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BASIC INTRODUCTION TO GEARBOX
SELECTION
When selecting a gearbox a user normally knows at least three
things – the input speed; the output speed or required gear
ratio and the motor power. In addition, he may know the driven
machine’s absorbed power, from experience or measurement
on similar systems.
When turning to a catalogue of gearboxes, the user will find
two or three different ratings – a mechanical power capacity;
a thermal power capacity; and an allowable overhung load on
the input and output shafts. Each of these ratings must be
modified to take account of the type of duty the gearbox will
experience and for ambient conditions.
Mechanical rating
The mechanical ratings in the catalogue typically apply to a
gearbox driven by a uniform power source and driving a ma-
chine with a uniform load requirement for 10 hours per day. In
practice, this is seldom the case, so the required power must
be increased to allow for the type of prime mover, the loading
characteristics and the hours of use. This is accomplished by
multiplying the prime mover power by a mechanical service fac-
tor, which will be found tabulated in the catalogue. In addition,
if the gearbox is subjected to reversals or frequent start-ups, a
further check is required and a start factor, dependant on the
frequency of starting, will also be found in the catalogue. The
larger of the two powers thus calculated is then used to select
a gearbox from the mechanical rating tables.
apply to a gearbox at sea level in a large enclosed space at
an ambient temperature of 20oC. Factors for different alti-
tudes, locations and temperatures are given in the catalogue,
and the absorbed power is divided by these factors to reach
the required thermal rating pertaining to the actual conditions.
This can then be compared with the thermal ratings in the cata-
logue for units with no cooling; units with fan cooling; units with
water cooling; and units with both water and fan cooling. If
none of these exceeds the required thermal rating then there is
the choice of using a larger gearbox or pumping the oil through
an external cooling system.
Overhung load capacity
If a gearbox is driven by or is driving a pulley, sprocket or
pinion attached to one of the gearbox shafts, then the gearbox
experiences an overhung load on that shaft. In certain applica-
tions (for instance mixers or stirrers) an axial thrust may also
be imposed on the output shaft. Allowable overhung radial and
axial loads are tabulated in the catalogue, again subject to a
factor dependant on the type of load. The tabulated figures
are for the most unfavourable conditions of direction of the
load and rotation of the shaft and when the gearbox is trans-
mitting the catalogue power. They can, therefore, sometimes
be increased, but this must be referred to the manufacturer

Thermal rating

Again, the thermal ratings in the catalogue usually have to be

modified for ambient conditions. The tabulated ratings usually

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