Understanding, calculating, and applying: Your comprehensive guide to gear reduction for maximum performance.
What exactly does “reduction to slow” mean?
A reduction to slow, often referred to as reduction , occurs when a gearbox reduces the input speed, to decrease the output speed. This simultaneously leads to an increase in output torque. The gear ratio ‘i’ is greater than 1.
How does a reduction to slow affect torque and speed?
With a reduction to slow, the speed at the output is reduced. In return, the torque at the output increases ideally proportional to the gear ratio (M_Output ≈ M_Input * i). This effect is crucial for applications that require high forces.
Which types of gearboxes from ATEK are particularly suitable for a reduction to slow?
ATEK Drive Solutions offers a wide range of gearboxes for reductions to slow, including spur gearboxes for robust applications, planetary gearboxes for high reductions in a small space (e.g., up to i=100 and more stages), worm gearboxes for very high single-stage reductions (often over i=100:1), and bevel gearboxes for angular drives. We also offer custom special gearboxes..
When is a multi-stage gearbox sensible for a reduction to slow?
A multi-stage gearbox is used when very high overall reductions to slow are needed, which cannot be realized economically with a single gearbox stage. Multi-stage planetary gearboxes, for example, can achieve reductions of i=100 and above , where the overall efficiency is determined by the multiplication of the efficiencies of the individual stages.
What advantages does ATEK’s modular system offer for gearboxes for reductions to slow?
ATEK’s modular system allows for millions of configurations. This leads to a high variety of variants and enables us to quickly provide suitable solutions for specific requirements for reductions to slow, often with short delivery times thanks to our large inventory.
How does ATEK ensure efficiency in gearboxes that implement a reduction to slow?
ATEK places value on high product quality and optimized designs. The efficiency (ηG) is considered during the design process (M_Output = M_Input * i * ηG). Modern materials, precise manufacturing, and optimized lubrication contribute to the minimization of losses , which is especially important in multi-stage reductions to slow, as the efficiencies of the stages multiply.
Can ATEK also develop custom solutions for a reduction to slow?
Yes, one of our core competencies is the development of custom special solutions, even in small series. If standard gearboxes do not meet your requirements for a reduction to slow, our engineers will develop a tailored drive solution for your application.
Is there a difference between “reduction to slow” and “reduction”?
No, the terms “reduction to slow” und “reduction” are used synonymously in drive technology. Both describe a gear ratio ‘i’ greater than 1, where the output speed is lower and the output torque is higher than at the input.. Beide beschreiben ein Übersetzungsverhältnis ‘i’ größer als 1, bei dem die Abtriebsdrehzahl geringer und das Abtriebsdrehmoment höher als am Antrieb ist.
Die Reduction to slow (reduction) is a fundamental mechanism in drive technology that reduces the speed, to significantly increase the torque (M_Output ≈ M_Input * i), which is essential for force-intensive industrial processes.
A precise design considering the efficiency (ηG) is crucial for efficiency; modern gearboxes with sensors can, for example, reduce downtimes by up to 30% and increase the efficiency by 5-10%.
ATEK Drive Solutions offers a diverse range of gearbox solutions (spur, planetary, worm gearboxes) for reductions to slow, including custom adaptations and fast delivery through a modular system. Discover the world of gear reduction! We explain how to maximize torque, calculate the right reduction, and find typical application cases in industry. Benefit from our expertise!
Do you want more torque and less speed? The reduction to slow, also known as reduction, is the key! We show you how to use this technique profitably. Do you need individual advice? Contact us now.
Entdecken Sie die Welt der Getriebeuntersetzung! Wir erklären, wie Sie Drehmoment maximieren, die richtige Übersetzung berechnen und typische Anwendungsfälle in der Industrie finden. Profitieren Sie von unserem Expertenwissen!
Sie wollen mehr Drehmoment und weniger Drehzahl? Die Übersetzung ins Langsame, auch Untersetzung genannt, ist der Schlüssel! Wir zeigen Ihnen, wie Sie diese Technik gewinnbringend einsetzen. Benötigen Sie individuelle Beratung? Nehmen Sie jetzt Contact now!
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Introduction to reduction to slow
Die reduction to slow (reduction) reduces speed in drive technology in favor of higher torque. This article deals with the fundamentals, calculations, and applications of this important gearbox function. For example, starter motors (>50 Nm) or drives for conveyor belts (several tons of load) generate the necessary force by such speed reduction to overcome starting resistance. Find the suitable solution for your gear motor..
What is a reduction to slow?
Reduction, the core principle of reduction to slow, means that the driven element rotates slower than the driving one. The gear ratio ‘i’ is > 1 (e.g., i=5: output speed = 1/5 input speed), allowing for targeted power adjustment through the reduction to slow gear ratio.
Why is the reduction to slow used?
Mainly, it is used for torque amplification (e.g., presses that deform sheets with 200 t) and for adapting high motor speeds to slow working speeds, optimizing energy input and process safety. See reduction to slow zur Drehmomentverstärkung eingesetzt (z.B. Pressen, die Bleche mit 200 t verformen) und zur Anpassung hoher Motordrehzahlen an langsame Arbeitsdrehzahlen, was Energieeinsatz und Prozesssicherheit optimiert. Siehe modular industrial gearboxes, which often include mechanisms for a reduction to slow reduction.Fundamentals and definitions of the reduction to slow
The gear ratio ‘i’ quantifies the changes in speed and torque achieved by a reduction to slow erzielt wird. Es wird bestimmt durch Zähnezahlen (z.B. Antrieb 20, Abtrieb 100 Zähne -> i=5) oder Riemenscheibendurchmesser. Ein i > 1 bedeutet Untersetzung, also eine reduction to slow.
- Das Übersetzungsverhältnis ‘i’ ist eine Schlüsselgröße zur Beschreibung von Drehzahl- und Drehmomentänderungen in Getrieben, insbesondere bei der reduction to slow.
- Es wird durch das Verhältnis der Zähnezahlen bei Zahnrädern oder der Durchmesser bei Riemenscheiben bestimmt, um die gewünschte Drehzahlreduzierung zu erreichen.
- Ein Wert von i > 1 kennzeichnet eine reduction to slow (Untersetzung).
- Die Formel für ‘i’ lautet i = Antriebsdrehzahl / Abtriebsdrehzahl oder i = Zähnezahl Abtriebsrad / Zähnezahl Antriebsrad. Diese Formel ist zentral für jede reduction to slow.
- Im Gegensatz dazu bedeutet i < 1 eine Übersetzung ins Schnelle, bei der das Drehmoment sinkt.
- Bei einer Untersetzung, dem Ergebnis einer reduction to slow, steigt das Drehmoment idealerweise proportional zum Übersetzungsverhältnis ‘i’ an (M_Abtrieb ≈ M_Antrieb * i).
Das Übersetzungsverhältnis (i)
Definition: i = n_Antrieb / n_Abtrieb (Drehzahlen) oder i = z_Abtrieb / z_Antrieb (Zahnräder). Bei Riementrieben: i = D_getriebene Scheibe / D_treibende Scheibe. Ein i=3 bedeutet, dass die Abtriebsdrehzahl durch die reduction to slow auf 1/3 der Eingangsdrehzahl reduziert wird.
Unterschied zur Übersetzung ins Schnelle
Bei i < 1 (Übersetzung ins Schnelle) rotiert das getriebene Rad schneller, das Drehmoment sinkt – das Gegenteil der reduction to slow (z.B. Spindeln >15.000 U/min, Ventilatoren). Mehr zur Übersetzung ins Schnelle.
Die Rolle des Drehmoments
Drehmoment (M) ist umgekehrt proportional zur Drehzahl (n). Bei einer Untersetzung, also einer reduction to slow, steigt M_Abtrieb idealerweise um Faktor i: M_Abtrieb ≈ M_Antrieb * i (z.B. 10 Nm Motor, i=10 -> 100 Nm durch die reduction to slow). Siehe Elektromotoren mit Getriebe.
Anwendungen der Übersetzung ins Langsame
Untersetzungen, also Realisierungen der reduction to slow, sind in vielen Bereichen verbreitet: Der erste Autogang (oft i > 3) und Anlasser (bis 13:1) nutzen diese Art der Drehzahlreduzierung für hohes Anlaufdrehmoment. Industrieroboter, Förderbänder und Schwerlastkräne (Lasten >100 t) benötigen ebenfalls eine effektive reduction to slow, um ihre Aufgaben zu erfüllen. Siehe hochübersetzende Winkelgetriebe oder mehrstufige Stirnradgetriebe für Beispiele solcher Getriebe.
Automobilindustrie
In der Automobilindustrie ist die reduction to slow von fundamentaler Bedeutung. Schaltgetriebe nutzen verschiedene Übersetzungen; der erste Gang hat die größte Untersetzung (i=3.5-4.5), eine typische Anwendung der reduction to slow, um das Fahrzeug aus dem Stand zu bewegen. Die Spreizung der Gänge optimiert Kraft und Verbrauch für verschiedene Fahrbedingungen durch angepasste Übersetzungen ins Langsame oder Schnelle.
Industrielle Anwendungen
Auch in industriellen Anwendungen spielt die reduction to slow eine entscheidende Rolle. Werkzeugmaschinen (Fräsen, Drehmaschinen) nutzen die reduction to slow, um hohe Motordrehzahlen für ein großes Drehmoment am Werkzeug zu reduzieren (z.B. Portalfräsen von 3000 U/min auf wenige U/min). Diese Form der Drehzahlwandlung ist Standard in Verpackungsmaschinen, Pressen und in der Robotik, wo präzise und kraftvolle Bewegungen durch eine reduction to slow realisiert werden.
Getriebearten und ihre Eigenschaften für die Übersetzung ins Langsame
Die Wahl der Getriebeart für eine reduction to slow depends on the required gear reduction, the available installation space, and the specific operating conditions. Spur gearboxes are a robust choice for a reduction to slow with i≈10 (single-stage). Planetary gears offer high power density and enable high multi-stage Übersetzungen ins Langsame (up to i=100 and more) in coaxial arrangement. Worm gears are predestined for very high single-stage Übersetzungen ins Langsame (often over i=100:1) and provide the advantage of self-locking (e.g., in lifting devices), albeit with a lower efficiency (typically 50-70%). See planetary gearboxes und worm gearboxes for more detailed information.
- The selection of the appropriate type of gearbox is determined by factors such as the required gear ratio for the reduction to slow, the available installation space, and the specific operating conditions.
- Spur gearboxes are a robust choice for single-stage Übersetzungen ins Langsame up to about i=10 and are characterized by straight-line power transmission.
- Planetary gears offer high power density and enable high multi-stage Übersetzungen ins Langsame (up to i=100 and more) in coaxial arrangement, making them ideal for compact applications that require strong speed reduction.
- Worm gears are predestined for very high single-stage Übersetzungen ins Langsame (often over i=100:1) and provide the advantage of self-locking, but at a lower efficiency (typically 50-70%).
- Bevel gears are used when a redirection of the drive axis, often by 90 degrees, is required. reduction to slow .
- Gearboxes that are used for a reduction to slow include, in addition to spur and bevel gears, also planetary gears, which consist of a sun gear, planet gears, and a ring gear, and achieve high reductions in a small space.
- Despite their lower efficiency, worm gears are particularly advantageous for lifting and positioning applications that require a secure reduction to slow .
Gearboxes
Gearboxes are common components for realizing a reduction to slow. Spur gears transmit motion in a straight line. Bevel gears redirect the axis (often 90°). Planetary gears (consisting of sun, planet, and ring gears) allow for high gear ratios ‘i’, thus strong Übersetzungen ins Langsame, in very tight spaces (e.g., in cordless screwdrivers).
worm gearboxes
Worm gears are ideal for very high single-stage gear reductions, a form of extreme reduction to slow (e.g., i=60:1 for turntables). Self-locking is a significant advantage in lifting and positioning applications that require reliable reduction to slow , despite the typically lower efficiency.Calculation and design of gearboxes for slow speed translation
A correct design is essential for every reduction to slow and is based on specific application requirements (such as target speed and torque, e.g., in a spindle press with 500 kN). The gearbox efficiency (ηG, typically 85-98% per stage) is a crucial factor in realizing a reduction to slow : M_Abtrieb = M_Antrieb * i * ηG. An efficiency ηG of 90% reduces the transferable torque by 10%, which must be taken into account in the design to avoid under-dimensioning. See reduction to slow um 10%, was bei der Auslegung berücksichtigt werden muss, um eine Unterdimensionierung zu vermeiden. Siehe adjustable gear motors.
Determination of the gear ratio
The determination of the gear ratio ‘i’ is a core step in planning a reduction to slow. From the desired target speed (e.g., 300 RPM) and the available motor speed (e.g., 3000 RPM), the necessary gear ratio ‘i’ for the reduction to slow (in this example i=10). The target torque (e.g., 50 Nm) and motor power (e.g., 6 Nm taking ηG into account) must be coordinated.
Consideration of efficiency
A three-stage gearbox designed for a reduction to slow (each stage with 90% ηG) has an overall efficiency ηG_total of about 73%. A power loss of over 25% must be compensated during motor selection. A high efficiency in the reduction to slow saves energy and reduces operating costs.
Selection of the type of gearbox
When selecting the type of gearbox for a reduction to slow , criteria such as the gear ratio ‘i’ (single-stage often up to i≈10 for a simple reduction to slow), the required torque, the operating speed, the available installation space, and costs are relevant. For high gear ratios ‘i’, that is a strong reduction to slow, in a compact space (such as in robotic joints with i > 100), multi-stage planetary gears are often the preferred choice. See continuously variable gear motors.Current trends and future developments in slow speed translation
Modern gearboxes that are used for the reduction to slow are increasingly utilizing sensors (for temperature, vibration, torque) for condition monitoring and predictive maintenance. This can reduce downtime by up to 30%. Advances in lightweight construction (using materials like CFRP or aluminum alloys) and optimized lubrication and bearing systems increase efficiency in realizing a reduction to slow (by 5-10%).
Digitalization and networking
In the context of Industry 4.0, the networking of gearboxes that realize a reduction to slow enables adaptive process management through direct communication with higher-level control systems. An automatic adjustment of the reduction to slow to the current load situation can reduce energy consumption by up to 15%.
Lightweight construction and efficiency enhancement
Topology optimization reduces the weight of gearbox components (by up to 20%) without compromising stability, which is particularly advantageous in dynamic applications of the reduction to slow . New lubricants with lower viscosity and improved emergency running properties minimize friction losses and thus increase the efficiency of the reduction to slow.
Die reduction to slow, also known as gear reduction, is a central and indispensable tool in modern drive engineering. Careful design taking efficiency into account is crucial for optimal performance and durability for any application of a reduction to slow . Contact us for expert advice on your specific requirements for a reduction to slow.
