EXP PR EQ180 en R0 - 1 Reduction Units

EQUIPMENT
REDUCTION UNITS
TRAINING MANUAL
Course EXP-PR-EQ180
Revision 0.1
Exploration & Production
Equipment
Reduction units
EQUIPMENT
REDUCTION UNITS
CONTENTS
2. WHAT ARE REDUCTION UNITS USED FOR? ..............................................................4

3. THE DIFFERENT TYPES OF REDUCTION UNITS ........................................................5
3.1. WORM REDUCTION UNITS ....................................................................................5
3.2. HELICAL REDUCTION UNITS .................................................................................6
3.3. PARALLEL SHAFT REDUCTION UNITS .................................................................7
3.4. PLANETARY REDUCTION UNITS ...........................................................................8
3.5. INDUSTRIAL REDUCTION UNITS ...........................................................................9
4. REDUCTION UNIT APPLICATIONS .............................................................................10
5. OPERATING PRINCIPLE..............................................................................................11
5.1. COMPOSITION.......................................................................................................11
5.2. PRINCIPLE .............................................................................................................11
5.3. THE DIFFERENT TYPES OF TEETH.....................................................................14
5.3.1. Straight-cut gears ............................................................................................14
5.3.2. Helical-cut teeth...............................................................................................14
5.3.3. Bevel-cut teeth ................................................................................................15
5.3.4. Worm-cut teeth................................................................................................16
5.3.5. Hypoid-cut teeth ..............................................................................................17
5.4. DEFINITION OF A REDUCTION UNIT RATIO .......................................................19
6. SERVICING AND MAINTENANCE ...............................................................................20
7. GLOSSARY ...................................................................................................................22
8. LIST OF FIGURES ........................................................................................................23
9. LIST OF TABLES ..........................................................................................................24
Training course EXP-PR-EQ180-FR

Last revised: 14/05/2007 Page 2 / 24
Equipment
Reduction units
1. OBJECTIVES
Aim of the present course is to allow the future operator to understand the basic
mechanical principles of reduction units, (the gear reducers)
At the end of this course, the attendee would be able to:
Explain functions of reducers
Enumerate the different types of reducers encountered on site
List the different applications
Expose the working principles of reducers
Enumerate the different types of gear used within reducers
Calculate the ratio of a reducer
Follow up a maintenance program for reducers

Equipment
Reduction units
2. WHAT ARE REDUCTION UNITS USED FOR?

A reduction unit is a mechanical component
which reduces the rotational speed of a drive
shaft.
A reduction unit transmits a high torque to the

driven machine (pump, compressor,
alternator or generator).
Figure 1: Example of a reduction unit (1)
Figure 2: Example of a reduction unit (2)

Equipment
Reduction units
3. THE DIFFERENT TYPES OF REDUCTION UNITS
3.1. WORM REDUCTION UNITS
Figure 3: Worm reduction unit
Figure 4: Cutaway view of a worm reduction unit and helical type

Equipment
Reduction units
3.2. HELICAL REDUCTION UNITS
Helical reduction units perfectly illustrate the compact design of the new series of drives.
They are robust angle drives adapted to all mechanical applications where a compact
assembly is required.
They provide a very wide torque range: 200 to 50000 Nm.
Helical reduction units are used when the power must

be transmitted through 90.
They are very efficient, particularly for applications

where precision, efficiency, high speeds (up to
6500 rpm depending on the size and the range)
and high loads are required.
Figure 5: Cutaway view of a helical reduction unit
Figure 6: Helical reduction unit

Equipment
Reduction units
3.3. PARALLEL SHAFT REDUCTION UNITS
Parallel shaft reduction units can be used in a wide range of configurations, even in the
most unfavourable conditions, thanks to their torque range (130 to 18000 Nm) and the
large number of positions in which they can be installed and their wide range of
applications.
These gear motors are compact due to the layout of the reduction unit's casing.
The numerous output shaft and hollow shaft variants, and

the possibility of installing the hollow shaft reduction unit
using a reaction arm, feet or flanges, allow the right solution
to be chosen at a cost-effective price.
This is why this reduction unit has established itself

worldwide as a solution for applications involving translation
movement.
Figure 7: Cutaway view of a parallel shaft reduction unit
Figure 8: Parallel shaft reduction unit

Equipment
Reduction units
3.4. PLANETARY REDUCTION UNITS
Planetary gear motors are compact, have a low backlash and have one or two trains for
powers of up to 3000 Nm to handle the most advanced, high-precision positioning tasks.
Due to their structure they are ideal for use in compact assemblies with little available
space.
Figure 9: Planetary reduction unit

Equipment
Reduction units
3.5. INDUSTRIAL REDUCTION UNITS
Production versions of 2 or 3 train parallel shaft reduction units are highly robust thanks to
their very compact one-piece casing.
Whether foot mounted, flange mounted or with a hollow shaft, with a wide range of
versions and options, allows them to be used for torque ranges of up to 65000 Nm, even in
difficult conditions.
Figure 10: Industrial reduction unit

Equipment
Reduction units
4. REDUCTION UNIT APPLICATIONS

Reduction units can be found in many industrial sectors.
They are used where the drive shaft rotational speed of an internal combustion engine,
electric motor, turbine, etc., must be modified.
Figure 12: Gear motor
Figure 11: Reduction unit for mixer
Figure 13: High load reduction unit
Figure 14: Marine reduction unit

Equipment
Reduction units
5. OPERATING PRINCIPLE
5.1. COMPOSITION
Figure 15: Composition of a reduction unit
5.2. PRINCIPLE
For a reduction unit to have a correct efficiency there

must be no tooth friction.
This is obtained by the shape of the teeth; we talk about

involute teeth which are such that they mesh with each
other without slide.
Figure 16: Example of teeth (1)

Equipment
Reduction units
The contact must also be very regular, i.e. a

tooth must take the relay well before the
previous tooth has finished meshing.
For conventional teeth, there is a good

regularity up to a reduction ratio which must not
exceed a value of around 4 or 5 for normal
tooth sizes (the term modulus is used for the
tooth size).
Figure 17: Example of teeth (2)
If we increase this ratio the problems begin, i.e. contact begins to deteriorate (only one
tooth in contact at a time), and it will no longer be possible to achieve the ideal involute
shape.
The only way to correct this problem is to

reduce the tooth modulus or increase the
diameter of the pinions.
If the size of the gear wheels is increased, the

sizes become unacceptably large Hence
reduction units are limited to a single stage do
not exceed a ratio of around 4.
Figure 18: Gears and pinions of a reduction

unit
There is, of course, the notable exception of

GWS reduction units for indoor or park-flyer
which reaches ratios of up to 11, but the powers
at stake are low, which means that very small
teeth can be used.
Figure 19: Example of a reduction unit
For applications with a lower efficiency

requirement, and small reduction ratios
(maximum of 3), there is also the solution of
belt reduction units which can transmit
considerable powers while remaining cost-
effective.

Equipment
Reduction units
This is always at the expense of size and no doubt of higher weight.
Figure 20: Composition of a reduction unit

Equipment
Reduction units
5.3. THE DIFFERENT TYPES OF TEETH
A gear pair is an elementary mechanism consisting of two gears mobile around axes of
invariable relative position, and one of which turns the other by the action of teeth
successively in contact: we say that the two gears are conjugated.
The smaller gear is called: the pinion; and the larger: the gear (a rack is a gear of infinite
radius).
There are 4 different types of gears:
Straight-cut gears
Helical-cut gears
Bevel-cut gears
Worm-cut gears
Hypoid cut gears
5.3.1. Straight-cut gears
The pinion is the smaller of the two

gears and is often the driving gear.
The shape of the gear varies with the

dimensions.
Straight teeth are used for small

equipment and internal teeth.
Figure 21: Straight-cut teeth
5.3.2. Helical-cut teeth
They transmit movement between two parallel shafts. The inclination of the teeth (helix
angle) is the same for both gears, but in opposite directions.
Helical gears provide a transmission which is more flexible, more progressive and less
noisy than straight gears.

Equipment
Reduction units
The forces transmitted are higher (more teeth in

contact), even at high speeds.
Figure 22: Helical-cut teeth
The axial thrust can be neutralised by using two

gears on each shaft, each with reversed helical
teeth or a single gear with two symmetrical rows of
teeth (called chevron or herringbone gears).
Figure 23: Helical gears with two symmetrical

rows of teeth
Inconvenient of this type is the important axial
thrust which requires specific bearings
5.3.3. Bevel-cut teeth
These are the simplest teeth and they have

the same problems as the straight gears at
high speeds (noise, high pressures on the
teeth, etc.).
Figure 24: Bevel-cut teeth
They are used to transmit movement

between two nonparallel shafts whose
axes are concurrent (the most frequent
type have axes at 90).

Equipment
Reduction units
The primitive surfaces are no longer

cylinders but cones.
The cones are tangents on a contact line

MM' and their common summit is the
point S (intersection of the rotational
axes).
Figure 25: Right-angle bevel gears
They reduce noise at high speeds and the

transmission is more progressive.
The typical pressure for straight teeth is

20 or 1430', it is 35 for helical teeth.
5.3.4. Worm-cut teeth
The transmission is achieved by a screw with one or more threads meshing with a gear.
The direction of the helix is the same for the screw and for the gear.
These gear systems give high reduction

ratios and can be non-reversible.
They provide the "smoothest" meshing of all

gear systems.
Their operation is silent and impact-free.
However, they have a high level of slide and

friction; thus their efficiency is poor.
Efficiency is affected by good lubrication

and an adapted choice of materials (steel
screw and bronze gear).
Figure 26: Worm

Equipment
Reduction units
5.3.5. Hypoid-cut teeth
Hypoid gears are helical bevel gears employed when the axes of the two shafts are
perpendicular but do not intersect. One of the most common uses of hypoid gearing is to
connect the drive shaft and the rear axle in automobiles.
Helical gearing used to transmit rotation between shafts that are not parallel is often
incorrectly called spiral gearing.

Equipment
Reduction units
Position of
Types Teeth size Type of contact and friction
shafts
Linear
Straight
Rotation and slight slide
Curve
Continuous mesh
Helical
Rotation and pivoting
Cylindrical
Axial thrust
Parallel
Curve
Continuous mesh
Chevrons
Thrust compensated
Cylindrical Linear
Straight
rack Rotation and slight slide
Linear
Straight
Rotation and slight slide
Inclined straight
Concurrent
Bevel Curve
rectangular
Continuous mesh
Spiral
Axial thrust
Chevrons
Curve
Tangent wheel
Slide, slight rotation and pivoting
Gear and globoidal Wider contact than with a tangent wheel

Worm worm Mainly slide (stretching the oil film)
Non-
concurrent Helical gears
Curve
rectangular Helicoidal
Rotation, pivoting and slide
Hypoid
Curve
Particularly very high slide speed at high
Inclined spiral
pressures
Axial thrust
Non
concurrent Hyperboloid Left
oblique
Table 1: Types of reduction units

Equipment
Reduction units
5.4. DEFINITION OF A REDUCTION UNIT RATIO
A reduction unit transmits a high torque to the driven machine.
The step-up ratio or the step-down ratio is the ratio of the product of the number of teeth
on the driving gear and of the product of the number teeth on the driven gear.
In the vast majority of cases, gear trains are used as gear reducers (reduced speed and
increased torque).
The direction of rotation of an external gear train can easily be determined by counting the
number of gears in contact.
If this number is even, the driven gear rotates in the same direction as the driving
gear.
If this number is odd, the driven gear rotates in the opposite direction to the driving
gear.
For internal gear trains, this method must be reversed i.e. if an even number of gears are
in contact, the driven gear rotates in the opposite direction to the driving gear.
A gear train's step-down ratio is the ratio of the product of the number of teeth on the
driving gears and of the product of the number of teeth on the driven gears.
Train with 1 gear pair
R2/1 = Z1 / Z2
Train with 2 gear pairs
R4/1 = (Z3 . Z1) / (Z4 . Z2)
R = Ratio Z = Teeth

Equipment
Reduction units
6. SERVICING AND MAINTENANCE

As with all moving mechanical parts, reduction units need to be lubricated, whether by
oiling, by oil splash lubrication or by an oil distribution system.
This lubrication gives long machine life and also reduces the noise and the vibrations
which may be generated by the meshing teeth.
Application with a paintbrush Gravity lubrication (drop lubrication)
Mechanical lubricator (drop tube) Sprayed with a spray can
Manually sprayed with a gun Automatic sprayer
Figure 27: Reduction unit lubrication (1)

Equipment
Reduction units
Figure 28: Reduction unit lubrication (2)

Equipment
Reduction units
7. GLOSSARY

Equipment
Reduction units
8. LIST OF FIGURES
Figure 1: Example of a reduction unit (1) .............................................................................4
Figure 2: Example of a reduction unit (2) .............................................................................4
Figure 3: Worm reduction unit..............................................................................................5
Figure 4: Cutaway view of a worm reduction unit and helical type.......................................5
Figure 5: Cutaway view of a helical reduction unit ...............................................................6
Figure 6: Helical reduction unit ............................................................................................6
Figure 7: Cutaway view of a parallel shaft reduction unit .....................................................7
Figure 8: Parallel shaft reduction unit ..................................................................................7
Figure 9: Planetary reduction unit ........................................................................................8
Figure 10: Industrial reduction unit.......................................................................................9
Figure 11: Reduction unit for mixer....................................................................................10
Figure 12: Gear motor........................................................................................................10
Figure 13: High load reduction unit ....................................................................................10
Figure 14: Marine reduction unit ........................................................................................10
Figure 15: Composition of a reduction unit ........................................................................11
Figure 16: Example of teeth (1) .........................................................................................11
Figure 17: Example of teeth (2) .........................................................................................12
Figure 18: Gears and pinions of a reduction unit ...............................................................12
Figure 19: Example of a reduction unit ..............................................................................12
Figure 20: Composition of a reduction unit ........................................................................13
Figure 21: Straight-cut teeth ..............................................................................................14
Figure 22: Helical-cut teeth ................................................................................................15
Figure 23: Helical gears with two symmetrical rows of teeth..............................................15
Figure 24: Bevel-cut teeth..................................................................................................15
Figure 25: Right-angle bevel gears....................................................................................16
Figure 26: Worm ................................................................................................................16
Figure 27: Reduction unit lubrication (1) ............................................................................20
Figure 28: Reduction unit lubrication (2) ............................................................................21

Equipment
Reduction units
9. LIST OF TABLES
Table 1: Types of reduction units.......................................................................................18


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EQUIPMENT

2. WHAT ARE REDUCTION UNITS USED FOR? ..............................................................4

Training course EXP-PR-EQ180-FR

At the end of this course, the attendee would be able to:

Explain functions of reducers

Enumerate the different types of reducers encountered on site

List the different applications

Expose the working principles of reducers

Enumerate the different types of gear used within reducers

Calculate the ratio of a reducer

Follow up a maintenance program for reducers

Training course EXP-PR-EQ180-FR

2. WHAT ARE REDUCTION UNITS USED FOR?

A reduction unit transmits a high torque to the

Figure 1: Example of a reduction unit (1)

Figure 2: Example of a reduction unit (2)

Training course EXP-PR-EQ180-FR

3. THE DIFFERENT TYPES OF REDUCTION UNITS

3.1. WORM REDUCTION UNITS

Figure 3: Worm reduction unit

Figure 4: Cutaway view of a worm reduction unit and helical type

Training course EXP-PR-EQ180-FR

3.2. HELICAL REDUCTION UNITS

They provide a very wide torque range: 200 to 50000 Nm.

Helical reduction units are used when the power must

They are very efficient, particularly for applications

Figure 5: Cutaway view of a helical reduction unit

Figure 6: Helical reduction unit

Training course EXP-PR-EQ180-FR

3.3. PARALLEL SHAFT REDUCTION UNITS

The numerous output shaft and hollow shaft variants, and

This is why this reduction unit has established itself

Figure 7: Cutaway view of a parallel shaft reduction unit

Figure 8: Parallel shaft reduction unit

Training course EXP-PR-EQ180-FR

3.4. PLANETARY REDUCTION UNITS

Figure 9: Planetary reduction unit

Training course EXP-PR-EQ180-FR

3.5. INDUSTRIAL REDUCTION UNITS

Figure 10: Industrial reduction unit

Training course EXP-PR-EQ180-FR

4. REDUCTION UNIT APPLICATIONS

Figure 12: Gear motor

Figure 11: Reduction unit for mixer

Figure 13: High load reduction unit

Figure 14: Marine reduction unit

Training course EXP-PR-EQ180-FR

Figure 15: Composition of a reduction unit

For a reduction unit to have a correct efficiency there

This is obtained by the shape of the teeth; we talk about

Figure 16: Example of teeth (1)

Training course EXP-PR-EQ180-FR

The contact must also be very regular, i.e. a

For conventional teeth, there is a good

Figure 17: Example of teeth (2)

The only way to correct this problem is to

If the size of the gear wheels is increased, the

Figure 18: Gears and pinions of a reduction

There is, of course, the notable exception of

Figure 19: Example of a reduction unit

For applications with a lower efficiency

Training course EXP-PR-EQ180-FR

This is always at the expense of size and no doubt of higher weight.