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Gearbox Guide
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What is a Gearbox?
A gearbox is a mechanical device utilized to increase the output
torque or change the speed (RPM) of a motor. The motor's shaft is
attached to one end of the gearbox and through the internal
configuration of gears of a gearbox, provides a given output torque
and speed determined by the gear ratio.
Physical Properties
The physical components of gearboxes vary from one gearbox type
to another, as well as differences between manufacturers. Most
gearboxes are constructed from steel materials such as iron, aluminum and brass. Unlike other gearbox types, spur
gearboxes can also be made with plastics such as polycarbonate or nylon. Other than the raw materials used, the
orientation of the gear teeth play a major role in the overall efficiency, torque and speed of the system. Straight gear
teeth gearboxes are typically used in low-speed applications. These gearboxes can be noisy, and may have lower
overall efficiency. Helical gearboxes are typically used in high-speed applications. These gearboxes are quieter in
operation than straight gear teeth gearboxes, which may improve their overall efficiency.
Types of Gearboxes
There are many types of gearboxes manufactured throughout the world. One of the main differences between
individual gearboxes is their performance characteristics. Choosing from the various gearbox types is application
dependent. Gearboxes are available in many sizes, ratios, efficiencies and backlash characteristics. All of these
design factors will affect the performance and cost of the gearbox. There are several types of gearboxes which are
listed below:
Bevel Gearbox
Bevel Gears
There are two types of bevel gearboxes which include either straight or spiral teeth gears. Straight
bevel gears have straight and tapered teeth and are used in applications requiring slow speeds.
Spiral bevel gears have curved and oblique teeth and are used in applications requiring highperformance, high speed applications.

Figure 1: Straight Bevel Gearbox

Figure 2: Spiral Bevel Gearbox

Physical Properties
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Bevel gears are typically constructed from cast iron, aluminum alloy or other steel materials but vary
between manufacturers.
Note: Gears made from steel materials can be noisy when coming into contact with other gears and
also make them prone to wear.
Applications of Bevel Gears
Bevel gearboxes use bevel gears and are mainly used in right angle applications with the shafts in a
perpendicular arrangement.

Print Press
Power Plants
Automobiles
Steel Plants
Hand Drills
Differential Drives
Advantages of Bevel Gears

Right angle configuration

Durable
Disadvantages of Bevel Gears

Axes must be able to support forces

Poorly cut teeth may result in excessive vibration and noise during operation
Helical Gearbox
Helical Gears
Helical gears are cut at angles which allow for gradual contact between each of the helical gear teeth.
This type of innovation provides for a smooth and quiet operation. Gearboxes using helical gears are
applicable in high horsepower and efficient applications.

Figure 3: Helical Gearbox

Physical Properties
Helical gears are typically constructed from cast iron, aluminum allow or iron material but may vary
depending on the manufacturer.
Note: Gears made from steel materials can be noisy when coming into contact with other gears and
also make them prone to wear.
Applications of Helical Gears
Helical gears are widely used in applications which require efficiency and high horsepower.

Oil Industry
Blowers
Food and Labeling
Cutters

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 Cutters
Elevators
Advantages of Helical Gears

Can be meshed in parallel or cross orientation

Smooth and quiet operation
Efficient
High horsepower
Disadvantages of Helical Gears

Resultant thrust along axis of gear

Additives to lubrication
Spur Gearbox
Spur Gears
Spur gears are made with straight teeth mounted on a parallel shaft. The noise level of spur gears is
relatively high due to colliding teeth of the gears which make spur gear teeth prone to wear. Spur
gears come in a range of sizes and gear ratios to meet applications requiring a certain speed or
torque output.

Figure 4: Spur Gearbox

Physical Properties
Spur gears are typically constructed from metals such as steel or brass, and plastics such as nylon or
polycarbonate. The material used to construct spur gears may vary depending on the manufacturer.
Note: Gears made from steel materials can be noisy when coming into contact with other gears and
also make them prone to wear.
Applications of Spur Gears
Spurs gears are used in applications requiring a decrease in speed with high output torque.

Cut-to-Length
Packaging
Speed Control
Construction
Power Plants
Advantages of Spur Gears

Cost-effective
High gear ratios
Compact
High torque output
Disadvantages of Spur Gears

Noisy
Prone to wear

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Worm Gearbox
Worm Gears
Worm gears are able to withstand high shock loads, low in noise level and maintenance-free but are
less efficient than other gear types. Worm gears can be used in right angle configuration. The worm
gearbox configuration allows the worm to turn the gear with ease; however, the gear cannot turn the
worm. The prevention of the gear to move the worm can be used as a braking system. When the worm
gearbox is not active, it is held in a locked position.

Figure 5: Worm Gearbox

Physical Properties
Worm gears are typically constructed of aluminum, stainless steel and cast iron. The material used
varies depending on the manufacturer.
Applications of Worm Gears
Worm gears are used in applications requiring high speeds and loads and can be configured for rightangle applications.

Mining
Rolling Mills
Presses
Elevators/Escalator Drive Systems
Advantages of Worm Gears

High precision
Right-angle configurations
Braking system
Low noise
Maintenance-free
Disadvantages of Worm Gears

Limitations
Nonreversible
Low efficiency
Planetary Gearbox
Planetary Gears
Planetary gearboxes are named so due to their resemblance to the solar system. The components of
a planetary gearbox include a sun gear, ring gear and planetary gears. The sun gear is the central
gear which is fixed in the center, ring gear (annulus ring) which is the outer ring with inward-facing
teeth, and the planetary gears which rotate around the sun gears and mesh with both the sun and ring
gear.

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Figure 6: Planetary Gearbox

Physical Properties
The sun, ring and planetary gears of a planetary gearbox are constructed of aluminum, stainless steel
or brass. The material used varies depending on the manufacturer.
Note: Gears made from steel materials can be noisy when coming into contact with other gears and
also make them prone to wear.
Applications of Planetary Gearboxes
Planetary gearboxes are used in applications requiring low backlash, compact size, high efficiency,
resistance to shock, and a high torque to weight ratio.

Slewing Drives
Lifts
Cranes
Machine Tools
Automotive
Advantages of Planetary Gears

High power density

Compact
Highly efficiency in power transmission
Greater stability
Load distribution among planetary gears
Disadvantages of Planetary Gears

High bearing loads

Complex design
Inaccessibility
Types of Gearmotors
As the name states, a gearmotor consist of an electric motor (brushless, brush, AC, servo) and gear reducer, also
referred to as a gearbox, integrated into a simple package. A gearmotor combination reduces complexity and
lowers costs in designs requiring high torque low speed output. Gearmotors can be manufactured to be integral or
be combined as separate components. Gearmotors which have the motor and gear reducer sharing the same shaft
is what is meant by integral. Anaheim Automation offers a wide selection of stepper gearmotors, brushless
gearmotors, DC gearmotors and AC gearmotors integrated with either spur, planetary or worm gears.
Gearmotors are used in many applications in industrial applications as well as in everyday household appliances.
Industrial applications include cranes, lifts, jacks and conveyor machines. Everyday household appliances
gearmotors are used in are washing machines, mixers, clocks, hand tools like drills and dryers.
How do Gearboxes Work?
All gearboxes work in a similar fashion. The directions
the gears rotate are dependent on the input direction
and orientation of the gears. For example, if the initial
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and orientation of the gears. For example, if the initial

gear is rotating in a clockwise direction, the gear it
engages will rotate counterclockwise. This continues
down the line for multiple gears. The combination of
different size gears and the number of teeth on each
gear plays a significant role in the output torque and
speed of the shaft. High gear ratios allow for more
output torque and lower speeds, while lower gear ratios
allow for higher output speed and less output torque.
A planetary gearbox works relatively the same. A planetary gearbox system is constructed with three main
components: a central sun gear, a planet carrier (carrying one or more planet gears) and an annulus (an outer ring).
The central sun gear is orbited by planet gears (of the same size) mounted to the planet carrier. The planet gears are
meshed with the sun gear while the outer rings teeth mesh with the planet gears. There are several configurations for
a gearbox system. Typical configurations consist of three components: the input, the output and one stationary
component.
For example: one possible configuration is the sun gear as the input, the annulus as the output and the planet carrier
remaining stationary. In this configuration, the input shaft rotates the sun gear, the planet gears rotate on their own
axes, simultaneously applying a torque to the rotating planet carrier that in turn applies torque to the output shaft
(which in this case is the annulus). The rate at which the gears rotate (gear ratio) is determined by the number of
teeth in each gear. The torque (power output) is determined by both the number of teeth and by which component in
the planetary system is stationary.
How are Gearboxes Controlled?
The output of a motor (i.e. stepper, brushless, AC and brush motors) is used as the input of the gearbox and controls
the speed at which the gearbox rotates. The configuration below illustrates the driver controlling the external motor,
which is connected as the input shaft of the gearbox. As a result, when the driver is powered, the motor shaft rotates
inside the gearbox causing the output shaft of the gearbox to rotate. The output speed and torque is dependent on
the internal configuration of the gearbox.

How to Select the Appropriate Gearbox

When considering a gearbox, many factors need to be considered to meet specific application requirements:
Gear Ratio
Gear ratios are defined as the correlation between the numbers of teeth of two different gears. Commonly,
the number of teeth a gear has is proportional to its circumference. This means that the gear with a larger
circumference will have more gear teeth; therefore the relationship between the circumferences of the two
gears can also give an accurate gear ratio. For example, if one gear has 36 teeth while another gear has 12
teeth, the gear ratio would be 3:1.
Output Torque
Output torque is dependent on the gear ratio used. To obtain a high output torque, a large gear ratio would be
selected. Using a large gear ratio will lower the output shaft speed of the motor. Inversely, using a lower gear
ratio, a smaller output torque value would be delivered into the system, with a greater motor speed at the
output shaft. This statement illustrates the relationship that both torque and speed are inversely proportional to
one another.
Speed (RPM)
Speed is proportional to the gear ratio of the system. For example, if the input gear has more teeth than the
output gear, the result will be an increase in speed at the output shaft. On the other hand, having the reverse
scenario with more gear teeth at the output compared to the input will result in a decrease of speed at the
output shaft. In general, the output speed can be determined by dividing the input speed by the gear ratio. The
higher the ratio the lower the output speed will be and vice versa.
Gear Arrangement
Gear arrangement is an ingenious engineering design that offers various benefits over the traditional fixed
axis gear system design. The unique combination of both power transmission efficiency and compact size

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Gearbox Guide

axis gear system design. The unique combination of both power transmission efficiency and compact size
allows for a lower loss in efficiency. The more efficient the gear arrangement, (i.e. spur, helical, planetary and
worm) the more energy it will allow to be transmitted and converted into torque, rather than energy lost in heat.
Another application factor to be taken into account is load distribution. Since the load being transmitted is
shared among multiple planets, the torque capacity is increased. The higher number of planets in a gear
system will increase the load ability and enhance torque density. Gear arrangements improve stability and
rotational stiffness because of a balanced system, but it is a complex and more costly design.

Figure 8: Fixed-Axis vs. Planetary Gear System

In Figure 8, the gear arrangement on the left is a traditional fixed axis gear system with a pinion driving a
larger gear on an axis parallel to the shaft. On the right, is a planetary gear design system with a sun gear
(pinion) surrounded by more than one gear (planet gears) and is encompassed in an outer ring gear. The two
systems are similar in ratio and volume, but the planetary gear design has three times the higher torque
density and three times the stiffness due to the increased number of gear contacts.
Fixed Axis Gear System:
Volume = 1, Torque = 1, Stiffness = 1
Planetary Gear System:
Volume =1, Torque = 3, Stiffness = 3
Other gear arrangements as mentioned in the Types of Gearboxes segment of this guide are bevel, helical,
cycloid, spur and worm.
Backlash
Backlash is the angle in which the output shaft of a gearbox can rotate without the input shaft moving, or the
gap between the teeth of two adjacent gears. It is not necessary to consider backlash for applications which
do not involve load reversals. However, in precision applications with load reversals like robotics, automation,
CNC machines, etc., backlash is crucial for accuracy and positioning.
Advantages of a Gearbox

Low noise level

High efficiency
High reduction ratios
Increase in output torque
Decrease in output speed
Durable
Disadvantages of a Gearbox

More costly than other drive systems

Proper lubrication is necessary for smooth running
Poorly cut teeth may result in excessive vibration and noise during operation
Quality matters and adds to cost
Troubleshooting
Problem: Gearbox Becomes Hot
Solution: The exterior temperature of the gearbox may become hot due to several reasons. Please refer to the
following information, take the necessary steps to solve this issue. If the gearbox temperature is excessive, please
consult the manufacturer.

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consult the manufacturer.

1. Ambient temperature is above advised level - If the ambient temperature is too high, it may
diminish the efficiency of the gearbox. Install a cooling fan or move the application to a more viable
location.
2. Proper ventilation - Proper ventilation is necessary, not only for the gearbox but for all
electrical/mechanical equipment to function properly. Ensure that there is adequate air flow in the area
of the equipment to allow for system cooling.
3. Improper shaft alignment - The first step is to check the alignment of the input shaft of the motor to
the gearbox. It is necessary that the input shaft of the motor be aligned with the gearbox to ensure the
proper use of the gearbox.
4. Overload - Decrease the load of the gearbox and observe if the temperature lowers. If not, your
application may require a larger gearbox model.
5. Lubrication Poor lubrication for the bearings and gears. Consult with the manufacturer regarding
warranty information.
6. Improperly mounted bearings - Reassembly may be required of the gearbox. Consult with the
manufacturer regarding warranty information.
Problem: Loud/Vibration Noise
Solution: Loud or vibration noises can be due to many different sources discussed in this section.
1. Improper installation - Improper installation may be a result of loose bolts or misalignment
between the motor and gearbox. Tightening loose bolts and aligning the motor and gearbox may solve
the issue of excessive noise.
2. Input speed too high - Lowering the input speed may help reduce the noise.
3. Overload - Decreasing the load may help reduce the noise. If not, a larger-sized model gearbox will
be required.
4. Worn or damaged bearings - Worn or damaged bearings may need to be replaced. Consult with
the manufacturer regarding warranty information.
5. Lubrication - Gears/bearings need to be properly lubricated for cohesiveness. Consult with the
manufacturer regarding warranty information.
Problem: Input/Output Shafts Do Not Rotate
Solution: Before going through the below instructions, ensure the motor shaft rotates to isolate any problem with the
motor or gearbox.
1. Proper installation - Ensure that all bolts connecting the motor to the gearbox are securely
fastened.
2. Gear teeth are worn - Need to replace worn gears. Consult your dealer for warranty information.
3. Gears in locked position - Gears may need to be replaced due to wear and tear. Another
possibility would be that a foreign object may need to be removed from within the gearbox, causing
the gears to be in the locked position. Consult your dealer for warranty information.
Problem: Gear Teeth Wear
Solution: Wear and tear on gearboxes is natural occurrences. Proper use and system maintenance can help extend
their lifetime of the gearbox.
1. Proper installation - Ensure that all bolts connecting the motor and the gearbox are securely
fastened.
2. Excessive load - Wear and tear on the gear is caused by contact with other gears. Reducing the
load will lower the tension the gears make with one another. If a higher load is required, using a larger
gearbox may be necessary.
3. Input speed too high - Lowering the input speed may help reduce the amount of wear and tear on
the gears.

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the gears.

Gearbox Guide

4. Ambient temperature is above the advised level - If the ambient temperature is too high, it may
diminish the efficiency of the gearbox. Installing a cooling fan, or moving the application to a more
viable location may resolve this application.
Cost of a Gearbox
The price of a gearbox varies and is typically affected by size, accuracy specifications, backlash, and the gear ratio,
as well as the specific manufacturer. Gearboxes with a backlash in the range of 30 arc-minutes may cost as low as
$500. The cost for gearboxes with a backlash value under 5 arc-minutes will cost more than gearboxes with high
backlash values. Below is a list of gearbox products offered by Anaheim Automation. Comprehensive specifications
and pricing is available on our website at AnaheimAutomation.com, for each of the offered types:

Economy Gearboxes
High-Grade Gearboxes
Right-Angle Planetary Gearboxes
Rotating Output Flange Gearboxes
Formulas
Motor Torque x Gear Ratio = Torque at the Wheel
Input Shaft Speed (RPM) / Gear Ratio = Output Shaft Speed
Gear Ratio = Teeth on one gear : Teeth on a second gear
Example: If one gear has 60 teeth and a second gear has 20 teeth the gear ratio would be 3:1
Where are gearboxes used?
Advancements in technology and the evolution of gears have made more efficient and powerful gearboxes to be
developed and manufactured at lower costs. Toothed gear systems have evolved from fixed axis gear systems to
new and improved gears including helical, cycloid, spur, worm and planetary gear systems. Gearboxes are widely
used in applications that require desired output speed (RPM), control the direction of rotation, and to translate torque
or power from one input shaft to another.
Gearboxes are used in a variety of industries:
Aerospace In the aerospace industry, gearboxes are used in space and air travel, i.e. airplanes,
missiles, space vehicles, space shuttles and engines.
Agriculture In the agriculture industry, gearboxes are used for plowing, irrigation, pest and insect
control, tractors and pumps.
Automotive In the automotive industry, gearboxes are used in cars, helicopters, buses and
motorcycles.
Construction In the construction industry, gearboxes are used in heavy machinery such as
cranes, forklifts, bulldozers and tractors.
Food Processing In the food processing industry, gearboxes are used in conveyor systems, the
processing of meat and vegetable products, and packaging applications.
Marine Industry In the marine industry, gearboxes are used on boats and yachts.
Medical In the medical industry, gearboxes are used in surgical tables, patient beds, medical
diagnostic machines, dental equipment and MRI and CAT scan machines.
Power Plants In power plants, gearboxes are implemented in transformers, generators and
turbines.
Quiz
1. What is backlash on a gearbox?

A. The angle the output shaft of a gearbox can rotate without the input shaft moving.
B. The angle the input shaft of a gearbox can rotate without the output shaft moving.
C. The angle the gears inside the gearbox can rotate.

2. What type of gearbox would be used for right angle applications?

A. Bevel gearbox
B. Planetary gearbox
C. Worm gearbox
D. Helical gearbox

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D. Helical gearbox
E. A and C

Gearbox Guide

3. Gearboxes can be controlled by _________ motors?

A. Stepper
B. Brushless
C. Brush
D. AC
E. All of the above

4. The output speed of a gearbox is proportional to _____________?

A. Input shaft speed

B. Gear arrangement
C. Gear ratio
D. Torsional stiffness

5. What is NOT an advantage of a gearbox?

A. High efficiency
B. Increase/decrease of output torque
C. Increase/decrease of output speed
D. Less costly

6. If a brushless motor, rated for 4000 RPM, is combined with a gearbox with a gear ratio of 3:1, what will be
the speed of the output shaft?

A. 4000 RPM
B. 12000 RPM
C. 1333 RPM

7. What is the difference between helical gears and spur gears?

A. Helical gears are cut at angles while spur gears are cut straight.
B. Helical gears are cut straight and spur gears are cut at angles.
C. Helical gears are noisier than spur gears.

8. A gear train contains 2 spur gears. The input gear has 25 teeth and the output gear has 200 teeth.
Calculate the gear ratio.
Gear Ratio = 200/25 = 8:1
FAQ
Q. Are planetary and spur gearboxes bi-directional?
A. Yes, planetary and spur gearboxes are designed to be used for bi-directional operation. The direction the input
shaft rotates and gear arrangement of the gearbox will determine the rotation of the output shaft.
Q. Can Anaheim Automations motors be combined with a gearbox?
A. Anaheim Automations motors can be assembled with a gearbox to meet the necessary requirements of an
application. Motors and gearboxes can be purchased separately or be purchased as an assembled unit.
Customization is available. Minimum purchase requirements and a Non-Cancellable/Non-Returnable agreement will
apply.
Q. What is the lifetime of Anaheim Automations motors and gearboxes?
A. Yes, planetary and spur gearboxes are designed to be used for bi-directional operation. The direction the input
shaft rotates and gear arrangement of the gearbox will determine the rotation of the output shaft.
Q. What type of gearbox would be used for right angle applications?
A. A bevel and worm gearboxes are mainly utilized in right angle applications. They offer high efficiency and low gear
ratios. A straight bevel gearbox with straight cut teeth are utilized in slow speed applications, whereas spiral bevel
gearboxes with curved teeth are utilized in high performance, high speed applications. Worm gearboxes are also
available with right angle configurations. They are able to sustain high shock loads, low in noise, maintenance-free
but are less efficient than bevel gearboxes.
Q. Can gearboxes be backdriven?
A. Some gearboxes, such as spur gearbox can be backdriven, while some, such as the worm gearbox cannot be
backdriven.
Q. How many planet gears are there in a gearbox?
A. The amount of planetary gears in a gearbox differs based on specific application requirements. Most planetary
gearboxes consist of two or more planetary gears.
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gearboxes consist of two or more planetary gears.

Q. What is the difference between straight cut gears and helical gears?
A. Straight cut gears have straight and tapered teeth, and are used for low speed applications. Helical gears are cut
at angles to allow gradual contact between the gear teeth. This allows for smooth and quiet operation. Helical gears
are applicable in high horsepower and efficient applications.
Glossary

Figure 8: Fixed-Axis vs. Planetary Gear System

Addendum the height of the gear tooth above the pitch circle diameter.
Backlash the angle the output shaft of the gearbox can move without the input shaft moving.
Base Circle an imaginary circle used in involute gearing to generate the involutes that form the tooth profiles.
Bevel Gears used for right-angle applications. There are two types of bevel gears which are straight and spiral.
Bore the diameter of the hole in a sprocket, gear, bushing, etc.
Center distance distance between the axes of two meshed gears.
Circular Thickness the thickness of the tooth on the pitch circle.
Dedendum the depth of the tooth below the diameter of the pitch circle.
Diametrical Pitch the teeth per inch of the diameter of the pitch circle.
Differential Gear a bevel gear which allows two shafts to rotate at a different speed.
Gear a wheel with teeth that meshes with another wheel with teeth to translate motion.
Gear Center the center of the pitch circle.
Gear Ratio the ratio between the numbers of teeth of meshing gears.
Gear Train two or more gears meshed by their teeth. A gear train generates power speed through the meshed
gears rotating.
Helical Gear a gear with the gear teeth cut at angles.
Line of Contact the line or curve along which two tooth surfaces are tangent to each other.
Involute the curve which describes a line which is unwound from the circumference of the gear.
Pinion a small cogwheel which fits into a larger gear or track.

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Pinion a small cogwheel which fits into a larger gear or track.

Pitch Circle the curve of intersection of a pitch surface of revolution and a plane of rotation.
Pitch Diameter the diameter of the pitch circle.
Pitch Radius the radius of the pitch circle.
Planetary Gears a system that consists of three main components: the sun gear, ring gear, and two or more
planet gears. The sun gear is the located in the center, the ring gear is the outermost gear, and the planet gears are
the gears surrounding the sun gear inside the ring gear.
Pressure Angle the angle between the line of action and the normal to the surface of the tooth.
Spiral Bevel Gears shafts which are perpendicular to each other and are used in right-angle applications.
Spur Gear connect parallel shafts which have involute teeth that are parallel to the shaft.
Sun gear a gearwheel that rotates around its own axis and has other gears (planet gears) that rotate around it.
Torsional Stiffness - the measure of the amount of torque that a radial shaft can sustain during its rotation in a
mechanical system.
Working Depth the max depth a tooth of one gear extends into the tooth gear of mating gear.
Worm Gear a gear with one or more teeth with screwed threads.
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