generator to
produce electricity.
➔ Types of gears: Helical, spur, or planetary gears, which
are designed to withstand the high torque and variable
loads of the wind turbine.
➔ Location: between the low-speed rotor shaft and the
high-speed generator. The rotor rotates at speeds of 10-
20 rpm, while the generator needs to operate at higher
speeds, typically 1200-1800 rpm
➔ Gear ratio: The gearbox increases the rotational speed of
the rotor by a factor of 50-100, depending on the specific
turbine design. This is achieved through multiple stages
of gears, each with a different gear ratio.
Figure. 17

18. Mining Industry
❖ Purpose: Gearboxes are used extensively in the mining
industry for various applications, including conveying,
crushing, and processing of minerals.
❖ Types of gears: The type of gear used in mining industry
gearboxes depends on the application.
● Helical gears are commonly used in conveyor systems.
● while bevel gears are used in hoisting systems.
● Planetary gears are used in crushing and grinding
equipment due to their high torque and compact size.
Figure.19

19. Crushers
● Crushers are used to reduce particle size enough so that the material can be processed into finer
particles in a grinder Some crushers are mobile and can crush rocks as large as 1.5 meter (60 inches).
● Primarily used in-pit at the mine face these units are able to move with the large infeed machines
(mainly shovels) to increase the tonnage produced.
● In a mobile road operation, these crushed rocks are directly combined with concrete and asphalt which
are then deposited on to a road surface.
● This removes the need for hauling over sized material to a stationary crusher and then back to the road
surface.
Figure. 20
Figure. 21

20. Reclaimers/stackers
● Conveyor systems: Gearboxes are used in conveyor systems to transport materials from
one location to another. The gearboxes control the speed and torque of the conveyor
belt, allowing for efficient and reliable movement of bulk materials such as coal, iron
ore, and copper concentrate.
● Bucket wheel reclaimers are the ideal means of handling and moving large amounts of
bulk materials in the shortest possible time
Figure. 23
Figure. 22

21. Conclusion
● Gearboxes are essential in many industries such as mining, agriculture, transportation, manufacturing, and energy
production.
● They are used to transmit power, increase torque, and control speed in various mechanical systems.
● Gearboxes are also critical in controlling the speed and direction of rotational motion in electric motors and engines.
● They can improve the efficiency and lifespan of industrial machines by reducing wear and tear and providing precise
positioning.
● The selection of the appropriate gearbox for a specific application is critical to achieving optimal performance and
maximizing the lifespan of the machinery.
● Advances in technology have led to the development of more efficient and precise gearboxes, leading to improved
productivity and reduced downtime in industrial applications.

22. References
1. Singh, S. (2014). Gearbox fundamentals, design, and analysis. CRC Press.
2. Budny, W. (2019). Industrial gearboxes: design, applications, and maintenance. Springer.
3. Zhang, Y., Zhu, J., & Lin, Z. (2019). Research on dynamic characteristics of a gearbox in industrial
application. Journal of Mechanical Engineering Research and Developments, 42(2), 288-295.
4. Mishra, S., Singh, S., & Kumar, A. (2017). Industrial gearbox: Its applications, design principles, and analysis
techniques. Journal of Mechanical Engineering and Sciences, 11(1), 2588-2602.
5. Raja, M. R., & Jayakumar, S. (2016). Application of reliability analysis in industrial gearbox maintenance.
Journal of Engineering Science and Technology Review, 9(4), 70-77.
6. Pandey, R. K., & Tiwari, R. (2018). Gearboxes for wind turbines: An overview of technology trends,
challenges and opportunities. Renewable and Sustainable Energy Reviews, 91, 297-311.
7. Izdebska-Szanda, I., & Kuźmicz, W. (2020). Gearbox vibrations caused by gear wear—case study. Applied
Sciences, 10(18), 6527.

24. ● Wear and Tear: Frequent use of the shock absorber over a long period of time can cause wear and tear, leading to reduced
performance and eventual failure.
● Corrosion: Exposure to harsh environmental conditions, such as moisture and salt, can cause corrosion of the shock
absorber components, leading to failure.
● Impact Damage: The shock absorber can be damaged due to a sudden impact, such as hitting a pothole or a curb, which
can cause the internal components to fail.
● Manufacturing Defects: Poor quality materials or manufacturing defects can cause the shock absorber to fail prematurely.
● Improper Installation: Improper installation of the shock absorber can cause it to malfunction or fail.
● Fatigue Failure: Continuous and repeated cycles of loading and unloading can cause fatigue failure of the shock absorber,
leading to eventual failure.