The Past, Present and Future of Gear Drives
Power-dense, compact and customized gear drives bring versatility, efficiency
to an ever-changing industry
In an era when technology largely dictates the course of industry, one may
wonder if the industrial successes of the 20th century will all but disappear.
Regardless of the hype and promises, there are some elements of industrial applications
that require minimal change to keep up the pace.
Basic concept, basic device
Take the gear drive. Gear drives have long been the most cost-effective and
efficient means of controlling and varying speed in industrial applications.
Their very simplicity makes gear drives an integral part of powering equipment
in virtually any industry, from in-factory machine applications to overland
conveyor belts in the coal and other mining industries.
Although the materials, design, and efficiency of gear drives have evolved
with changes in industry, the basic purpose behind the mechanism has changed
little since the early days of wooden gears. The loud and maintenance-intensive
gear drives of 20 years ago have evolved into newer and more versatile models.
And yet, this traditional mechanical component need not change too dramatically
to meet 21st century industry demands.
Compact and powerful: The evolution of gear drives
Compared to the similarly-rated reducers of 20 years ago, today's gear drives
are much more compact and power-dense. The development and use of carburized
and ground gearing contributed to a more power-dense drive, allowing a much
greater load to be transmitted by a gear. Cleaner, harder steels and improvements
in bearing technology have made it possible for an end-user to apply a physically
smaller gear drive and receive the same amount of mechanical output.
With smaller surface areas to radiate heat, more compact drives needed external
means to aid in heat dissipation. This led to developments and improvements
in cooling methods for gear reducers, including pumps and coolers, cooling tubes,
cooling fans and electric fans.
Today, the standard for performance has never been higher. Today's end-user
is looking for smaller packages - more efficient gear drives that can handle
higher levels of load - for the lowest total cost. In addition, 24/7-production
requires drives with reduced maintenance requirements and high reliability.
End-users are looking for gear drives tailored to the needs of a specific application
- whether it's base or shaft mounted, right angle or parallel shaft, horizontal
or vertical.
However, this evolution using existing technology has its limits. Thus, gear
drive manufacturers will continue to improve designs, using new materials, improved
gear tooth form, and easier assembly, to further reduce the cost of torque.
Gear Drive role in the new business environment
Care for the installed mechanical base, including gear drives in any number
of industrial settings, has been influenced by other changes in industry. For
example, end-users have fewer maintenance personnel due to industry downsizing,
which has caused outsourcing of maintenance and inventory management to become
more prevalent. The trade-off comes in expertise; often the company selected
to manage the inventory is less knowledgeable regarding mechanical components
and their function in the plant. Because of this disconnect, end-users and distributors
have become more reliant on the expertise of gear drive manufacturers. Additionally,
advances in other technologies, such as remote monitoring, are helping address
the maintenance needs of users.
These shifting priorities mean that a gear drive manufacturer's responsibility
no longer ends with supplying a high-quality product. Many end-users and OEMs
that rely on gear drives are searching for a "package deal" of product and expertise,
with manufacturers also playing the role of consultants. Although the elimination
of moving components such as V-belt and chain drives has made equipment breakdown
less likely, maintenance reduction and services - most likely in the form of
continued support from the manufacturer - will continue to be a major perceived
benefit for end-users. They will seek out manufacturers who can offer call sites
and online support with downloadable services and maintenance literature.
Industry is also driving the standardization of gear drive components. User
emphasis on reducing maintenance parts and spares inventory is leading gear
drive manufacturers to design for maximum overlap of parts. End-users are turning
to manufacturers who can offer drive flexibility and instant availability of
standard components, whether complete gear drives or repair parts.
Industry glance: Coal mining
Gear drives enjoy popular use in both surface and underground coal mining applications.
Their use is dictated by the rugged environment and cramped working conditions.
Gear drives provide the "muscle" for the conveyors, which over time have become
larger to cover more distance and carry more material. Because of their ability
to adapt to rugged or hilly terrain, overland conveyors are still the most efficient
and economical means of bulk material transport. In underground mines, on the
other hand, the size and mobility of drives are critical considerations.
Changes in gear drive design have brought flexibility to this challenging environment.
Gear drive manufacturers have responded to the needs of the coal mining industry
with portable, or mobile drives, which do not require a foundation for mounting
within a mine. Mobile drives also eliminate the costly practice of abandoning
and burying a drive once the shaft is exhausted.
The newest in gear drives provide increased thermal capabilities and a variety
of mounting configurations, such as shaft mount, parallel, right-angle and alignment
free. Such drives are well suited for the coal industry, since the configuration
options allow the user to choose a mounting capability best suited for the application.
Shaft mounted and right angle drives provide a more compact design, which is
important in underground coal mining where space is limited. Drives with taper
bushings allow for easier assembly and disassembly of the gear drive to the
head pulley shaft. Alignment free arrangements eliminate all alignment between
the motor and gear drive, and gear drive and driven equipment, saving substantial
time and effort.
The need fulfilled by gear drives in industrial applications will only subtly
change, in comparison to the greater advantages to be found as complete system
integration brings productivity improvements. But the small, incremental improvements
in gear drive technology will continue to contribute to greater efficiency and
performance in the future.
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