For a power source to be put to useful work its energy must necessarily be transferred to some working implement. Through transforming the rotating force produced by an engine or motor, the direction of rotation, the speed, or the torque will be modified producing the optimum force needed for the work. All mechanical implements require maintenance and eventual repair. This transforming and transmitting device will eventually require Gearbox repairs.
A device, also known as a reducer, is required if the working machine has to run at output speeds which vary from engine speeds. Using gears of different ratios will produce needed changes in torque and speed.
A meshing of the rotating input or drive gear with a larger output gear, with more teeth, will slow the rotational speed. Torque can also be increased in this way, producing a mechanical advantage. Automobiles are applications where this is observed. The engine, in order to run smoothly, produces many times the number of rotations in a minute as can be used by the wheels.
Some applications such as large wind turbines will have the opposite requirements. Their structural and design requirements make it necessary that the blades of the turbine turn a slower speed than the several revolutions per minute required for generators to produce electricity. Here the gearbox increases speed.
These transmission devices can often be fairly complex. Multiple output speed choices can be supplied through multiple gears of several differing sizes. The automobile transmission exemplifies this. In order to overcome inertia and first put the car into motion requires that the engine’s rotational energy be slowed and its torque, or mechanical advantage, be increased significantly. An output gear of larger circumference and with more teeth than the input accomplishes this.
As the vehicle begins to travel at more speed and momentum increases, less torque is needed and more speed desired. Using successively smaller output gears results in faster rotation of the wheels. For high cruising speeds an overdrive gear may be available.
When steep hills are encountered the car’s momentum will again be slowed by the increased work demands of overcoming increased gravitational forces. Now it becomes necessary to gear down once again producing more torque, until the hill is climbed. Trucks carrying or pulling heavy loads will have the same demands. Those same trucks climbing hills will need gearing different from that of economy or cruising vehicles.
Changes of rotational direction or angle may sometimes be required. An example of this is the rotor of a helicopter. A rotating vertical shaft here transmits energy from the engine to drive a rotor turning at right angles to that shaft.
Wear and eventual failure of the gearbox and its components will occur over time, necessitating Gearbox repairs. In that event the causes of failure can be determined by skilled technicians through inspection and analysis of parts. Those damaged parts may be repaired or refurbished. If needed they will be replace with fabricated or manufactured parts. This unit should work exactly the same as a new one, or with some adjustments, possibly with extended life or improved performance.
Get the inside scoop on the different types of gear reducers and gearbox repairs now in our insider’s review on common gearbox problems