The Role of an Industrial Gearbox

An industrial gearbox is an enclosed system where mechanical energy is transferred from one device to a driving tool to increase torque and reduce speed. A gearbox is made of several components that work cohesively to complete a variety of industrial tasks that require high power delivery from the power source.

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Industrial gearboxes are used in countless applications. They can be found in most material handling equipment, crushers, conveyors, cooling towers, and cranes. The manufacturing industry utilizes gearboxes throughout the production process, especially when processing raw materials.

The most common types of gearboxes are helical gearboxes, helical-worm gearboxes, helical-bevel gearboxes, planetary gearboxes, and worm reduction gearboxes. This article will cover the basics of industrial gearboxes, including their importance and benefits.

The Importance Of An Industrial Gearbox

An industrial gearbox is a critical component in countless machines that are used in nearly every industry. Any device that needs to modify torque or speed likely has a gearbox of some kind. Without them, many devices will not function as efficiently. While industrial gearboxes do require maintenance considerations, they also maximize productivity and can minimize workplace accidents.

Recent technological advancements have made gearboxes, specifically industrial gearboxes, more powerful and affordable than ever before. They are typically used to monitor the direction of rotation and convert torque or power to the desired output. Industrial gearboxes are also quite reliable, making them a common component in modern gate drives.

Industrial gearboxes are highly customizable, making them well suited for just about any application. Specifications can allow a gearbox to handle various speeds and torque outputs. They can be designed in a way that can maximize speed or torque.

Industrial Gearbox Benefits

Industrial gearboxes are a great way to improve a company’s operational capacity. For industrial businesses, gearboxes are an essential component for creating products while also aiding in the maintenance of other systems. Industrial gearboxes can be used to multiply torque, reduce speed, and match inertia. Other benefits include:

Torque Multiplication

When mounted to the motor output shaft, gearboxes can provide a mechanical advantage. The number of gears, as well as how many teeth they have, will provide a mechanical advantage defined by a ratio. For example, a 5:1 gearbox can multiply torque by five times, allowing a motor that generated 100 lb-in. of torque to multiply the output to 500 lb-in.

Speed Reduction

In some circles, gearboxes are called gear reducers because they decrease the output speed. A motor that is running at 1,000 rpm that is fitted with a 5:1 ratio gearbox will output 200 rpm. The speed reduction improves overall system performance, given that many motors don’t operate efficiently at low RPMs.

Inertia Matching

In the past two decades, servomotor manufacturers introduced a series of improvements such as lighter materials, denser copper windings, and high-energy magnets specifically for motors that generate more torque for their given frame size.

If load inertia significantly exceeds that of the motor, it can cause increased settling times or excessive overshoot. Both problems decrease production line output. Conversely, a motor too large for its intended application is more expensive and requires more power to accelerate its inertia.

In these scenarios, an industrial gearbox can help balance the motor inertia to load inertia, creating a more responsive system. The motor encounters reflected inertia equal to load inertia when divided by the square of the gearbox ratio.

Cost Savings

All of these factors (torque manipulation, speed reduction, and inertia matching) cut costs. Industrial gearboxes enable the use of smaller motors and drives.

Superior Gearbox Industrial Gearbox Offerings

Superior Gearbox has been the trusted name for industrial gearboxes for over 45 years. We have expertise in speed control technologies, including a variety of manufactured helical gear motors, worm speed reducers, and bevel gear drives. Regardless of your production size or complexity, we are the company to talk to when it comes to industrial gearboxes.

We offer:

• Low Input Speed Worm Gear Reducers
• Helical Gearmotors
• Bevel Gear Drives
• Industrial Worm Gear Drives
• Custom Gear Drive Solutions
• Agricultural Gearboxes

Industrial gearboxes aid the transfer of energy between different machines. They can efficiently adjust the torque and speed for the converted energy into useable formats. That’s what makes them critical components in various manufacturing plants across the world.

While the COVID-19 pandemic resulted in a significant market slowdown in , the sector is slowly recovering and gaining its pre-pandemic growth rates.

In , the industrial gearbox market is valued at $41.4 billion, and it’s projected to grow to $49.2 billion by .

Let’s cover some of the main industrial gearbox market report findings in , including the market trends that shape the industry, key players, and other statistics.

The Industrial Gearbox Market in : 7 Key Trends

Here are 7 key industrial gearbox market trends:

Industrial Gearbox Market Size Growth

Between and , the industrial gearbox market size will grow at a 4.2% CAGR. This growth will be mainly driven by the development of the following sectors:

• Helical gearbox segment: This sector is forecasted to reach $18.8 billion by the end of (at a growth rate of 4.3% CAGR). This positive trend results from the increased demand for these compact and efficient gearboxes in the turbine, chemical, and power industries.
• Planetary gearbox segment: The planetary gearbox sector currently has a 29.6% industrial gearbox market share. This segment is projected to grow at a 4.9% CAGR by . The segment’s growth is driven by increasing investments in the food & beverage, mining, and cement industries.

Industrial Gearbox Manufacturers: Major Players

The leading industrial gearbox manufacturers are:

• Sumitomo Heavy Industries Ltd. (Japan)
• Rexnord Corp. (United States)
• David Brown Santasalo (UK)
• Siemens AG (Germany)
• Bonfiglioli Riduttori (Spain)
• Johnson Electric Holdings Limited (Hong Kong)
• Emerson Electric Co (United States)
• Flender (Germany)
• Kumera Corporation (Finland)
• Nanjing High Accurate Drive Equipment Manufacturing Group Co. Ltd (China)

Crucial Market Driving Factors

Here are some of the main drivers of the industry:

1. Development of Industrial Automation

There has been an increased use of manual task automation and robotization throughout various industrial manufacturing sectors (including the gearbox industry) in the past few decades.

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This has led to the manufacturing of more energy-efficient, high-precision gearboxes, resulting in the heavy growth of this sector.

2. Industrialization of the Middle East, India, and Southeast Asia

India, Southeast Asia, and the Middle East are heavily investing in infrastructure, healthcare, commercial and industrial manufacturing. Additionally, their power demand is steadily growing.

These increasing investments and energy demands have also driven the industrial market development, propelling the gearbox segment growth.

3. Rising Demand for Clean Energy

The increase in the global energy demand has driven the gearbox sector growth.

Another key trend is the growing demand for renewable energy such as wind power generation. Such clean energy sources rely heavily on industrial gears for their:

• High torque
• Ability to take on high axial and radial load
• Speed reduction properties

According to the latest Technavio industrial gearbox market report, wind turbine gearboxes are expected to decline in price by about 5% by (due to technological advancements in the manufacturing process.) This will further increase demand and stimulate the sector’s growth.

Main Market Restraining Factors

Here are some key factors that hinder the growth of the industrial gearbox sector:

1. High Manufacturing and Maintenance Costs

The market growth is hampered by the high gearbox manufacturing and maintenance costs. Most gearboxes are manufactured through complex engineering processes like milling, grinding, and turning.

These processes also generate a lot of vibration, negatively impacting the gearbox surface. This makes the units more susceptible to breakdown and increases their maintenance costs.

2. Limited Investment Opportunities After COVID-19

The COVID-19 pandemic has halted all global manufacturing operations. This slowdown has resulted in fewer investment opportunities in the market. While the industry is slowly recovering, it has still not reached its pre-COVID state.

Regional Trends

The geographic trends for the industrial gearbox market are:

1. Dominance of the APAC Market

The APAC segment is expected to hold the largest gearbox market share due to the region’s massive economic growth in the following industries:

• Food & beverage
• Construction
• Power generation
• Agriculture and more

Some key players in the Asia-Pacific region are India, Japan (forecasted at a 2.3% CAGR), Korea, and China (China alone is estimated to reach $11.2 billion by ).

2. Growth of Other Geographic Markets

Other geographic market trends in the forecast period - are:

• USA: The United States currently has over 20% of the total market share (about $8.4 billion).
• Canada: The country will show growth of 2.4% CAGR over that period.
• Germany: The country’s gearbox market is expected to grow at a 3.2% CAGR rate.
• Europe: The European market is projected to reach $11.9 billion by .

Leading Industrial Gearbox Segments

The leading industrial gearbox segments for the forecasted period - are as follows:

• Gearboxes by type: The helical gearbox segment will spearhead the market due to its advantages over other gearbox types.
• Gearboxes by design: Parallel axis will be the dominating gearbox design.
• Gearboxes by industry: The power industry will have the biggest growth based on the market trend forecast.

Recent Market Developments

Some of the leading market developments in the gearbox industry in recent years include NGC’s breakthroughs:

• : In , Nanjing High Accurate Drive Equipment Manufacturing Group Co. Ltd (NGC) introduced their WinGearTM brand. The gearboxes are lightweight, have reduced electricity costs, and feature advanced bearing technology.
• : The company took an order for 656 dual-stage gearboxes for the subway system in Perth, Australia. The manufactured gearboxes have advanced features like high vibration resistance, solid bearings, and a wide operating temperature range (-25℃ to 50℃).

Industrial Gearbox Market Trends: Takeaways

While the gearbox market is still in its recovery stages in the COVID-19 aftermath, it is showing signs of slow recovery. The forecasts predict that major developments in the industry will drive growth in the next 5 years.

If your company relies on industrial gearboxes to sustain everyday operations, it’s vital to ensure your gearbox units are in healthy condition. If you’re in need of industrial gearbox repair, don’t hesitate to contact Houston Pump and Gear.

We are an industrial gearbox repair company that provides gearbox inspection, reverse engineering, repair, overhaul, and gear cutting services.

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