Reductor

Gears
There are two types of gears: Helical spur gears and helical bevel gears. They are produced from alloyed cementation steels. Machining of gears (turning, threading, deburring and wedge) is completed. Then, heat treatment is applied to provide the cementation depth suitable for the gear module and the surface hardness of 58-60 HRC. After the heat treatment, the bearings of the gear shafts, the gear holes and the tooth profiles of the gears are ground. With the profile shifts made in the gears, undercutting is prevented especially in the pinion gears. Grinding the tooth profiles ensures quiet operation of the gearbox.

Shafts
Input shafts of reductors are generally pinion gear shaft. In this case, the material of the input gear shafts is cementation steel. The pinion gear in the reductors input shaft and the input shaft material are C45 steel. The reductor output shafts are also made of C45 material. Input and output shafts are ground in k6 tolerance up to Ø50 mm diameter, and in m6 tolerance in diameters larger than Ø50mm.       Screw centering and pulling holes are drilled on the shaft ends in accordance with DIN 332. The keys on the input and output shafts are machined according to DIN 6885/1. Keys of input and output shafts are supplied with the reductor.

Bearings
Conical roller or spherical cylindrical roller bearings are used in the bearings of reducer shafts and gears. The bearings of reducer shafts and gears could be Conical roller or spherical cylindrical roller. Selection should be made based on the bearing life. This must be at least 50,000 hours.

Sockets
Reductor's body parts are gray cast iron with GG 20 quality. The sockets could be made of GGG-42 quality ductile iron with a request. Special reductor bodies are made of steel welded construction. There are oil filling and drain plugs and oil level indicator on the bodies. Some reductor models have inspection covers where all gears could be seen, and heavy reductors have lifting eyes. The oil filler plugs of the reductors also act as ventilation holes. 

Sealing
The sealing between the reductor socket and its covers is with liquid gasket; The sealing of the input and output shafts is provided by rubber oil seals. The reductor output shafts could be connected to the construction machine with elastic or rigid clutches, spur gears and chain gear systems. In order to increase the lifetime of the shafts, bearings and clutches and to ensure the vibration-free operation of the system, it is necessary to adjust the shaft axes well and to minimize the angular and linear deviations between the shaft axes. When coupling with gears, the shafts must be parallel to each other and the gears must engage each other along the entire thread surface. Reductor input shafts to motor; It is suitable to connect with belt-pulley systems, elastic clutches, hydraulic or electromagnetic lamella clutches. During coupling with connectors, the shafts are coaxial (coaxial); ensuring the parallelism of the shafts to each other in belt-pulley systems; It is necessary for the life of the connectors, motor and reductor shaft bearings and for the vibration-free operation of the system. 

Lubrication
Lubrication of reductors operating in horizontal position is provided by the method of bath impact lubrication. If the power would be transmitted by the gear unit is close to or above the thermal power limit, the lubrication of the gear unit is provided by forced circulation, injection and if necessary forced cooling lubrication systems. Reductors operating in the vertical position are also lubricated with bath lubrication, just like the reductors in the horizontal position. However, since there is no possibility of impact lubrication in vertical gear units, the oil level of the gear unit must be high and especially the gear unit must be completely filled with oil. The second solution for the lubrication of vertical gear units is forced circulation lubrication. The gears and bearings on the upper part of the reductors are directly lubricated by spraying oil. In the forced circulation lubrication system, since the reductor does not need to be filled with oil, there are not problems such as heating and overflowing of oil.

Efficiency
In principle, there is a 1.5% power loss in each stage of spur and helical helical gear reductors. Power loss in helical bevel gear reductors is between 2.5 - 3% for each stage. Power loss of worm gear reductor; It differs between 5% - 50% depending on the number of screw blades, screw rise angle, input speed, material and processing quality of the worm screw volute gear pair.

   
Regarding this principle, the efficiency of helical gear reductors:
The efficiency of one-stage (1 gear pair) reducer 98.5%
The efficiency of the two-stage (2 gear pairs) reducer is 97%
The efficiency of the three-stage (3 gear pairs) reducer is 95.5%
The efficiency of the four-stage (4 gear pairs) reducer is 94%                           

Painting
The inner surfaces of the reductors are painted with primer, the outer surfaces are painted with primer and two coats of topcoat paint. Topcoat paint could be cellulosic, synthetic or epoxy.