Cycloidal gearboxes or reducers consist of four basic components: a high-speed input shaft, a single or Cycloidal gearbox substance cycloidal cam, cam followers or rollers, and a slow-speed output shaft. The input shaft attaches to an eccentric drive member that induces eccentric rotation of the cycloidal cam. In substance reducers, the first track of the cycloidal cam lobes engages cam fans in the housing. Cylindrical cam followers act as teeth on the internal gear, and the number of cam supporters exceeds the amount of cam lobes. The next track of substance cam lobes engages with cam supporters on the result shaft and transforms the cam’s eccentric rotation into concentric rotation of the result shaft, thus raising torque and reducing velocity.
Compound cycloidal gearboxes offer ratios ranging from as low as 10:1 to 300:1 without stacking levels, as in regular planetary gearboxes. The gearbox’s compound decrease and will be calculated using:
where nhsg = the number of followers or rollers in the fixed housing and nops = the quantity for followers or rollers in the sluggish speed output shaft (flange).
There are many commercial variations of cycloidal reducers. And unlike planetary gearboxes where variations derive from gear geometry, heat treatment, and finishing procedures, cycloidal variations share simple design principles but generate cycloidal motion in different ways.
Planetary gearboxes are made of three simple force-transmitting elements: a sun gear, three or even more satellite or planet gears, and an interior ring gear. In a typical gearbox, the sun gear attaches to the insight shaft, which is linked to the servomotor. Sunlight gear transmits engine rotation to the satellites which, subsequently, rotate inside the stationary ring equipment. The ring equipment is portion of the gearbox housing. Satellite gears rotate on rigid shafts connected to the earth carrier and trigger the planet carrier to rotate and, thus, turn the output shaft. The gearbox gives the output shaft higher torque and lower rpm.
Planetary gearboxes generally have one or two-gear stages for reduction ratios ranging from 3:1 to 100:1. A third stage can be added for actually higher ratios, nonetheless it is not common.
The ratio of a planetary gearbox is calculated using the next formula:where nring = the number of teeth in the internal ring gear and nsun = the amount of teeth in the pinion (input) gear.
Comparing the two
When deciding between cycloidal and planetary gearboxes, engineers should 1st consider the precision needed in the application form. If backlash and positioning accuracy are crucial, then cycloidal gearboxes offer the best choice. Removing backlash can also help the servomotor handle high-cycle, high-frequency moves.
Following, consider the ratio. Engineers can do that by optimizing the reflected load/gearbox inertia and quickness for the servomotor. In ratios from 3:1 to 100:1, planetary gearboxes provide greatest torque density, weight, and precision. Actually, not many cycloidal reducers provide ratios below 30:1. In ratios from 11:1 to 100:1, planetary or cycloidal reducers can be used. However, if the mandatory ratio goes beyond 100:1, cycloidal gearboxes keep advantages because stacking levels is unnecessary, so the gearbox can be shorter and less expensive.
Finally, consider size. The majority of manufacturers offer square-framed planetary gearboxes that mate precisely with servomotors. But planetary gearboxes grow in length from single to two and three-stage styles as needed gear ratios go from significantly less than 10:1 to between 11:1 and 100:1, and to greater than 100:1, respectively.
Conversely, cycloidal reducers are larger in diameter for the same torque yet are not as long. The compound decrease cycloidal gear train handles all ratios within the same package deal size, therefore higher-ratio cycloidal gear boxes become also shorter than planetary versions with the same ratios.
Backlash, ratio, and size provide engineers with a preliminary gearbox selection. But deciding on the best gearbox also involves bearing capability, torsional stiffness, shock loads, environmental conditions, duty cycle, and life.
From a mechanical perspective, gearboxes have become somewhat of accessories to servomotors. For gearboxes to execute properly and provide engineers with a stability of performance, life, and value, sizing and selection should be determined from the strain side back again to the motor as opposed to the motor out.
Both cycloidal and planetary reducers are appropriate in virtually any industry that uses servos or stepper motors. And even though both are epicyclical reducers, the differences between the majority of planetary gearboxes stem more from equipment geometry and manufacturing procedures instead of principles of operation. But cycloidal reducers are more diverse and share little in common with each other. There are advantages in each and engineers should consider the strengths and weaknesses when selecting one over the other.
Benefits of planetary gearboxes
• High torque density
• Load distribution and posting between planet gears
• Smooth operation
• High efficiency
• Low input inertia
• Low backlash
• Low cost
Benefits of cycloidal gearboxes
• Zero or very-low backlash stays relatively constant during existence of the application
• Rolling instead of sliding contact
• Low wear
• Shock-load capacity
• Torsional stiffness
• Flat, pancake design
• Ratios exceeding 200:1 in a compact size
• Quiet operation
The need for gearboxes
There are three basic reasons to employ a gearbox:
Inertia matching. The most common reason for choosing the gearbox is to regulate inertia in highly dynamic situations. Servomotors can only just control up to 10 times their personal inertia. But if response time is critical, the engine should control significantly less than four occasions its own inertia.
Speed reduction, Servomotors run more efficiently at higher speeds. Gearboxes help keep motors working at their optimum speeds.
Torque magnification. Gearboxes offer mechanical advantage by not merely decreasing quickness but also increasing result torque.
The EP 3000 and our related products that make use of cycloidal gearing technology deliver the most robust solution in the most compact footprint. The main power train is made up of an eccentric roller bearing that drives a wheel around a set of internal pins, keeping the reduction high and the rotational inertia low. The wheel includes a curved tooth profile instead of the more traditional involute tooth profile, which gets rid of shear forces at any stage of contact. This style introduces compression forces, rather than those shear forces that could exist with an involute gear mesh. That provides numerous functionality benefits such as for example high shock load capacity (>500% of rating), minimal friction and wear, lower mechanical service elements, among numerous others. The cycloidal style also has a huge output shaft bearing span, which provides exceptional overhung load capabilities without requiring any extra expensive components.
Cycloidal advantages over additional styles of gearing;
Able to handle larger “shock” loads (>500%) of rating in comparison to worm, helical, etc.
High reduction ratios and torque density in a concise dimensional footprint
Exceptional “built-in” overhung load carrying capability
High efficiency (>95%) per reduction stage
Minimal reflected inertia to engine for longer service life
Just ridiculously rugged as all get-out
The overall EP design proves to be extremely durable, and it needs minimal maintenance following installation. The EP is the most dependable reducer in the industrial marketplace, in fact it is a perfect match for applications in weighty industry such as for example oil & gas, main and secondary steel processing, commercial food production, metal slicing and forming machinery, wastewater treatment, extrusion products, among others.